This file contains relevant notes from installation and commissioning of the 'new' model S6961 motor controllers for the Hall-C moller collimators and target ladder motion control system. It also serves as the logbook for system experts. In June-July, 2002 the eight original motor controllers were removed and replaced with the newer models. During this changeover, the wiring for the interlocks, limit switches, and home switches was first documented, then re-worked through newly installed termination strips in the motor control panel. A jpdf image of the (corrected) wiring diagram is located nearby to this file. It is named S6961_WIRING.eps. As of 7/28/02 the system seems to be properly reconfigured and operational. The (EPICS) software is still to be modified and tested. Lessons learned about the system are: 1) Wiring or at least diagram error: HOME and +EOTa limit switchs on col-5 were interchanged. Corrected. 2) Had to reverse A+/A- motor leads on target ladder controller to get the motor to run in the correct direction. 3) Motor power leads for collimators 1 and 7 were interchanged at the control panel. It was straightforward to correct this by swapping the cables at the motors. I did so and relabeled the cables. 4) Proper homing of target ladder requires that its controller be set to "HE1" - which tells controller which side of the limit switch to call home. The collimators use "HE0" which is the factory default. 5) Target ladder speed should not be as high as 0.2 inches/second. Set it to 0.1 inches/second. Set acceleration/decelaration to 1.0 to reduce overshoot when limit switch is hit. Since at least one of the limit switches is near the physical end of travel you may jam the mechanism if the motor doesn't stop quickly. 6) Setting the collimator controllers to 3.6A causes the motors to be extremely noisey. 2.6A setting seems fine. 7) Controllers 1 and 7 were intermittently giving "AMPLIFIER FAULT". It turns out that IDC specs a maximum motor cable length of 50 feet. We are well above this limit. The problem is cable capacitance. I made these controllers start working (I hope reliably!!) by DISCONNECTING BOTH THE CABLE SHIELD AND THE GROUND WIRE at the controller end. This is, in fact, recommended by the manufacturer as the motors (and therefore, the cable ground wire) are connected to ground at their end by virtue of being mounted on a conductive, grounded object. Leaving the ground wire connected causes a ground loop. Grounding the shield increases the cable capacitance. IF WE HAVE AMP FAULT TROUBLE IN THE FUTURE WE SHOULD CONSIDER INSTALLING LOWER CAPACITANCE MOTOR POWER CABLES OR, BETTER YET, RELOCATING THE CONTROLLERS SO THAT THEY ARE CLOSER TO THE MOTORS. 8) The 'WAVEFORM" DIP switch on the controllers does not seems to have an impact on our system. Leave OFF. 9) The brake/light relay box (sits under the beamline below the solenoid) now has diodes across the coils to protect the solid-state outputs that drive them. I had to install a fourth relay which is simply 'made up' whenever power is applied to the relay box. This relay provides a closed circuit back to the controllers to indicate that the relay box is on and connected. Previously this had been indicated by the presence of 24v on the same pair of wires. 10) It is not clear that the brakes on collimators 1 and 5 are strong enough to prevent powered motion of the collimators. However, their intended function is to prevent unpowered drift of the collimators and I expect that this does work. I can hear the brakes being energized/de-energized when the corresponding relays make up. 11) I installed a 9-pin (DB9) connector on a cable at the motor controller panel which is a parallel circuit to the RS232 cable that goes to the EPICS interface module on IOCHC10. This is for convenience when downloading/controlling the controllers locally. I successfully communicated witht the controllers through this cable even with the IOC connected at the same time -- although I'm sure this is not recommended. 12) Sometimes it is necessary to reboot the IOC after the motor controllers have been power cycled. A couple of times I noticed the IOC start its own reboot when the controller power was turned on. Be alert to this, because an IOC reboot CAN put the cryogenics into a stupid state. ======================================================================= 8/15/02 hcf David Wetherholt has provided an additional software component in the IOC code which will allow ColTestCmd to properly read the contents of the S6961 controller memory. The command to the controller is "nUA" (n=1-8, of course). To get the IOC to capture and report the entire response from the controller, do this... IOC> ColTestCmd "8UA ",2 The '2' is the important new feature. ======================================================================= 8/19/02 hcf I found the target ladder mechanical system frozen (again). I finally freed it by lubricating the bushing under the knurled knob used for manually moving the ladder (loosen and retract the nut and lubricate there). Looks OK now. Motor 5 (hole collimator) was making a noise while moving. I found the motor controller set to 3.6A. I set it at 2.6A and it is now quiet, but still moves fine. ======================================================================= 10/24/02 hcf A new IOC processor was installed last week. I sent the collimators "home" a few days ago, but the screen forever displayed "busy". This morning, after and IOC reboot, I exercised all the controllers. Number 1 would not move, so I checked the front panel of the controller... it showed AMP FAULT!! Crap! Except for this, they appeared to work fine until I tried another "go home" at which time the system stayed 'busy' again.