LDSS focus position and temperature readout

Contents



Introduction

The motorized LDSS focus drive sometimes fails despite repeated attempts by the operator. This intermittent problem is likely caused by noise on the focus encoder signal. The existing sensor is also sensitive to humidity and dust. Cleaning the sensor seems to restore operation but costs observing time.

We will replace the original focus encoder with a lower-noise system.

Focus depends on instrument temperature. An on-instrument temperature readout was requested by site staff and we will include a temperature readout with this upgrade.


Original focus system

A stepper motor moves the spring-loaded LDSS camera via a lead screw and lever arrangement. This changes the distance of the camera from the CCD. As designed (see pages 110-113 of G. D. Shaw's thesis), the travel range is 0.768 mm (0.030 inches) with 0.000830 mm (0.000033 inches) per motor step.

A Super Linear Variable Capacitor (SLVC) encodes the camera position, measuring travel directly against the instrument body. The SLVC (inside the brass cylinder with two setscrews shown below, mounted in LDSS on a bare-metal L-bracket) produces a 0 to 10 V signal over a 4.9 mm travel range. This voltage signal is sent through a cable from the instrument to the control chassis located under the telescope platform where it is digitized to 12 bits and reported to the operating software. This signal has been noisy from the beginning, as noted in Shaw's thesis. The original LDSS focus algorithm allowed 10 iterations to land in a +/-8 micron error band.

Original SLVC focus encoder in LDSS

Since arriving at Magellan, LDSS has had new optics and control software installed, but the original focus drive and readout were not changed.



Upgrade

Focus encoder

We will replace the existing SLVC with a Linear Variable Differential Transformer (LVDT). The LVDT is a spring-loaded and sends a 4-20 ma current loop to an A/D converter. Current loops can be less susceptible to external noise than direct voltage signals and we expect a clean signal from this transducer. This device is protected against dust and humidity (IP67).

The A/D converter will be mounted near the LVDT, inside the instrument. The converter has an Ethernet interface so data acquisition is simple; a similar scheme is used for encoding the LDSS wheels.

The benefits of the new system are:
  1. A lower-noise signal should reduce the frequency of noise-induced failures
  2. The new encoder is better protected against dust and humidty
  3. The Ethernet interface allows us to remove some serial protocol conversion hardware and the signal condtioning module

Temperature sensor

LDSS focus depends strongly on temperature. The instrument does not now have an internal temperature sensor so the dome air temperature is used to estimate focus offsets. By installing a temperature sensor on the instrument, a more relevant temperature becomes available and the instrument control software can be calibrated to estimate the correct focus value. We will install the temperature sensor and provide a visual readout for the observer. Automatic temperature compensating software may be considered for the future.



New components

Positek P103 LVDT encoder

P103 photo

The new LDSS focus encoder is a Positek P103 LVDT (Positek website), model P103.10EL100NRT (cost is about USD$620, purchase order). The option codes on the part number are for 10 mm travel (10), 4-20 ma, 2-wire signalling (E), cabling with IP67 class gland connection with 100 cm cable length (L100), a front flange mount (N), spring loaded plunger (R), and a dome end on the plunger (T).

This LVDT operates between -40 and +125 C and is protected against dust and water. Because an LVDT does not have load-bearing or electrical contacting parts, there is nothing to wear out. A current loop signal is less sensitive to power supply voltage fluctuations and systematic offsets due to cable and connector losses, which reduces system noise. The manufacturer's estimated mean time between failure is about 40 years. Our P103 sensor requires 18-28 VDC to operate.

The primary reason for choosing this sensor is that it provides directly a 4-20 ma current loop signal that varies linearly with plunger position. No external controllers are needed so the parts count is small, although the device itself is bulky because it contains all the needed circuitry.

Details are in the product data sheet (local copy) and the installation instructions (local copy). There is also an Autocad DWG file (PDF version).


P103 LVDT drawing

The LDSS encoder has the mounting flange as shown in the upper left drawing, and the IP67 gland connection as shown in the lower right drawing.


Analog Devices AD592 temperature sensor

AD592 temperature sensor
We use an Analog Devices AD592BNZ temperature sensor on the LDSS spectrograph camera. This precision transducer outputs one micro ampere for each degree K, operating between -25 and +105 C. A precision 10Kohm metal film resistor is wired in parallel to the built-in 200K ohm shunt in the A/D converter, so the drop resistance is 9524 ohms. The temperature in Kelvins is thus the measured voltage times 105.0. The LDSS software does this correction and presents degrees C to the observer.

T(Celsius) = (105.0 x Voltage) - 273.15

We do not correct for non-linearity. The typical non-linearity error for the AD592BNZ is 0.1 C with a maximum expected of 0.25 C in the 0 to 70 C range. We want to measure temperature changes of about 0.5 C so the advertised repeatability and stability of 0.1 C is adequate.

EtherTRAK ET-8INS A/D converter (IP 200.28.147.70 at LCO)

EtherTRAK ET-8INS

We selected an EtherTRAK model ET-8INS (local copy of data sheet; local PDF copy of instruction manual) by Sixnet (cost is about USD$850, purchase order). This device has eight (8) inputs that can be used for either voltage or 4-20 ma A/D conversion. It requires 10-30 VDC power and communicates through an Ethernet CAT-5 connector. We use one input in 4-20 ma mode to read the focus encoder and one input in 0-5 V mode to to read the AD592 temperature sensor.

This device operates between -30 to +70 C in 5% to 95% relative humidity, non-condensing. From the Sixnet website:

EtherTRAK Mechanical Dimensions

image\rmmech_wmf.gif

ET-8INS Wiring Diagram 

image\et8ins_wmf.gif

ET-8INS Performance Specifications

Number of channels

8

Lowest voltage range

+/- 0.062 Volts

Maximum voltage range

+/- 10 Volts

Auto-polarity current range

4-20 mA and 0-20 mA

Thermocouple types (see note 1)

J,K,E,R,T,B,C,N,S

A/D resolution

16 bits (0.003%)

Full scale accuracy (@20° C)

+/- 0.02%

Input span & offset adjustability

+/- 25%

Span & offset temp. coefficient

+/- 30 ppm per ° C typical

Voltage range input impedance

200K Ohms

Current range input impedance

100 Ohms

CMRR (at 50/60 Hz)

140 dB

DMRR (at 50/60 Hz)

66 dB

Common mode input voltage

+/- 25 VDC between two input terminals

Common mode input voltage

1200 Volts between inputs and ground

No damage input voltage

+/- 50 VDC

Typical scan rate (all 8 channels)

800 mS - 1,000 mS, depending on

   using 100 mS / channel mode

signal types (revised 6/30/04)

   (See Notes 2 and 3 below)

 

Typical scan rate (all 8 channels)

300 mS - 500 mS, depending on

   using 60Hz-50 mS / channel mode

signal types (revised 6/30/04)

   (See Note 2 below)

 

Typical scan rate (all 8 channels)

400 mS - 600 mS, depending on

   using 50Hz-50 mS / channel mode

signal types (revised 6/30/04)

   (See Note 2 below)

 

Fastest scan rate (all 8 channels)

100 mS (revised 6/30/04)

   using 16 mS / channel mode

 

   (See Note 2 below)

 

 

 

Ethernet communications

See System Specs

Isolation (from Ethernet port)

1200 Volts RMS 1 Minute

Required supply voltage

10-30 VDC (1.6 watts typical)

Operating temperature range

-30 to 70° C

Storage temperature range

-40 to 85° C

Humidity (non-condensing)

5 to 95%

Flammability (module plastic)

UL 94V-0 materials

Electrical safety

UL 508, CSA C22.2/14; EN61010-1 (IEC1010), CE

EMI emissions

FCC part 15, ICES-003, Class A; EN55022, CE

EMC immunity

EN50082-1 (IEC801-2, 3, 4) CE

Surge withstand

IEEE-472 (ANSI C37.90)

Vibration

IEC68-2-6

Hazardous locations

UL 1604, CSA C22.2/213-M1987, (Class I, Div 2, Groups A, B, C, D), EN50021 (zone 2)

Marine/offshore locations

Det Norske Veritas (DNV) No. 2.4 (Class A and B)

Notes:

  1. Thermocouple inputs are cold-junction compensated and reported as °F or °C.

  2. These specifications apply to ET-8INS modules manufactured afterJuly 30, 2004. Performance characteristics of earlier modules may be different. Consult the factory for more information.

  3. The default analog input integration time for this module is 100 mS per channel. This mode is recommended for all applications where moderate noise filtering is desirable.

Specifications are subject to change. Consult the factory for the latest information.




Mounting brackets

LVDT bracket (click for PDF):

LVDT assembly drawing

 Positek P103 bracket (click for PDF):

P103 LVDT bracket for LDSS

Reference surface (click for PDF; this should be re-built to move the plunger down a bit):

LDSS P103 focus LVDT reference bracket

EtherTRAK chassis

EtherTRAK mounting base (click for PDF):


EtherTRAK mounting base drawing

EtherTRAK front panel (click for PDF):

LDSS focus encoder chassis front panel


Wiring and cables

EtherTRAK chassis wiring (click for PDF):

EtherTRAK wiring diagram
The temperature sensor is on Channel 1 and the focus encoder is on Channel 2.

Sensor cable wiring (click for PDF):

Sensor cable drawings

Power and shutter power cables (click for PDF):

LDSS focus encoder power cable drawing




Assembled chassis

LDSS focus encoder chassis front view
A front view of the assembled A/D converter chassis: The large yellow cable supplies 24 VDC power to the chassis. This connects back to the power supply in the LDSS motion control chassis under the platform.

There are five smaller panel connectors. The leftmost is 24 VDC output to the LDSS shutter controller (gray cable). This connection replaces the previous cable and connector in this area of the instrument, and is the only 4-pin connector on the panel.

The next connector to the right, with the black cable connected, is the LVDT input. The LVDT is the large cylinder at the right of the photo.

The next connector to the right, with a gray cable, is the AD592 temperature sensor, which can be seen on top of the LVDT at the end of the gray cable.
LDSS focus encoder chassis front panel
This photo above shows the front panel without the cables connected. The two spare connectors are not wired to anything.


LDSS focus encoder chassis top view
This is a rear quarter view of the EtherTRAK chassis in the lab.


AD592 temperature sensor
This is a closeup of the AD592 temperature sensor cable.


Installed in LDSS
The new focus encoder is seen at the right in this internal view of LDSS. The new items are the focus encoder chassis and the temperature sensor. We left the old focus encoder translator in the instrument but disconnected power and the old SLVC sensor.


LVDT encoder
View of the new LVDT focus encoder inside LDSS.




Testing

Lab testing

We mounted a micrometer head next to the P103 LVDT and connected the EtherTRAK ET-8INS to measure the output scale, repeatability, and stability.

P103 LVDT test setup


We measured the output scale to be 103.4 DN for 0.001 inches displacement (0.2457 microns per DN, but we use a slightly different number in the observer software). The data in the table below are shown to the nearest 10 ADU. The digitization is finer than we could read on the micrometer head, but by resetting the micrometer carefully we saw repeatability to +/-5 DN (the LVDT is a better sensor than the micrometer). From these coarse measurments, we find that the system is linear to at least 3.6 data numbers (0.88 micron). A relative positioning requirement of +/-4 microns (+/-16 DN) is desired, so this device is adequate. A motor step is 1.25 microns (measured at LCO), so +/-4 microns is +/-3.2 motor steps.

Jiggling wires severely on the LVDT did not affect the readout, nor did varying the supply voltage by 10%.

DN readout vs. P103 encoder shaft extension

Shaft position (inches) Data numberDeviation from linear regession
0.000 4150-1
0.0256730-5
0.05093201
0.075119106
0.100144902
0.12517070-2
0.150196604
0.175 222400
0.200 24820-5
0.250 29990-3
0.275 325803

P103 output vs displacement plot2

Testing at LCO

After installation in LDSS, while testing in the Aux building, we ran the camera focus to the limits by hand and found these data numbers at the limits:

The total range is 25700-21620=4080 units. At 0.246 microns per unit, the total focus travel is thus 4080x0.246=1003.7 microns or about 1 mm.

The number reported on the LDSS3 control GUI is the encoder number multiplied by 0.2464. (This scale factor of 0.2464 is slightly different from the actual value of 0.2457 because we set the software value on an early two-point scale measurement in the lab rather than the above linear fit.) So the extreme limits are 6332 (25700*0.246) and 5327 (21620*0.2464). In software, we limit the available range to be between 5400 and 6300.

During the day, over a period of a few hours, we noticed gradual drifts of a few tens of data numbers (10 data numbers is 2.46 microns). We assume this is due to temperature changes causing expansion and contraction of the instrument.

N.B.: These numbers may change if we replace the reference bracket to eliminate a shim that was installed to get us within range.

We confirmed operation of the spare temperature sensor (already cabled). The spare reads to within 0.1 C of the installed item at room temperature. We noticed a small self-heating effect on hookup.

A scan through focus by Jorge Bravo is presented in the summary report.


Installation plan for LDSS focus encoder and thermometer upgrade

We will need from the site before July 12, 2008:

Before Pasadena staff (AU) arrives on July 13, 2008:

  1. Inform AU & CB of IP address to use for the A/D converter (DONE)
  2. Transport LDSS to the upper level of the auxilliary building (site staff; DONE)
  3. Collect equipment and supplies noted above (DONE)

After Pasadena staff arrival:

  1. We will need occasional help from an electronics person and a mechanical person
  2. Change the IP address of the EtherTRAK module (AU; plan to do this before shipping the equipment; DONE)
  3. Meet with instrument specialist, instrument scientists, electronics tech, etc., to inspect and understand the hardware (DONE)
  4. Confirm the IP address by email or phone with Christoph (AU; DONE in Pasadena)
  5. Open LDSS, remove the grism wheel (site staff, AU; DONE)
  6. Remove and box the existing SLVC components (site staff, AU; DONE)
  7. Connect the encoder testing setup, temperature sensors, and A/D converter to the LDSS network on the platform and verify that it still works (AU, CB in Pasadena, Monday July 14; DONE in the aux building)
  8. Drill and tap mounting holes for sensor readout chassis in the LDSS body (site staff; DONE)
  9. Mount the sensor readout chassis (this contains the A/D converter and panel receptacles for sensors) (AU; DONE)
  10. Build cable for 24 VDC supply connection (may need to trace cable to the shutter panel to identify + and - wires) (Jones; DONE)
  11. Connect a 24 VDC lab supply to confirm A/D power-up (AU; DONE)
  12. Disconnect 24 VDC supply (AU; DONE)
  13. Attach the AD592 temperature sensor to the camera body with Kapton tape (AU; DONE)
  14. Dress AD592 wiring and plug it into the A/D chassis (AU; DONE)
  15. Install the new LVDT brackets (use Bellevilles; AU; DONE by Navarrette)
  16. Install LVDT (AU; DONE by Navarette)
  17. Plug in Ethernet CAT-5 cable to the A/D converter and run it to the exit panel on LDSS (AU; DONE)
  18. Plug in A/D Ethernet connection to the network (AU; DONE)
  19. Plug in a laptop to the network (AU; DONE)
  20. Connect the 24 VDC lab supply and power-up A/D chassis (AU; DONE)
  21. Verify that the temperature sensor and LVDT are active (AU uses vendor software on his laptop; DONE)
  22. Install LDSS on the telescope (Site staff; DONE)
  23. Work with Christoph on the phone to get the software calibrations, etc. (AU. CB in Pasadena; Wednesday July 16; DONE)
  24. On-sky testing in the early PM during the engineering run (DONE)

Shipping manifest


LineQtyDescription
11P103 LVDT bracket
21Encoder reference bracket
32Kapton tape spools
41Blue ethernet cable, 2 m long
51Spare bulkhead power connector Spare 3-wire bulkhead power connector (Remke 303P0010N1)
623-wire power cable Yellow 3-wire cables (Remke 703A0131D1)
71Wired AD592 temperature sensor with plug and 1 m cable (AU will hand-carry the spare)
8410 K ohm 1/4 watt metal film resistors
914-wire cable from chassis to shutter power, 1 m (might not be long enough)
1012Belleville washers
112Ethernet passthrough couplers
121Spare 3-wire cable plug
131Spare 4-wire bulkhead receptacle
141 setAssorted M4 screws (6,8,10 mm)
151Spare 3-wire bulkhead receptacle
162#29 drill bits
172Taps for 8-32
181P103 LVDT, cabled, with micrometer head testing jig
191Spare EtherTRAK A/D converter with software CD
201LDSS focus encoder set (EtherTRAK in chassis with connectors, ground strap)
2168-32 x 3/8 SHCS




Installation report

Summary

The existing SLVC encoder was removed from the instrument and replaced with the LVDT encoder. The old transducer electronics remain in the instrument and new communications electronics were installed. A summary report (PDF) was submitted to the LCO techncial group.

Sunday, July 13, 2008

Uomoto arrived in the afternoon. LDSS was already in the aux building. Navarrette, Merino, and Uomoto opened the instrument and removed the grism wheel and motor mechanisms. We removed the old SLVC encoder and its mounting hardware and Navarrette installed the mounting hardware for the new LVDT system. Quiroz, Alfaro, and Cortes drilled and tapped the mounting holes for the chassis in the side of the instrument.

Monday, July 14, 2008

We mounted the new electronics in LDSS and installed the sensor cables. We used an ethernet switch to connect a laptop and the EtherTRAK to the network. We used a lab supply to put 24 VDC on the EtherTRAK chassis. After power-up, we used the SIXNet  IO Tool Kit to verify that the EtherTRAK and sensors were working.

Birk in Pasadena then confirmed that he could read the EtherTRAK device with his software.

The LVDT reading was near the end of travel, such that we went to the 15 bit limit before the end of travel. Uomoto will make a new reference plate that's 1 mm lower. In the meantime, some aluminum tape was stacked to make a shim.

Jones removed three LED status lights from the EtherTRAK board to make it dark. I had previously confirmed with SIXNet (talked to "Andrew") that this would not affect the operation. It voids the warranty, however. The LED lights in the spare EtherTRAK were not removed.

Jones made new cables. These provide the 24 VDC from the motor controller chassis to the focus encoder and 24 VDC from the focus encoder chassis to the shutter controller. Previously, the 24 VDC from the motor controller chassis was used only to power the shutter controller. The 24 VDC to the shutter controller simply passes through the focus encoder chassis.

We confirmed operation of the spare temperature sensor (this was not available before shipping).

Tuesday July 15, 2008

Merino, Quiroz, and Uomoto reassembled LDSS in the aux building and Quiroz drilled two holes for a temporary mounting location for an Ethernet switch.

LDSS was rolled out to the Clay dome under the aluminizing tank (Quiroz, Alfaro, Merino, Navarrette) and re-installed on the telescope.

Bravo & Cerda installed the cables and Cortes installed a power cable for the Ethernet switch. In the end, however, there were enough Ethernet cables in the cable wrap to avoid using the Ethernet switch.

Birk communicated with the focus encoder from Pasadena.

Wednesday July 16, 2008

Birk (Pasadena) & Uomoto (Las Campanas) confirmed that the focus encoder could be commanded from the modified LDSS gui and scaling factors and signs were confirmed. The range of focus motion was set to 5400 to 6300 units (microns) on the LDSS screen. This range is off the camera travel limits by about 1/6 turn of the motor. Birk downloaded the new software to Guanaco and Zorro.

Bravo & Uomoto operated the software but Cryotiger problems prevented gettting data tonight. Covarrubias arrived in the early evening.

Thursday July 17, 2008

Bravo measured focus values for many filters and found that the recorded offsets (wrt SDSS r) were far from the previous "correct" values.



IP addresses in LDSS:




Parts list


LineQtySparesCatalog pictureDescriptionManufacturer/Part no.Vendor/Vendor no.CostNotes
1.0021Cable end for sensors3-conductor male plug for sensor cablesHirose / MXR-8PA-3PB(71) (local copy)Digikey / HR1821-ND16.03Cable ends from AD592 temperature sensor and Positek P103 LVDT
2.0010Hirose connector4-conductor male plug for shutter cableHiroseMXR-8PA-5PB(71) (local copy)Digikey / HR1822-ND16.29Cable end from shutter panel to chassis
3.0021Panel connector for sensors3-conductor female receptacle for sensor cablesHirose / MXR-8RA-3S(71) (local copy)Digikey / HR1826-ND8.83Front panel connectors for AD592 temperature sensor and Positek P103 LVDT
4.0011Panel receptacle for shutter power4-conductor femail receptacle for shutter cableHirose / MXR-8RA-4S(71) (local copy)Digikey / HR1827-ND9.64Front panel receptacle for shutter cable
5.0011Cable end for 24 VDC incoming power3-conductor female plug, single keyway, external thread, for 24 VDC input powerRemke 703A0131D1McMaster / 3214K4237.72Front panel connector for incoming 24 VDC from power supply in the motion control chassis.
6.0011Front panel power input connector3-conductor male receptacle, single keyway, external thread, for 24VDC input powerRemke 303P0010N1McMaster / 3214K4423.27Cable end for incoming 24 VDC from the SOLA supply in the motion control chassis to the front panel power input.
7.0011AD592 temperature sensorTemperature transducer in TO-92 package, 1 micro-amp/KAnalog Devices / AD592BNZ (local copy)Digikey / AD592BNZ-ND10.82One of these temperature sensors is taped to the camera barrel and the other [?]
8.0011Positek P103 LVDTLVDT with 4-20 ma output, 10 mm strokePositek / P103.10EL100NRTEveright Precision / P103.10EL100NRT620.00LVDT to measure position of the LDSS camera relative to the LDSS body
9.0011EtherTRAK A/D converter8-port 16-bit A/D with Ethernet communicationsSixnet / ET-8INS-USixnetET-8INS-U850.00Instrumentation module to read 4-20 ma current loops and voltages with Ethernet
12.010Ethernet cableEthernet patch cable, 2 m, blueAssmannA-MCUP-80020/B-R (local copyDigikey / AE9947-ND5.18Ethernet cable from the A/D chassis to the outside wall of LDSS (not long enough; used one from LCO stock)
13.011CAT5E inline couplerEthernet CAT5E inline couplerAssmann / A-TA3534-R (local copy)Digikey / AE10093-ND 8.02Interface to the external Ethernet cable
14.0118-32 tap8-32 steel hand tapGreenfield 15284McMaster / 2522A7183.61Tap for cutting holes in LDSS to mount A/D chassis
15.011#29 drill bitDrill bit, size 29N/AMcMaster / 30585A421.12Drill bit for tapping holes in LDSS to mount A/D chassis
16.011Kapton tapeKapton tapeN/AMcMaster / 7639A626.72 for a 5-yard rollLow-static tape for AD592 sensor placement
17.066Belleville disk springsBelleville disk springsGardner Spring MB0281-010McMaster / 9712K115.07 for 12Help prevent the LVDT and reference bracket from coming loose
18.04someM4 x 8 mm screwM4 x 8 mm shcsBrikksen
McMaster / 91292A1086.01 for 100Attach LVDT brackets to LDSS
19.02someM4 x 10 mm screwM4 x 10 mm shcsBrikksenMcMaster / 91292A1166.35 for 100Attach LVDT bracket to LDSS
20.01810K metal film resistor10 K ohm metal film resistor, 1/4W, 1%?Digikey / P10.0KCACT-ND
P10.0KCACT-ND
0.171 eaDrops voltage from AD592 for EtherTRAK signal


August 14, 2008
Alan Uomoto, Jennifer Marshall, Christoph Birk, Jorge Estrada