1. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 1 DQLPU Functional Test Bench Front view Rear view

2. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 -Test Bench approach - Test Bench hardware -DQLPU individual test details -Test Bench software -Conclusions 2 2 Outline:

3. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 -Test Bench approach - Test Bench hardware -DQLPU individual test details -Test Bench software -Conclusions 3

4. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 4 DQLPU crate (Local Protection Unit for the LHC Main Magnets) 1 2 3 4 5 6 1 2 3 4 5 6 DQQDL => Redundant quench detectors based on analog measurement bridge (Magnet APerture) DQHSU => Quench heater circuit supervision DQCSU => Crate supervision DQAMC => Fieldbus coupler DQIPF => Fieldbus & programming connector (passive board)

5. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 5 Test Bench main requirements:  This test bench will perform a FUNCTIONAL test (not an hardware test...) A hardware test verifies each component on a PCB board A functional test verifies the behaviors of an assembled syste m  The whole assembled DQLPU crate will be tested each individual board has been previously tested on its corresponding test bench  The GUI must be simple, non expert must be able to use this test bench Thanks to the provided user manual, any team member should be able to run a test  Up to 4 DQLPU crates can be tested in one test sequence not at the same time but one after the other

6. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 6 DQLPU Test Bench structure Like most of industrial test benches, the different elements of the DQLPU test bench are:  General Tester Crate In the DQLPU test bench case, it’s a National Instrument PXI crate with different NI modules inside, this assembly is designated as the GTC  Test Controller Card The TCC is the interface between the GTC and the device to test. It is generally used to adapt the different voltages. In the DQLPU test bench it is mainly used as a multiplexer  Device Under Test: The whole DQLPU crate

7. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 7 DQLPU Test Bench resources Hardware resources:  National Instrument PXI platform is used for the GTC  A simple TCC will ensure the Multiplexer function and all interconnections between the 4 DQLPU crates. There is no active electronic on this TCC ( the relays will be directly powered by the PXI relay driver module). Software resources:  National Instrument LabWindows CVI is used  The embedded processor runs with Windows 7 (Microsoft office is supported)

8. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 -Test Bench approach - Test Bench hardware -DQLPU individual test details -Test Bench software -Conclusions 8

9. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 9 DQLPU DQLPU test bench overview

10. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 10 Common resources:  NI PXI 8106 controller  NI PXI 4110 PSU  NI PXI 6733 analog I/O  NI PXI 6221 general purpose DAQ Individual resources:  NI PXI 2567 64-channel relay driver  DQAMC Worldfip connection DQLPU DQLPU test bench overview

11. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 11 The National Instrument PXI modular system as GTC

12. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 12 NI PXI-8106 Controller Ni PXI-8106 - Intel core 2 Duo processor - Works with Microsoft Windows Integrated IO - 10/100/1000 Base TX Ethernet - 4 Hi-Speed USB ports - RS232 serial port - IEEE 1284 ECP/EPP parallel port - GPIB Controller  Middle range controller in terms of power and price  GPIB is very useful for industrial test benches connection (the parallel port is used with former Xilinx Parallel 4 JTAG probe)

13. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 13 NI PXI 4110 PSU Ni PXI-4110 - 3 independent DC PSUs - 1 x 0 → 6 V DC up to 1 A - 2 x 0 → ± 20 V DC up to 1 A (Ext PWR) - 16-bit U and I set point - 16-bit U and I read back function Triple-Output Programmable DC Power Supply  for DQLPU T.B. : a pair of PXI 4110 is required  DQLPU current consumption can be limited and can be read

14. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 14 NI PXI 4110 PSU Connection  All diodes on the motherboard can be tested  No insulation between ISO and COM voltages on the Test Bench

15. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 15 NI PXI 2567 64-channel Relay Driver Module Ni PXI-2567 - Control up to 64 external relays -Works with internal or external power sources 1.25 A for all channel with internal power 600 mA per channel with external power  for DQLPU T.B. : 4 x PXI-2567 are required  Direct TCC connection with standard 78-pin D-SUB female connector  For DQLPU T.B. : the total TCC relays consumption is no external power required

16. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 16 NI PXI 6733 Analog Output Ni PXI-6733 - 8 independent analog output - 16-bit output (after calibration) - ± 10 V DC output  Direct TCC connection with SH68-68-EP shielded cable

17. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 17 NI PXI 6733 Analog Output connection  DQQDL A and B can be simultaneously tested

18. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 18 NI PXI 6221 General Purpose DAQ Ni PXI-6221 - 24 digital I/O  Direct TCC connection with SHC68-68-EPM shielded cable

19. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 19 GTC to TCC interconnection  These interconnections are realised only once during the test bench configuration. They are accessible from the front side.

20. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 20 TCC to DUT (DQLPU) individual interconnection  These interconnections must be realised each time a new DQLPU is inserted for test and are accessible from the rear side.

21. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 -Test Bench approach - Test Bench hardware -DQLPU individual test details -Test Bench software -Conclusions 21

22. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 22 How to define the tests to execute on the DQLPU ? 1) The key point is the knowledge of the DQLPU functionality. From the different board schematics, a “reverse engineering” has been performed and the global DQLPU functionality deduced. 2) The test bench has no access to individual board connectors, since only the motherboard connectors are accessible. Taking into account this restriction, specific paths have been identified to test most of the DQLPU functionality. 3) After a review with the different design engineers, all relevant tests have been considered and have been clearly described in the document “DQLPU TEST PLAN”.

23. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 23 EDMS document “DQLPU TEST PLAN”

24. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 24 Test bench monitoring paths CVI provides simulated parameters to the DQLPU under test DQAMC sends monitoring data to the gateway via the FIP Labview running on a desktop PC reads the value gathered by the gateway CVI via data socket protocol communicates with Labview application The FIP functionality is indirectly tested 1 1 2 2 3 3 4 4

25. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 25 DQLPU Power Supply tests (Common and Isolated) DQLPU Common power supply

26. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 26 DQLPU Power Supply tests (Common and Isolated) DQLPU Isolated power supply

27. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 The 12 independent power supplies are individually tested. This test performs the following actions :  Check short circuit between the different power supplies (soldering, PCB …)  Check integrity of the 12 power diodes (mounting side, soldering …)  Each individually current consumption is measured, recorded and compared to defined thresholds (min & max)  The power diodes forward voltages are measured and compared to defined thresholds Direct tests: Indirect tests (monitoring path):  The 12 readback voltage values are compared to the real ones DQLPU Power Supply tests details

28. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 28 DQQDL aperture measurement tests

29. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 29 The 4 MAP voltages are individually tested. This test generates a voltage between -80mV and 80mV on each simulated MAP. These voltages are below the DQQDL trigger thresholds (thus, no interlocks are generated) Indirect test (monitoring path):  The 4 readback voltage values are compared to the applied values DQQDL aperture measurement tests details

30. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 30 DQQDL HDS Firing relays tests

31. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 31 This function checks the real MAP voltage required to close the HDS firing relay on each DQQDL board. This test increases the simulated MAP voltage till the HDS firing relay is activated. The real value is precisely measured.  Checks the integrity of the DQQDL HDS firing path ( threshold, relay …) Direct test : DQQDL HDS Firing relay tests details

32. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 32 DQQDL Interlock relay tests

33. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 33 This function checks the capability of each DQQDL board to close the interlock relay. This test applies on the DQQDL MAP inputs a voltage higher than the maximum threshold.  Checks the integrity of the DQQDL interlock path ( threshold, relay …) Direct test : DQQDL Interlock relay tests details

34. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 34 DQHSU reading heater current tests

35. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 35 This function checks the readback capability of the DQHSU to read the 4 heater currents. This test applies a voltage on the different DQHSU “I IN” inputs. Indirect test (monitoring path):  The 4 readback current values are compared to the applied values DQHSU reading heater current tests details

36. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 36 DQHSU reading heater voltage tests

37. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 37 This function checks the readback capability of the DHSU to read the 4 heater voltages. This test applied a voltage on the different DQHSU “V IN” inputs. Indirect test (monitoring path):  The 4 readback voltage values are compared to the applied values DQHSU reading heater voltage tests details

38. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 38 DQLPU interlock tests

39. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 39 This function checks the integrity of the two interlock connectors mounted on the motherboard. A binary pattern is applied on one connector and then read back on the second connector. Direct test :  The sent pattern is compared to the readback pattern DQLPU interlock tests details

40. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 -Test Bench approach - Test Bench hardware -DQLPU individual test details -Test Bench software -Conclusions 40

41. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 41 LabWindows/CVI  Labwindows CVI is an ANSI C integrated development environment provided by National Instrument.  Like Labview, the implementation of Graphical User Interface is very easy to implement.

42. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 42 The whole DQLPU test bench is arranged around 3 distinct GUIs. DQLPU test bench interface  Initialisation GUI Prior to any test, a self test is executed on the whole test bench (GTC & TCC). The test is stopped if some errors appears during the self test

43. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 43  Help GUI This online help is intended to quickly allow the operator to fix minor hardware problems during initialisation, typically some cabling mistake.

44. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 44  Main GUI The main GUI is the most important one and is used to launch all tests. Only two tabs are necessary to control the full test bench.

45. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 Test list file concept The tests sequence and the associated parameters are extracted from an Excel file:  Function name : user friendly name of the test that must be executed  Short description : only used to gives information to the operator  Parameters : define the behaviours of the current test  Action on fail : the behaviour in case of errors

46. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 Advantage of the test list file  If the global test must be launched several times, the same test list file can be reused.  The test report is archived together with the test list file, so the conditions of the test can be easily retrieved.  The test list file avoids many setup errors: more easy to write a complete test sequence in an excel sheet that configuring many objects in different graphical panels.  The operator can easy modify the sequence and behaviours of the tests without any knowledge in C programming and without having to recompile the whole test bench C code.

47. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 Test report The test report is easy as possible. Microsoft word is used to realise this report. Each individual test adds a new line in the report after the previous one.

48. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 -Test Bench approach - Test Bench hardware -DQLPU individual test details -Test Bench software -Conclusions 48

49. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 49  Thanks to the concept of “Generic Test Bench” based on NI PXI, this type of test bench can be smoothly realised for another crate/system.  The test bench is based on EDMS document “DQLPU TEST PLAN”. The latter describes all relevant tests identified following an internal EP review.  In complement of the individual board tests, this functional test bench validates the DQLPU crate functionality. Conclusions

50. Christophe Martin / DQLPU Test Bench MPE-TM of 24/10/2013 50 Thanks for your attention