From Tuesday morning, October 20, to Wednesday morning, we worked at North End to investigate the issue of power supply channels failing after power cycling.
The affected units are Rohde & Schwarz HMP4040 four-channel power supplies used by NCAL and PCAL. On several occasions over the past few years, individual output channels have failed after a restart following a power shutdown, or after switching off the power supply using the "red" power button on the HMP4040.
Each output channel on these power supplies is independent and electrically isolated from the other channels. The units have a "red" power button to disconnect them from the 230 V mains supply and an “Output” button to enable the output channels. See photo.
NCAL
Two HMP4040 power supplies are used to power the NCAL system:
Motors drivers
Each +30 V channel powers one NCAL motor. Each channel includes a shunt regulator (Maxon 309687) designed to absorb the energy generated by the motors during braking, thereby protecting the power supplies against potentially destructive reverse current. These protection circuits were set to 56 V, which is too high to provide effective protection for the power supplies.
The voltage at the motor controller inputs was measured during motor braking. No voltage increase was observed, indicating that the protection circuits remain inactive under these conditions. Therefore, no evidence was found that these braking phases pose a risk of damaging the power supply channels. The behaviour during an uncontrolled shutdown may differ from that observed during normal motor braking. At the end of Tuesday morning, the jumper JP1 (see the purple circle in the picture) of the shunt regulator of all NCal motor controllers have been set to the open position, meaning that the voltage is now limited to 27 V. The voltage for all motor power supply has been reduced from 30 V (NE) or 32 (WE) to 26 V in all buildings
Electrical grounding and isolation
Each motor and its associated sensors are mounted on a table suspended from the supporting structure. (photo) The following observations were made:
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The impedance between each table and the main tower structure is 100 kΩ, except for one table that is not electrically isolated (on the left-hand side, near the equipment racks).
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On the non-isolated table, disconnecting the photodiode connector located on the motor side results in a measured impedance of 50 kΩ between the table and its support.
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The GND of the +30 V rails is connected to the tables.
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The GND of the +5 V rails is completely isolated from the tables and the supporting structure. The only apparent path from the +5 V ground to the structure is through the ADC inputs used to read the sensors, since the ADC grounds are connected to the structure. During operation, a voltage of approximately 150 mV was measured between the +5 V ground and the structure.
When the power supplies are switched on using the “Output” button, some of the +30 V channels enter overvoltage protection. The affected channels vary randomly between restarts. The power supplies' overvoltage protection thresholds are set to 32.5 V, their maximum setting. No overvoltage transients were observed on the supply rails at startup using an oscilloscope. This behaviour therefore appears to be related to the internal operation of the power supplies. When the output voltage was reduced to 26 V instead of 30 V, this behaviour was no longer observed.
Finally, the protective earth and the output grounds were connected together on the power supplies, as shown by the purple wires in the picture. This modification affected the position measurements of the NCAL tables powered by the +5 V channels ( grounding-north-west.png , grounding-south-est.png), changing their offsets. However, it should provide a better-defined ground return path for the +5 V supply.
It would probably be preferable to electrically bond the tables to the supporting structure to improve equipotentiality around the electronics. However, this would not explain the channel failures. Since these connections could introduce untested electromagnetic compatibility (EMC) side effects, they were not implemented.
PCAL
One HMP4040 power supply (No. 32) provides the following voltages:
This image shows how the PCAL bench is wired. Within the PCAL enclosures, all electronic equipment is electrically connected to the supporting structure. No modifications to the existing wiring appear to be necessary.
After switching off the laser, we repeatedly switched the power supply outputs on and off using the “Output” button while monitoring the PD1 signal. No abnormal behaviour was observed.
We then switched off the outputs using the “Output” button and completely powered down the unit using the "red" power button. After switching the unit back on, we found that channel 2 (+12 V) had failed.
Previous failures had affected channel 3 (−15 V) on two occasions and channel 1 (−12 V) on one occasion. The failures therefore appear to affect different channels rather than being confined to a specific output.
We also observed that when an HMP4040 is switched off using the red power button, a residual voltage of approximately 1 V appears on each output channel for a few seconds. The available current is approximately 2 mA. We do not understand this behaviour of the HMP4040. Normally, before the outputs are enabled, each channel should be disconnected by an internal relay. It is therefore unclear why these residual voltages are present, but this behavior is present on all HMP4040.
The failed power supply was replaced with unit No. 20. The protective earth connection on the front panel was then connected to the output grounds and to the rack chassis. The PCAL setup was restarted and returned to operating points identical to those observed before the intervention.
Conclusion
The measurements carried out have not provided a convincing explanation for the failure of power supply channels following a restart. We modified the GND and protective earth wiring, but there is no guarantee that this will resolve the issue. To switch off the output channels, it is preferable to use the “Output” button rather than the "red" power button.