3P6-PLA-ESO-60100-00..
Contents
1. essere nennen een eene nennen 25 6 1 2 Encoder Signal Test Box ae date ete pe e De 26 6 1 3 VMEASA 27 6 1 4 DBSC Maintenance Program 27 6 1 5 i ee tre e p ein a ge Pee re ib etn dign 29 Page 4 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document 3P6 PLA ESO 60100 0001 6 1 6 EE EE 29 6 1 7 Hot Wire Thermo Anemometer eese 30 6 1 6 bee usine 31 6 2 NON STANDARD 9 000 0 2 nnne n n n 32 6 3 3 6 M2 MAINTENANCE TASKS UNDER REMEDY AND OR 32 6 4 3 6 2 MAINTENANCE FORM eere ee eene nennen nn n n nnn 32 69 PICTURES REPE OUI 33 INDEX OF FIGURES AND TABLES FIGURE 1 REFERENCE FOCUS DRIVE CCW CURRENT GRAPH ener nennen eet 9 FIGURE 2 REFERENCE FOCUS DRIVE CW CURRENT OGRAIPH ccce 9 FIGURE 3 REFERENCE X DRIVE CCW CURRENT DRAN 13 FIGURE 4 REFERENCE X DRIVE CW CURRENT GRAPH eene 13 FIGURE 5 REFERENCE Y DRIVE CCW CURRENT DRAN 16 FIGURE 6 REFERENCE Y DRIVE CW CURRENT GRAPH eene 16 FIGURE 7 MED FRONT EE 25 FIGURE 8 MED REAR PANEL ener enne E a nn eres ete nasse eset sete nasa ese enn 25 BIGUREO MEBD AC e EN E2. 9 8 amp 8 si 2 W 17 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 3 3 2 Rotary Encoder Description Encoder signals test inspection Actions Follow the same procedure as on 3 1 2 and fill in the pertinent section of the 3p6 M2 maintenance form additionally add comments if anomalies are found Frequency Once every year Caveats Same as on 3 2 2 if X is replaced by Y 3 3 3 Baumer Init Limit Sensors Description Check the functionality and repeatability of the Init Limit sensors Actions Same as on 3 2 3 if X is replaced by Y Fill in the pertinent section of the 3p6 M2 maintenance form and add comments if anomalies are found Frequency Once every year Caveats Same as on 3 2 3 3 3 4 Catastrophic Limit Sensors Description Check the functionality of the catastrophic Limit sensors Actions Same as on 3 1 5 Frequency Once every two years Caveats Same as on 3 1 5 18 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 4 M2 ELECTRONICS MAINTENANCE TASKS 4 1 Electronics Cabinet 4 1 1 Cabinet Description Cabinet tightness inspection and general mechanical condition Actions 1 Inspect for proper adjustment and sealing of the front and back doors 2 Check the condition of the doors gaskets both t
3. isi tet teni ee nee EET EUR REENEN 11 32 e EE 12 3 2 1 Servo MOLT REED 12 3 2 2 Rotary Encode fiz hissing D ue P HAE RE EUR ERES 14 3 2 3 Baumer Tetris 14 3 2 4 Catastrophic Limit Sensors 15 3 3 EE 15 3 3 1 Servo cide cous o ideiei 15 3 3 2 EE 17 3 3 3 Baumer Init Limit Aensorg 17 3 3 4 Catastrophic Limit Sensors 17 4 M2ELECTRONICS MAINTENANCE 5 8 4 0 002040 440 0200 00 1 4 18 4 1 ELECTRONICS IEN 18 4 1 1 18 4 1 2 e EE 18 4 1 3 VMEASA Voltage Rails Supply ete aue tede te dete dee 19 4 1 4 VME Chassis Power Supplies eese eene tenete nennen nennen rennen 20 4 1 5 Focus Servo Amplifier edi tete ede et epe etae 20 4 1 6 X Servo Amplifier eed t eee ee tede t edet 21 4 1 7 Y Servo Ampliftef ea t I RUE EIER EFE EE EE 22 42 RACE COOLING i eher RIO e uUa atra ie eed ER os 22 4 2 1 VLT Electronic Cabinet Cooling System eese 22 4 2 2 Safety E 23 5 GLOBAL MAINTENANCE TASKS u200s0000rsossnnsonsnnsnnsnnsnnsnnsnnsnnssnssnnsonsnnsnnsnnsnnsnnssnnsonsnnsonsnnsnne 24 9 1 e OC E En LR 24 39 2 ether gege eege ees eere 24 VE RN N I KE 25 EMI D E 25 6 1 1 Mitutoyo Encoder Display MED
4. 6 maximum Acoustically inspect the fans they should produce an even single pitched sound Fill in the pertinent section of the 3p6 M2 maintenance form and add comments if anomalies are found Frequency Once every six month 23 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 Caveats The main function of the Electronic cabinet cooling system is to extract the heat of the rack but at the same time keep the internal temperature almost identical to the ambient This is important to avoid thermal gradients that could deteriorate the seeing of the telescope The temperature values above presented are only a reference and of course will vary accordingly with the ambient temperature 4 2 2 Safety Thermostat Description Check the thermostat setting and functionality Actions Dial setting 30 C Aim a hot air gun from a distance of 50 cm and put a handheld thermometer prove touching the thermostat case Heat up the thermostat using the minimum power setting of the gun until it trips of Monitor the hot air temperature while testing Fill in the pertinent section of the 3p6 M2 maintenance form and add comments if anomalies are found Frequency Once every two years q y y y Caveats Be aware that this test de energize the whole rack and is intended for ultimate protection only During normal operation this thermostat will never be activated therefore when doing the test try to b
5. 6 telescope 2 control system focused on the electronics electro optical and electro mechanical components of the system The mechanics is briefly covered where relevant and shall be covered somewhere else in detail Appended to the document you could find useful information for servicing and diagnosing the system together with references to the technical documentation and the newly defined maintenance tasks to be incorporated under Remedy and or Maximo 1 2 REFERENCE DOCUMENTS REI 3p6 M2 Control Electronics Doc No 3P6 DSD ESO 60400 0001 Issue 2 0 J Alonso 24 January 2005 RE2 1 3 APPLICABLE DOCUMENTS ESO VMEASA XI 4 Channel DC Servo Amplifier Technical Manual VLT MAN ESO 17130 0273 Issue 3 0 AP2 ESO VMEASA BACKPLANE Technical Manual VLT MAN ESO 17130 0274 Issue 3 0 AP3 VLT Electronic Cabinet Cooling System User Manual VLT MAN ESO 17130 1603 Issue 1 0 F Biancat Marchet April 27 1998 APA USER Manual MACCONTROLLER MACA INC Version 4 2 AP5 Harmonic Drive Operations Manual AC Servo Amplifier SC 500 510 AP6 6 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 1 4 ACRONYMS amp ABBREVIATIONS AC Alternating Current DC Direct Current DBSC Digital Brushless Servo Control software VME Versa Module Europe LCU Local Control Unit PPR Pulse Per Revolution PC Personal Computer UL Upper Limit LL Lower Limit HARPS High Accuracy Radia
6. E 26 FIGURE 10 INCREMENTAL ENCODER OUTPUT SIONALS 26 FIGURE LI VMEASA HANDSET oan te ora dae vies Ordre cue en do 27 FIGURE 12 DBSC PROGRAM MAIN WINDOW 28 FIGURE 13 DBSC PROGRAM PLOTTING PHASE CURRENT cessere enne 28 FIGURE 14 DBSC PROGRAM DOING OFFSET TUNING 29 5 6 eiecti seem ansieht mut ee oec eee Ee e dee y e oe const edd te 31 BIG URE167 X7 CABEE nec reo C DIR UNE S 31 FIGURE 17 FOCUS LINEAR ENCODER CONNPCTOR 33 FIGURE 18 FOCUS CATASTROPHIC LIMIT SWITCHES 00 0000000000000000000000000000000000000 33 TABLE 1 VME AUXILIARY POWER SUPPLY TOLERANCE cscssscccccecesssssscecececseseaececececsessaececeeeceesenseaeeeeeees 19 TABLE 2 VME POWER SUPPLY TOLERANCR nennen tete ranae seen 20 TABLE 3 VME4SA CHANNEL ennt tensa nennen 27 TABLE 4 ANEMOMETER RANGES AND RESOLUTION 30 TABLE 5 NON STANDARD SPARE 32 5 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 1 INTRODUCTION 1 1 PURPOSE AND SCOPE This document is intended to serve as a maintenance guide plan for the 3p
7. EUROPEAN SOUTHERN OBSERVATORY Organisation Europ enne pour des Recherches Astronomiques dans l H misph re Austral Europ ische Organisation f r astronomische Forschung in der s dlichen Hemisph re LA SILLA PARANAL OBSERVATORY 3P6 M2 MAINTENANCE PLAN Doc No 3P6 PLA ESO 60100 0001 Issue 1 0 Date 17 August 2005 Prepared J Alonso Name Date Signature Approved R Parra Name Date Signature Released G Ihle Name Date Signature Page 2 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 CHANGE RECORD 17 08 2005 3 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 INDEX OF CONTENTS LER INTRODUCTION RE 5 Ld PURPOSE AND SCOPE ce een EHI RU 5 1 2 JAREFERENCEDOCUMBNYTS tinet eri pee he c hee e an a 5 1 3 APPLICABLE DOCUMENTS RR rte etr eene ir piede 5 14 ACRONYMS amp 6 Ze M2 OVER VIB W t 7 221 E 7 ER EE H 3 M2ELECTROMECHANICAL MAINTENANCE TASKS u200200000000000000000200200000n000000000000000000 8 Beli FOCUS DRIVE EE 8 3 1 1 TE 8 3 1 2 Rotary EE 10 3 1 3 Mitutoyo Linear Encoder 10 3 1 4 Baumer Sensors s een ENEE e EE EA ette u eee ette cent 11 3 4 5 Catastrophic Limit Sensors
8. ade near the VME board component side The air speed shall be 0 5m sec 1096 maximum Fill in the pertinent section of the 3p6 M2 maintenance form and add comments if anomalies are found Frequency Once every year Caveats From left to right the VME modules and power supplies are 1 MVME 2604 Power PC 604 32MB RAM CPU 2 MAC INC Servo control module 3 VMEASA I DC Servo amplifier module 4 VME Multi voltage DC power supply 5 Stacked 15 volts power supplies Exercise special care when unplugging and plugging back the VME modules Always be sure that the modules are sliding properly over the insertion rails and after for insertion apply and even force at the top and bottom of the module s front panel Fail to observe these precautions could result in malfunction and or connector s pin damage 4 1 3 VME4SA Voltage Rails Supply Description VME auxiliary power supplies checkout Actions Measure the DC and AC noise voltage of the VME power supplies Use a multi meter and a 20 Mhz bandwidth oscilloscope The voltage and noise values shall be Nominal Tolerance Noise 20Mhz BW Volts Volts Volts Peak Peak max 15 0 750 0 450 0 1 15 0 750 0 450 0 1 Table 1 VME auxiliary power supply tolerance Fill in the pertinent section of the 3p6 M2 maintenance form and add comments if anomalies are found Frequency Once every year 20 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan D
9. ails test the Init Limit sensors Disconnect the linear encoder from the system at the patch box labelled FOCUS and connect it to the MED With the handset move the axis toward each limit UL and LL and once reaching the particular limit press the zero button of the display box Go out of the limit and come back this time don t zero the display box When back on limit the readout must be ideally 0 in practice shall be within 2 counts Fill in the pertinent section of the 3p6 M2 maintenance form and add comments if anomalies are found Frequency Once every year Caveats For the focus drive 1 count of the MED corresponds to lum of axis displacement 1 count is the unitary increment or decrement of the right most display digit After removing the display box reconnect everything properly adjusting in place the bayonet fixation of the connector 3 1 5 Catastrophic Limit Sensors Description Check the functionality of the catastrophic Limit sensors Actions Using the VMEASA handset refer to 6 1 3 for the handset details drive the axis to the UL and LL Page 12 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 Once on each limit insert a 0 5mm thickness blade in between the Omron D4D 1532N limit switch actuation wheel and the carriage itself The complete rack shall be de energized at the 220V mains supply level when the blade is inserted Wait ten seconds and remove t
10. cal eccentricities of the motor screw combination Therefore the amplitude of the envelope shall normally lie within 0 2 Amperes peak peak and by itself is a powerful tool for diagnosing and or predicting mechanical problems i de n T US p Time sec 10 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 3 1 2 Rotary Encoder Description Encoder signals test inspection Actions Use the encoder signal test box refer to 6 1 2 for test box usage details and the X7 adapter cable refer to 6 1 8 for X7 cable details Connect the test box to the X7 connector of the focus servo amplifier and inspect the signal outputs with an oscilloscope settings channels 1 amp 2 at 2V div time base 515 normal trigger channel 1 at 1 8V triggering level With the aid of the VMEASA handset refer to 6 1 3 for handset details drive the axis at the highest possible speed While moving measure the amplitude and 90 phase difference of the signals and compare them with the reference in Figure 10 section 6 1 2 Fill in the pertinent section of the 3p6 M2 maintenance form and add comments if anomalies are found Frequency Once every year Caveats The focus drive utilizes the rotary encoder signals only for velocity feedback Therefore the X7 connector at the focus servo amplifier remains unused during normal operation X7 output is used only during this pa
11. connect the MED to the X7 connector of the X amplifier Move the axis toward each limit UL and LL When performing this test due to the extremely high resolution resolution not precision and stability of the axis you should bias the axis momentarily using the DBSC program This is to allow a stable readout When doing the LL use 20mV offset and for the UL use 20mV offset Be sure to re establish the original value when finishing For testing after setting the proper bias move the axis toward the limit while stop on limit press the zero button of the display box Go out of the limit and come back to the limit this time don t zero the display box When back on limit the readout must be ideally 0 in practice shall be within 1200 counts Fill in the pertinent section of the 3p6 M2 maintenance form and add comments if anomalies are found Frequency Once every year Page 15 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 Caveats For the X drive 1 count of the MED corresponds to 0 0016um resolution not precision One count is the unitary increment or decrement of the right most display digit To resume normal operation be sure to reconnect the original cable at X7 and do not forget to re establish the proper offset Secure the connector properly in place without over tightening the screw fixations 3 2 4 Catastrophic Limit Sensors Description Check the functionality of the catas
12. due to the fact that the X mechanism is not counter balanced very heavily preloaded and no flexion couplings are used between the motor and the screw 1 177 n 8 a es 49 i 4 7 KR e E E S 14 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 3 2 2 Rotary Encoder Description Encoder signals test inspection Actions Follow the same procedure as on 3 1 2 and fill in the pertinent section of the 3p6 M2 maintenance form additionally add comments if anomalies are found Frequency Once every year Caveats The X drive utilizes the rotary encoder signals both for velocity and position feedback Therefore the X7 connector at the X servo amplifier must be unplugged for performing the test This is to allow the X7 cable to be plugged To resume normal operation be sure to reconnect the original cable at X7 Be sure to secure the connector properly in place without over tightening the screw fixations 3 2 3 Baumer Init Limit Sensors Description Check the functionality and repeatability of the Init Limit sensors Actions Using the VMEASA handset refer to 6 1 3 for the handset details and the MED Display refer to 6 1 1 for the MED details test the Init Limit sensors Disconnect the X7 encoder connector at the X servo amplifier and by the aid of the X7 cable
13. e effective and avoid multiple on and offs of the system this is to minimize possible harmful transients Page 24 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 5 GLOBAL MAINTENANCE TASKS 5 1 External Inspection Description Inspection of the overall system externally electronic rack and mechanism itself Actions Check 1 Rack mechanical fixations to the M2 structure 2 Cable fixations and layout 3 Forgotten tools or loose components 4 Water leaks from the coolant hoses 5 Loose gaskets and or below protections Fill in the pertinent section of the 3p6 M2 maintenance form and add comments if anomalies are found Frequency Once every six months Caveats N A 5 2 Internal Inspection Description Inspection of the overall system internally Components inside the rack such as amplifiers VME chassis DIN rail mounted components etc Actions Check 1 Loose components inside the rack 2 Loose screw terminals 3 Cable fixations and layout 4 Forgotten tools 5 Water leaks from the coolant hoses Fill in the pertinent section of the 3p6 M2 maintenance form and add comments if anomalies are found Frequency Once every six months Caveats N A 25 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 6 APPENDIX 6 1 Tools 6 1 1 Mitutoyo Encoder Display MED The MED is an encoder counter box s
14. egrate a brushless AC motor together with a harmonic reduction gear and an incremental 1500 PPR optical shaft encoder coupled to the motor axis Each linear drive is complemented by end of stroke high precision limit init switches together with coarse catastrophic limit switches Every actuator is accompanied by three screw terminals group All the connections from the actuator and limit init switches are routed trough these terminals to the control LCU power amplifiers cabinet The signal groups correspond to AC motor drive incremental encoder and limit init switches The control electronics is mounted on top of the M2 unit inside a hermetically sealed Kniirr cabinet equipped with an active heat exchanger unit The cabinet houses a VME LCU three AC servo amplifiers and support circuitry Externally the control cabinet receives only the mains 220V AC power supply the Ethernet connection one inlet and one outlet coolant hoses By opening the rear door an external PC could be connected via RS232 to each AC servo amplifier and to the LCU console port This is for setup and engineering monitoring and maintenance of the servo amplifiers and VME CPU configuration From the control cabinet three identical groups of signals are routed to its close neighbour the M2 drive Page 8 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 3 M2 ELECTROMECHANICAL MAINTENANCE TASKS 3 1 Focus Drive 3 1 1 AC Servo Mot
15. ge offset lurking around like a drunken sailor does not inspire confidence and shall be investigated CAUTION Potentially hazardous voltages are present at some servo amplifier s screw terminals 4 1 6 X Servo Amplifier Description Visual inspection velocity loop DC offset tuning and DC offset monitoring Actions Same as on 4 1 5 Frequency Once every two years Caveats Same as on 4 1 5 CAUTION Potentially hazardous voltages are present at some servo amplifier s screw terminals Page 22 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 4 1 7 Y Servo Amplifier Description Visual inspection velocity loop DC offset tuning and DC offset monitoring Actions Same as on 4 1 5 Frequency Once every two years Caveats Same as on 4 1 5 CAUTION Potentially hazardous voltages are present at some servo amplifier s screw terminals 4 2 Hack Cooling 4 2 1 VLT Electronic Cabinet Cooling System Description Check the cooling system functionality measure the air velocity at the fans Actions Repeatedly press the downward arrow labelled pushbutton at the unit s front panel You will step trough 4 indications 1 Mode local 2 Controller Status active 3 Tinlet 0 9 C Toutlet 6 4 C 4 Ambient temp 8 6 C Cabinet temp 8 4 C Measure the air velocity at each of the four fan outlets Use the thermo anemometer Air velocity reference value 0 5m Sec 109
16. he blade the power must be re established Fill in the pertinent section of the 3p6 M2 maintenance form and add comments if anomalies are found Frequency Once every two years Caveats Be aware that this test de energize the whole rack and is intended for ultimate protection only During normal operation this limit will never be activated therefore when doing the test try to insert and remove the blade effectively avoiding multiple on and offs of the system this is to minimize possible harmful transients 3 2 X Drive 3 2 1 AC Servo Motor Description Acoustical and visual servomotor inspection and phase current consumption measurement Actions For X drive follow the same steps as on 3 1 1 Of course this time connect the laptop to the X servo amplifier serial port connector X6 Frequency Once every year Caveats You should acquire graphs similar to the reference ones shown below The peak current value of both phases shall be within the margins marked on the reference graphs as upper and lower limit Note that the envelope in the curve represents the instantaneous current fluctuations due to the mechanical eccentricities of the motor screw combination Therefore the amplitude of the envelope shall normally lie within 0 5 Amperes peak peak and by itself is a powerful tool for diagnosing mechanical problems Note that for the X drive the current consumption is significantly higher than for the focus drive This is mainly
17. he rubber and metallic ones 3 Check the cables feed trough for proper tightness with the aid of a flashlight illuminate from the opposite side you are looking 4 Check for condensation inside the cabinet Fill in the pertinent section of the 3p6 M2 maintenance form and add comments if anomalies are found Frequency Once every year Caveats The cabinet is KN RR Pro Rack type These cabinets are hermetically sealed mechanically thermally and electrically When opening and closing be sure that the door s gaskets are properly seated if necessary push the door not only from the lock 4 1 2 VME LCU Description VME bus contact cleaning VME boards dust off fans checkout air ducts and or internal surfaces dust off Actions 1 Remove the VME modules and dust off the modules by blowing air onto them 2 Clean the contacts of connectors P1 and P2 with oil free contact cleaner 3 Inspect for bended or loose pins 4 Dust off the fans and check them acoustically normally they should produce a single pitched sound 5 Dust off the air ducts and or internal surfaces 6 Measure the air flow by the aid of a Hot Wire Thermo Anemometer refer to 6 1 7 for the usage of the anemometer For inserting the anemometers prove temporarily remove the Page 19 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 blind plates of the front panel Ideally the air flow measurement shall be m
18. here you should connect your oscilloscope probes for testing note that this is a custom modification not a Mitutoyo standard feature Refer to 6 1 1 cc 7 H D 2 27 Agilent Technologies Figure 10 Incremental Encoder Output Signals The phase difference between A and B signals must be 90 15 27 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 6 1 3 VME4SA Handset The handset is plugged in the front panel of the VME4SA and used for manually driving the velocity servo loops During normal operation of the system the handset function is disabled by software Therefore for activating the handset function it is necessary to either reset the CPU and not allow bootstrap or turn off the power of the system remove the CPU and turn on again Figure 11 VME4SA Handset VMEASA Channel M2 Axis I Y II X III FOCUS IV N U Table 3 VME4SA channel assignment 6 1 4 DBSC Maintenance Program and PC As previously mentioned in this document the M2 servo amplifiers implement many features including velocity loop over temperature protection limit switches inputs for disabling the axis etc The velocity reference to the amplifier is an analogue signal and the velocity feedback is obtained from a 1500 PPR rotary encoder directly coupled to the AC motor axis these functions are managed by a flash memory equipped microprocessor inside the servo am
19. is particular oscilloscope includes multi meter If necessary refer to instrument s manual for operating instructions 6 1 6 Multi Meter Fluke 85 III True RMS multi meter or equivalent If necessary refer to instrument s manual for operating instructions 30 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 6 1 7 Hot Wire Thermo Anemometer EXTECH407123 Hot wire thermo anemometer This is a digital handheld instrument with a probe for measuring air speed The specifications are as follows Display type 2000 counts LCD Basic accuracy 3 Probe diameter 1 3cm telescopic Units Range resolution Ft min 40 to 3940 10 m sec 0 2 to 20 0 1 Km hr 0 7 to 72 0 0 1 MPH 0 5 to 45 0 0 1 Knots 1 0 to 31 0 0 1 Table 4 Anemometer Ranges and Resolution If necessary refer to instrument s manual for operating instructions Page 31 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 6 1 8 X6 and X7 Cables The X6 cable is a standard RS232 null modem pins 2 and 3 crossed Dsub9 male to Dsub9 female 4 meters length The cable is used for connecting the DBSC PC to the servo amplifier under test Figure 15 X6 Cable The X7 cable is a special two meter length twisted pair cable equipped with Dsub9 male connector on one side and on the other a 6 pin Hirose connector Mitutoyo standard The cab
20. l Velocity Planetary Search BW Band Width TBD To Be Defined ELC Electronics MED Mitutoyo Encoder Display N A Not Available N U Not Used Page 7 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 2 M2 OVERVIEW 2 1 History Since ever the 3 6 telescope f 8 secondary unit has suffered from considerable mechanical instabilities This together with the inability to introduce online corrections to the decentring comma has severely limited the optical performance of the telescope Considering that the new generation of instruments e g HARPS need to exploit the maximum possible optical image quality attainable with the telescope a new mechanical design based on the NTT secondary unit concept was designed and built The new M2 unit is equipped with VLT complaint computer controlled servo drives for the focus X and Y motions of the secondary mirror unit The unit was commissioned during September August 2004 and is successfully operating since them This zero failure year period was the base criteria for defining the frequency of the various maintenance tasks 2 2 System The motion control electronic components used for the M2 are gt MACC4 INC AP4 and VME 4SA AP1 VME VLT standard modules gt Harmonic Drive AC Servo Amplifier SC500 510 AP5 Three Harmonic Drive Systems servo actuators type FHA 25B 3015E E150 are used for rotating the focus X and Y driving screws These actuators int
21. le is used for monitoring the rotary encoder signals with the Mitutoyo encoder display Figure 16 X7 Cable Page 32 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 6 2 Non Standard Spare Parts Most of the spare parts needed for the M2 system are standard VLT components The list below includes mostly non standard special parts Item Description Qty Harmonic Drive Servo Amplifier SC 510 MVMET712 VME CPU transition module standard item KNIEL gt CP 15 1 6 power supply AC Servo Armonic Drive Actuator FHA 25B with brake Line Filter Schaffner FN350 8 29 3 6 M2 Limit Switches Signal Conditioner Module Table 5 Non Standard Spare Parts gt m m 6 3 3 6 M2 Maintenance Tasks Under Remedy and or Maximo TBD and agreed by the ELC team 6 4 3 6 M2 Maintenance Form TBD and agreed by the ELC team 3P6 M2 MAINTENANCE PLAN Page 33 Plan Document 17 08 2005 3P6 PLA ESO 60100 0001 6 5 Pictures Te bean G e amp Figure 18 Focus Catastrophic Limit Switches
22. ocument Doc 3P6 PLA ESO 60100 0001 Caveats For measuring use the power supply s front panel test points The voltage noise level is specified for 20 Mhz bandwidth 4 1 4 VME Chassis Power Supplies Description VME power supplies checkout Actions Measure the DC and AC noise voltage of the VME power supplies Use a multi meter and a 20 Mhz bandwidth oscilloscope The voltage and noise values shall be Nominal Tolerance Noise 20Mhz BW Volts Volts Volts Peak Peak max 5 0 250 0 125 0 1 12 0 600 0 360 0 1 12 0 600 0 360 0 1 Table 2 VME power supply tolerance Fill in the pertinent section of the 3p6 M2 maintenance form and add comments if anomalies are found Frequency Once every year Caveats For measuring use the power supply s front panel test points The voltage noise level is specified for 20 Mhz bandwidth 4 1 5 Focus Servo Amplifier Description Visual inspection velocity loop DC offset tuning and DC offset monitoring Actions Use the Mitutoyo display DBSC maintenance PC VMEASA handset and the X7 adapter cable refer to section 6 1 for details on these tools Turn of the external mains power switch red rotary knob at the rack side and disconnect the CPU module Connect the handset to the VMEASA Connect the MED and the DBSC PC to the servo amplifier Turn on the mains power at this point and since the system has no CPU the position loop will be disable and you
23. or Description Acoustical and visual servomotor inspection and phase current consumption measurement Actions Bring the telescope to the platform position do the inspections and measurements at the platform Visual inspection check for external deterioration of the motor housing and specially the cables passing into the motor via the two metallic cable feed troughs Acoustical inspection Drive the servo motor by using the VME 45 handset refer to 6 1 3 for details and closely listen to sound produced by the whole focus drive mechanism Under normal circumstances the sound is low level and most important single pitched Connect the laptop PC to the focus servo amplifier serial port connector X6 and perform the phase current measurement Drive the servo motor by using the DBSC Harmonic Drive program refer to 6 1 4 for details Acquire CCW and CW graphs and compare them with the reference graphs shown below Be sure that the peak currents are within the ranges marked on the reference graphs Fill in the pertinent section of the 3p6 M2 maintenance form and add comments if anomalies are found Frequency Once every year Caveats You should acquire graphs similar to the reference ones shown below The peak current value of both phases shall be within the margins marked on the reference graphs as upper and lower limit Note that the envelope in the curve represents the instantaneous current fluctuations due to the mechani
24. pecifically designed for Mitutoyo linear encoders When used with Mitutoyo linear encoders the least significant digit value corresponds to lum right most digit provided that the units and diameter switches at the rear panel are set to mm and off respectively The direction switch affects the counting direction only and can be set as desire The only relevant front panel buttons for our test are the green power switch and the yellow zero push button In our test application we will use the MED with two encoder types the linear Mitutoyo and the rotary encoders inside the M2 servo motors or harmonic drives The count to M2 axis linear displacement equivalence is for the linear encoder and for the rotary encoder 0 0016um resolution for both cases the precision is around 2um The MED was modified for monitoring with a single ended oscilloscope probe differential encoder signals Two banana receptacles named PH1 and 2 carry the encoder phases referenced to the binding post ground see Figure 8 Figure 8 MED Rear Panel Page 26 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 Figure 9 MED AC Adapter The MED is powered by the aid of an external AC adapter see Figure 9 6 1 2 Encoder Signal Test Box The encoder signal test box 15 the same unit described on 6 1 1 On the rear panel this unit has three test points label GND PH1 and PH2 w
25. plifier This microprocessor communicates via RS232 with a Windows program provided by the manufacturer for parameter setting parameter tuning diagnosing testing etc During normal operation the settings remain inside the flash memory of the amplifier and the RS232 link with the PC is not necessary This program is currently installed in a notebook and is available for M2 maintenance Since the program is under MS Windows is self explanatory well documented and easy to use We will use it mainly for phase current acquisition and offset tuning Below you can see two typical screens of the program In any event we will exercise the program in the laboratory with a mock up of one M2 axis before using it in the field 29 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 lajajo els a a vin None sl None Mow 11 AE 2222 Figure 14 DBSC Program doing offset tuning 6 1 5 Oscilloscope Fluke type 199 Scope meter Colour or equivalent Th
26. rticular test inspection Position feedback in this axis is provided by an independent linear encoder 3 1 3 Mitutoyo Linear Encoder Description Linear encoder functionality test inspection Actions Using the encoder signal test box refer to 6 1 2 for the test box details and the VMEASA handset refer to 6 1 3 for the handset details test the encoder functionality Disconnect the linear encoder from the system at the patch box labelled FOCUS see Figure 17 and connect it to the encoder test box With the aid of the VMEASA handset drive the axis at the highest possible speed While moving measure with an oscilloscope settings channels 1 amp 2 at 2V div time base 2mS normal trigger channel 1 at 1 8V triggering level the amplitude 90 phase difference of the signals and compare them with the reference in Figure 10 section 6 1 2 11 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 Fill in the pertinent section of the 3p6 M2 maintenance form and add comments if anomalies are found Frequency Once every year Caveats After removing the display box reconnect everything properly adjusting in place the bayonet fixation of the connector 3 1 4 Baumer Init Limit Sensors Description Check the functionality and repeatability of the Init Limit Sensors Actions Using the VMEASA handset refer to 6 1 3 for the handset details and the MED refer to 6 1 1 for MED det
27. trophic Limit sensors Actions Same as on 3 1 5 Frequency Once every two years Caveats Same as on 3 1 5 3 3 Y Drive 3 3 1 AC Servo Motor Description Acoustical and visual servomotor inspection and phase current consumption measurement Actions For Y drive follow the same steps as on 3 1 1 Of course this time connect the laptop to the Y servo amplifier serial port connector X6 Frequency Once every year Caveats You should acquire graphs similar to the reference ones shown below The peak current value of both phases shall be within the margins marked on the reference graphs as upper and lower limit Note that the envelope in the curve represents the instantaneous current fluctuations due to the mechanical eccentricities of the motor screw combination Therefore the amplitude of the envelope shall normally lie within 0 5 Amperes peak peak and by itself 15 a powerful tool for diagnosing mechanical problems Note that for the Y drive the current consumption is significantly higher than for the focus drive This is mainly due to the fact that the Y mechanism is not counter balanced very heavily preloaded and no flexion couplings are used between the motor and the Screw il a L p c zn n E ee a p i
28. will gain direct control of the velocity loop via the handset and the PC 21 3P6 M2 MAINTENANCE PLAN 17 08 2005 Plan Document Doc 3P6 PLA ESO 60100 0001 Monitoring the DC offset stability Connect the display to the servo amplifier and with the handset move the axis in both directions at low speed several times Once you release the handset switch the display readout must stop moving in a couple of seconds and remain with slight right most digit variations If when releasing the switch the axis continues drifting appreciably 210 counts per second adjust the offset refer to 6 1 4 for detailed procedure Visually inspect the amplifier checking all the screw terminal connections to be adequately tightened and the cables coming to the amplifier not stressed Fill in the pertinent section of the 3p6 M2 maintenance form and add comments if anomalies are found Frequency Once every two years Caveats The velocity loop of each axis Focus X Y is closed inside the servo amplifier itself and the command signal is an analogue voltage coming from the VMEAS A 1 Since the velocity loop is nested inside a digital position loop the drift due to voltage offset is compensated by the outer position loop and during normal operation is invisible However a minimized and stable DC offset is important to maximize the dynamic range of the control system and by itself is and indication of the health of the amplifier A volta
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