1006 - Power Supply and Endpoint Package V3: User Manual
Preliminary manual... This is a work in progress.
Table of Contents:
Purpose/Summary/Background
Physical Layout and Features
-General Tray Layout
-Pictures
-Wiring Diagram
-Power Supply Unit
-General Information
-HUGnetLab Board
-General and Diagrams
-A-D Chip Details
-HUGnetLab Accuracy
-Ground Loops
-Wiring Standards
-PWM and DAC Control
-Power Supply Controller Board
-General with Diagrams
-Switches and Dials
Operation with HUGnetLab
-Common and Default Settings for:
-Test
-Endpoint
-Commands to Use with Power Supply and Endpoint Package V3
Expansions/Upgrades Available
Purpose/Summary/Background:
The purpose of the user manual is to collect all the information about the power supply and endpoint packages and communicate it so that any user can operate the unit.
In this manual there is everything needed to operate the power supply and endpoint package. It contains pictures, descriptions and diagrams to help the user better understand the unit as a whole.
The V3 power supply and endpoint package is the third attempt at making an easy to use and high precision desktop power supply. The first two attempts were too cramped where the wiring and cable management were concerned. They also lacked a modular layout, making it hard to service for upgrades, new features and to replace parts. The current V3 package employs a 2D layout that spreads out the more delicate wiring zones and allows the operator to view the entire unit at a glance. It also increases the modular nature of the power supply and endpoint package to better accommodate HUG servicing and future upgrades.
Physical Layout and Features:
The V3 power supply and endpoint package utilizes stackable trays as the chassis, complete with handles and LRF (little rubber feet) support. All the components; the power supply, any HUGnetLab Boards, and all the wires are mounted face up on the aluminum tray chassis. This allows for maximum visibility and space for modifying the electrical components.
General Tray Layout-
The base of the tray is made from a sheet of aluminum while the two side panels are made from ultra high molecular weight (UHMW) Polyethylene. These side panels have handles and grooves cut from them. The handles for transportation of the tray and grooves so that the sides don’t hinder wiring up the HUGnetLab boards. On the bottom of the tray there are four adhesively attached rubber feet as well as allen bolts that play a part in the stackability. On the top of the tray sits the power supply, a power strip, a HUGnetLab board, a power supply controller board and then all the wires to connect the various components together.
The V3 package comes with one 48V power supply, a build E HUGnetLab board, and one power supply controller board. Everything comes pre-wired and capable of controlling one channel. Wiring diagram below:
*The only wires not included and that are shown in the diagram are the leads to the DUT (device under test).
Power Supply Unit-
The power supply used in the V3 power supply and endpoint package is a 48 volt AGT (Advanced German Technology) PSU. Some of the specifications include:
Output DC Voltage | 48 V |
Rated Current | 7.3 A |
Current Range | 0 - 7.3 A |
Rated Power | 350 W |
Voltage Adjustment Range | 41-52 V |
Input Voltage Range | 85-132VAC/180-264VAC |
Input Current | 6.5A/115V or 4A/230V |
AC Inrush Current | 25A/115V or 50A/230V |
Leakage Current | <3.5mA/240VAC |
Temperature Coefficient | +/- 0.03% |
These power supplies were modified by HUG in the following ways. The potentiometer was removed and two wires were soldered on in its place (the black and yellow wires in the left picture). Then a red wire was soldered to an internal IC of the power supply (right picture).
HUGnetLab Boards-
General and Diagrams-
In the standard V3 package there is one HUGnetLab board installed. The version E build of this board has 6 low voltage inputs (inputs 1-6) and 2 high voltage inputs (inputs 7 and 8). Below is the silk screen image and a picture of the wired up HUGnetLab board.
Below is the schematic of the HUGnetLab board. Note: the resistors to the input pins will change with the build version of the board.
A-D Chip Details-
The working voltage range of the A-D chip inputs is plus and minus 0.85 volts with reference to the endpoint ”Com” terminals. At the endpoint input terminals, that voltage is multiplied by the ratio of the input voltage divider. For inputs 1 through 6 that ratio is usually close to 1; giving a working common mode range of plus and minus 0.85 volts. For inputs 7 through 8 the ratio is typically 101 to 1; giving a working common mode range of plus and minus 85 volts.
If any input pin exceeds the working range, data from that endpoint may not be accurate. On differential inputs beware that common mode power line noise and static can temporarily cause the inputs to go out of range even when the differential signal is well within range.
HUGnetLab Accuracy-
Entire books can be written about accuracy of Analog to Digital (A-D) converters. In this section we will simplify it to how HUGnet is typically used. To get more deeply into the actual converter specifications refer to this manufacturer’s data sheet. http://www.analog.com/static/imported-files/data_sheets/ADuC7060_7061.pdf
As it comes from board assembly with no calibration; operated at room temperature (25C +-∓10C):
Low voltage inputs
Range +- .8V; Accuracy +-.25% of reading +-5uV; P-P Noise 5uV
High voltage inputs
Range +- 80V; Accuracy +-.45% of reading +-500uV; P-P Noise 500uV
After initial calibration and testing at HUG; operated at room temperature (25C +-10C)
Low voltage inputs
Range +- .8V; Accuracy +-.1% of reading +-5uV; P-P Noise 5uV
High voltage inputs
Range +- 80V; Accuracy +-.1% of reading +-200uV; P-P Noise 500uV
Most accurate possible; Temperature controlled +-1C; Gain of 64; Calibrated to local ground and voltage source. Only using 1 channel, pins 1+2
Low voltage inputs
Range +- 18.75mV; Accuracy as good as calibration +-0.14uV; P-P Noise .14uV
Ground Loops-
There should be a reference for differential voltage and current measurements. One of the negative legs should be tied to Cground. Otherwise the voltage will float out of range and won’t be reading properly.
Beware that some thermocouples are grounded to the sheath.
Some thermocouples with ceramic insulation to the sheath have leakage resistance. A case in point is a 1 foot length of .040 inch sheath ceramic thermocouple wire has around 10 megohms to sheath at room temperature and about ½ megohm when heated.
Thermocouples with no ground reference are best connected single ended. That grounds the thermocouple to the endpoint and prevents the inputs from going out of amplifier common mode range.
Only one ground reference per endpoint.
Each endpoint must have one of the common pins connected to one of the sensor grounds. If there are no sensor grounds (all sensors are floating) the sensors can all be connected single ended.
Beware of thermally induced EMF. Every electrical connection is a thermal EMF source. Any dissimilarity in the metals and any temperature differences can add 10s of microvolts per degree.
Wiring Standards for HUGnet Labs RJ11-
Note: HUGnet lab boards are designed to be powered by the data bus. Do not power them any other way unless you are a true ground loop wizard.
One 9 volt power supply can power at least 12 HUGnet Lab boards.
9 volt negative should be connected to RS485 ground.
Telephone modular plugs and jacks are a convenient way to connect the boards to the data bus.
6-pin (though sometimes only middle 2 or 4 used)
Numbered left-to-right looking into female connection.
Female: Photo of male below
Pin | Connection | Color in Telephony | Color using Cat5 | Color in USB to RS485* | Pair # |
1 | Not Used | Not Used | Not Used | Not Used | 3 |
2 | RS485 Data + | Black | Orange/White | Orange/Green | 2 |
3 | Power + (9vdc) | Red | Blue | N/A | 1 |
4 | Power - (gnd) | Green | Blue/White | Black | 1 |
5 | RS485 Data - | Yellow | Orange | Yellow/Brown | 2 |
6 | Not Used | Not Used | Not Used | Not Used | 3 |
*The red wire on the USB adapter is not used and just cut short.
Illustrated on a board with telephone wires
Note: On pins 1,2,3,4 if used in differential mode, the lower number is negative, the higher number is positive. (The lower pin is subtracted from the higher pin)
Note: On pins 5,6,7,8 when used in differential mode, the lower number is positive, higher number is negative.
Note: The color scheme of the telephony cable is correct. However, the silkscreen on this particular board is incorrect. We have forgone the A and B corresponding to Data lines and stuck with only + and -. In the current orientation of the board:
Far left = Data -
Middle left = Data +
Middle right = Power -
Far right = Power +
PWM and DAC Control-
A PWM (Pulse Width Modulator) uses a square wave, alternating varying durations of full on and off to create an average somewhere in between the the two extremes. This average will correspond to the desired output on the power supply.
The HUGnetLab board comes with one of three PWMs as the wired control channel. On the HUGnetLab board the PWMs are located in the SV3 pin header. The included HUGnetLab board is wired in pin 12, which is PWM1. Pin 6 is PWM3 and Pin 2 is PWM5. These are the only three PWMs used. Pin 1 in SV3 is positive 2.5 volts.
The DAC (Digital-to-Analog Converter) uses a constant voltage signal to create the average instead of using an alternating signal like the PWM.
The HUGnetLab board has a DAC output and is available for use. However, the power supply controller board will only interface with one of the three PWMs.
Power Supply Controller Board-
General and Diagrams-
Included with the V3 power supply and endpoint package is one power supply controller board. This board is part of the interface between the HUGnet system and the power supply. One of these controller boards is needed to control the output of one power supply. It contains three potentiometers and a toggle switch that are used in controlling the power supply. It has the terminals to connect the power supply to the HUGnetLab board (ie current sense and PWM signals) and also the negative terminal to complete the circuit to the DUT or “Cell.”
Switches and Dials-
The toggle switch has three positions: manual, automatic, and the middle position - minimum voltage. Then it has three (28 turn) potentiometers, one for the manual adjustment, one for the minimum voltage adjustment and one for the maximum voltage adjustment.
When the switch is flipped to “MANUAL”, the power supply then outputs what the “MAN” pot dictates. When the switch is flipped to the middle position, the power supply then outputs the minimum voltage dictated by the “MIN” pot. When the switch is flipped to the “AUTO”, the power supply is controlled by the HUGnet system and will be set by the PWM. Also, while in “AUTO” the voltage output cannot decrease further than the “MIN” setting and will not exceed the “MAX” setting.
Note: It is recommended to calibrate the “MIN” and “MAX” settings, with a multimeter, before the DUT is hooked up, to avoid any damage to your load. “MIN” can be calibrated while the toggle switch is in the middle position. “MAX” has to be calibrated in “AUTO” mode. This can be done by setting the output to a large value (something larger than the desired output) with the HUGnet system, then you adjust the “MAX” value down/up to the desired output. These are physical limits that are designed to protect the cell (the load) if delicate wires are involved.
Operation with HUGnetLab:
For general operation and site layout go here:
https://docs.google.com/document/d/195JXK2naH6CpcGj_3jpkSYctNryWFlmo42Je1G1Vfu4/pub
Note: All changes to an endpoint or test must be saved and then the device must be updated with the ‘Write Config’ option in the endpoint action menu. Otherwise, these settings will be lost or will not take affect.
Default Settings-
Input Tables-
When connecting to the HUGnetLab server, it will be required to sync input tables with the host computer. HUG has created 30+ input tables designed to handle many different sensors. If a new input table is required contact HUG.
Endpoints-
The HUGnetLab boards, Endpoints, are designed to handle up to 8 sensors, from thermocouples, to voltage sensors, pressure sensors, and power metering. Each sensor plugged into the endpoint will have an input to set up. Note: the endpoint must have firmware on it before setting up any Inputs, Outputs or Processes.
In the main setup screen of an endpoint will look similar to this:
-The Name, Location and Job are editable text boxes for the user.
-The Data Interval for endpoints should be set to 0.
-The Info Link URL is only used for tests.
-The Active section should be set to YES when the board is active and NO when the board is inactive (ie unplugged, decommissioned or replaced and no longer connected to the host computer).
-The Role section is still under development currently. It is designed to take the commonly used configurations for the HUGnetLab boards and make them an optional default layout. It would take all the settings and put them in automatically, giving the endpoint a base configuration.. The endpoint can then be further modified or populated with additional sensors.
-Push History to Master should be set to YES if that data should be sent to the server. It is not necessary to push the individual history for an endpoint to the server. Note: pushing endpoint history to the master server will slow down all history pushing. Set to NO if the tests should have the fastest history pushing!
-At the bottom, in the Data Channels section the user can see all of the data channels created from the sensors. Note: some sensors (like power metering, current and voltage gives you power and resistance so 1 input will output 4 data channels) will have more than one data channel created from one sensor. Currently the endpoints are limited to 12 data channels. Exceeding this value will result in the endpoint crashing and reverting to bootloader, a safeguard that repeats every second.
The user can also modify, the label, the data type, the units and the decimals displayed. Note: these settings will not affect the test in any way. It is recommended to not change these settings in the endpoint setup, but rather in the test setup (there will be the same options available there).
You can also modify the Control Channel labels. Using the PWM, there will be three default channels displayed. They are the PWM1 (top), PWM3 (middle) and PWM5 (bottom).
Setting up an Input:
Once the Edit Inputs button is clicked a screen will pop up displaying all the inputs currently on the endpoint. If this is a new board, there will be no inputs. For a every new endpoint the onboard RTD (T_Board) must be set up first (in the 0 slot), as it is required for any thermocouples to read properly. After that, the device inputs can go in any order.
Below are two examples of device inputs; on the left there is the onboard RTD and on the right there is an example of a power metering input.
-To use an Input Table the Input ID must be set to F9:Input Table Entry.
-The Type should be set to ADuCInputTable.
-The Table Entry is where you can select the correct input table from a drop down list.
-The settings following the Table Entry are unique to each type of Input Table, any question related to these settings should be directed at the HUG team.
Setting up an Output:
Outputs enable the DAC or PWM to be used by the control process. Below is the correct way to set up the PWM for use with the V3 PSU. Once the output is set up, the Label is the only field that should be changed.
Setting up a Process:
The Processes use information from the Inputs and Outputs of the endpoint. The data channel to control from the Inputs and the control channel to use from the Outputs. There are two types of controls in the HUGnet system: a level holder controller and a PID controller. Note: for advanced control loops the PID should be used. However the PID take more know-how to tune correctly. A level holder should be used for most instances.
-The Process ID will be set automatically when you select the Type to be either a PID or a level holder process.
-The Control Update/Sec should be set to 10 as a default. Note: only someone with an advanced knowledge of the control system should change this from 10.
-The Control or Control Channel determines the PWM or DAC to be used in the control process.
-The Data Channel (located in different spots between a PID and Levelholder) determines which channel the process will look at for adjustments and the channel that the process will control.
-The setpoint is the value the control process will adjust the data channel to. Note: make sure the setpoint is within the working range of the data channel before applying any power to the system.
-The Control Min and Max determine the working range of DAC and PWM units. Default to 0 as the min and 65535 as the max
Settings unique for the Level Holder Process:
-The Step (%) determines the step size that the controller will use to control. Note: this step size is represented by the percent of full scale. This means it will use a percentage of the control max and min. Default setting is 0.15% or about 100 units of the DAC or PWM.
-The Levelholder process has two limiters. Each one has a Data Channel, a high limit and a low limit. These can be set for any other data channel available on the current endpoint. Example: you can be controlling the voltage and then you can put a limit on both the current and power or even a thermocouple.
-The Tolerance will determine how close the control will get to the setpoint before changing the step size from the Step (%) to the smallest available unit (1, for the best control around the setpoint). This should be set to a default of 0.01 for power control. Note: this setting is in units of the data channel being controlled. Also, the control loop will oscillate if the tolerance is set too small.
Settings unique for the PID Process:
-The Input Offset
-The Error Threshold determines the last significant digit in the setpoint to control the data channel to.
-The “P”
-The “I”
-The “D”
-The Output Offset
HUGnetLab Commands:
There are three main commands that will be used with the HUGnetLab system and power supply. These commands must be entered in a terminal window. Typing out the base command without any parameters will bring up a help file that explains each possible parameter associated with that command. This allows changing of the control setpoint and tuning of the control parameters.
hugnet_setlevel
Hugnet_setlevel will set your process channel (either a DAC or a PWM) to one value and it will hold it there until specified with another command or until the board is reset (by unplugging or writing config). It will also allow any of the parameters to be changed in the levelholder process. This only works for a levelholder process! If the command is typed in as shown the following help screen will show.
This help file shows how the command should be setup to work correctly. Running the command with parameters in place will overwrite the defaults set in the Processes of an endpoint (determined by the DeviceID and the Table). The main parameters to set will be the DeviceID (-i), the Table (-P) and the Value (-V). Any parameter not entered in the command will NOT be changed from the default settings in the Process of the endpoint.
Example:
hugnet_setlevel -i 1020 -P 0 -V 25
This sets Process Channel 0 on board 1020 to a setpoint of 25. Note: If there are multiple processes set on a single endpoint, check in the Process Edit screen and make sure you are setting the correct channel.
hugnet_setpid
Hugnet_setpid will set your process channel (either a DAC or a PWM) to the desired setpoint until specified with another command or until the board is reset (by unplugging or writing config). It will also allow any other parameter in the PID process to be changed. This only works for a PID process! If the command is typed in as shown the following help screen will show.
The important parameters are the Device ID (-i), the Table (-T), the Value (-V) and only when tuning the PID process; the P (-P), the I (-I) and the D (-D).
hugnet_powerstep
Hugnet_powerstep will control a process with a text file. The text file contains a time duration (in seconds) and a setpoint to hold at for the duration. The text file can be configured to have any number of steps and setpoints. Note: the process will be held to the last entry in the text file even after the time duration has run out. The command help screen is shown below:
This help screen shows how to properly input the power step command. The important parameters are the Device ID (-i), the Table (-P), the step file (-s), the output file (-o) and the Test ID (-T). It also has the correct way to set up the step file (just a normal text file) for proper control.
Example:
hugnet_powerstep -i 1020 -s /home/user/Desktop/teststep.txt -P 0 -T FC0000 -o /home/user/Documents/teststepdata.txt
Expansion and Upgrades Available:
This section will change according to the current available upgrades and expansions. The Power Supply V3 deck can accommodate up to 6 Circuit Boards and one power supply.
HUGnetLab Boards:
We have boards available if the customer requires more inputs for sensors. Each board has 8 inputs; 6 low voltage inputs and 2 high voltage inputs.
Power Supplies:
We recommend buying a second tray that comes with all the components if a second power supply is needed.
HUGnetLab Power Supply Controller Boards:
We have these boards available to purchase for controlling a different power supply. We recommend getting a second tray if you need multiple power supplies.
Custom Solutions:
We are willing to work with the customer to satisfy the needs of their experiment.