Some common tasks required while maintaining BABAR systems

Last update by rayr on 07/30/03 



Introduction

This is where I will place some of the common tasks and instructions for those tasks. This is meant to be utilized by those within the maintenance group but I guess that anyone can try. If you are not sure then please wait and ask either Ray Rodriguez, Walt Innes or David Hamilton for help and/or guidance. 


Testing and replacing IOC's

Dale Kotturi is by far the "expert" for these devices but here goes an attempt to document what needs to be done. 

Installation and use manual for our version of the MVME-177

When logging onto the console for a particular IOC use the "xyplex" command from a bbr-devXX machine with the -f switch. 

Initial installation calls for the installation of M712 interface card for the connection of RJ-45 ethernet and DB-25 RS-232 serial console connection. 
The pin out for the serial connection DB-25 to RJ-45 is....

Once all connections are made power on the IOC. 
After initial boot from the factory you should get a buggy prompt, this is for the delivered OS. 
The is a small set of help files using "he" 
One should first set the time with the "SET MMDDYYHHMin" format 
Time can be checked with "time" command 

Diagnostics can now be accomplished using the following commands.... 
"sd" is set directory command should change to indicate diag. 
"st" accomplishes the default set of diagnostics, not all failures cause a halt so you should scroll back thru the list when done. 

If all has passed here then you are ready to exchange the boot proms at U1 and U2 with ones containing vxWorks 
After doing this and storing the originals with Ray you may now configure the 
 
 
 

To try to create a more stable environment for Ray, bbr-dev15 has it's own private /dataflow area, and a second ethernet interface plugged into a small 100Mbit switch (along with the ROMs in his test crate). The second ethernet interface has the IP address and ethernet address of odf-srv02, so that ROMs taken from the electronics hut will boot dataflow correctly without changes to their NVRAM settings. 

Two of the resources that are needed to maintain ROMs are tftp and rsh (for loading in the VxWorks kernel in various ways described below). Steffen has promised that those will remain enabled on bbr-dev15. 

There are two ways I can think of that the software can change in this environment without ray's approval: 

  • upgrades to the solaris operating system in a non-backwardly compatible way
  • using a ROM with a different version of the VxWorks kernel

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    At the time of this writing, the operating system on bbr-dev15 is SunOS58. The dataflow software and /dataflow/teststand/setup will have to be modified if that is changed. The VxWorks kernel version can be kept constant by Ray (if desired) by using the /dataflow/tgt/startup.save-kernel-to-flash script described below. 


    Testing ROMs and Dataflow components in general

    There are extensive instructions at this location.....

    /BFROOT/www/Computing/Online/DataFlow/doc/repair.html

    Questions can be addressed to Chris O'Grady and Ray Rodriguez

    Replacing Valve Actuators in the Electronics House cooling system


    If possible start monitoring the valve position and regulated temperature with StripTool before starting.

    Inform the Shift Leader about the planned work.

    Bypass the AC Power Shunt Trip Bypass Switches for the appropriate zone. 

    The shunt trip bypass is located in the rear of Rack B620B-6, setting the switch in the up position is bypassed.

    Unplug AC power to the Micromedia Control Panel which services the valve actuator to be replaced, usually found at the top or bottom of one of the racks in the set associated with the valve actuator. 

    If power is to remain on in the rack set being worked on monitor the temperature with the StripTool while work is performed and react accordingly.

    Replace the valve actuator paying close attention to the wiring and switch settings. The installation procedure provided by the manufacturer is here....
    SQX62U installation procedure

    Reapply AC power to the Micromedia Control Panel. Note: All of these should be plugged into a UPS service outlet. Immediately after applying power the valve actuator should begin an automatic calibration procedure, and the Manual Override Knob on the front of the controller should seek the fully closed position, this is done so that all reported positions after this are relative to this initial closed position. If it does not move there may be a problem with valve actuator or with its circuit connection. 

    The valve actuator should now be ready for operation but it is also important to test its operational behavior. This can be done by manually changing the Set Point Value on the Micromedia Controller of the actuator. Change the Set Point Value (SPV) a couple of degrees above and below the nominal operating value and monitor the valve actuator using both StripTool and visually, this will give you an idea as to the relation of the actual position to the electronically reported position. The valve should begin to either open or close in a step-wise manner as it adjusts to the new SPV. 

    Extremely Important -- Reset all the tripped channels, except the Shunt Bypass (SIAM 8, CH 7), on the CEN-ILK Crate before enabling the AC Power Shunt Trip Bypass Switches. If a channel cannot be reset, investigate the problem. The problem must be resolved before the shunt is enabled. Failing to reset a trip condition will cause AC power to shutdown in the affected zone. 

    Inhibit SIAM 8 CHANNEL 7, this is really only done so that you do not once again get an audible alarm.

    With only the Shunt Bypass tripped and inhibited on the CEN-ILK Crate, enable AC Power Shunt Trip Bypass Switch for the zone that was bypassed at the beginning of this process. All bypasses in the top rear of Rack B620B-6 should now be down or in the normal operating position.

    Reset the Shunt Bypass on the CEN-ILK Crate.

    Remove the Shunt Bypass inhibit on the CEN-ILK Crate.

    Inform the Shift Leader that the work is complete.

    Place an entry in the Shift Log.


    Recommended Tests


    How to Compile Standalone TPC/UPC/FC Software

    nless the TPC JP1 jumper is switched to give it the standard 8 buffers (see firmware section below for a few more details). 

    Running Fast Control Standalone Test Software


    Running Miscellaneous Utilites


    Running TPC Core Dataflow Software


    Note that this software can be run on the entire EMC ir-2 system in order to look for data corruption there. 


    Running PPCBug Diagnostics


    Reprogramming the Flashed Kernel from the VxWorks Prompt


    SBC Memory Addresses

    Note that accesses to everything except fast-control hardware (i.e. VME) appear byte-swapped. 

    Some Schematics

    
                
                

    FCTS Firmware Programming

    principle it could be used in every TPC, but we haven't made that happen. The small ORCA chip needs 0728XX. 

    CC Firmware Programming

    To program the Controller Card and UPC MACH chips, use the ispvm software installed on afs and the parallel port cable that was purchased from lattice. If the software is lost, it can be downloaded for free at latticesemi.com at the time of this writing. A copy also exists on bbr-dev15 in /dataflow/machprog/ispvm_v12_1_2_unix.tar.gz. "gunzip" this file and "tar xf" it. The file ispVMInstallation.pdf will be in the extracted tree and contains running instructions.

    To use the afs version, execute the following:

    source /afs/slac/package/lattice/ispvm_v12.1.2/setup_env.csh
    (to verify) ispvm /i /afs/slac.stanford.edu/g/cad/archive/babar/DAQ/CC/machverify.dld /t /o /Parallel
    (to program and verify) ispvm /i /afs/slac.stanford.edu/g/cad/archive/babar/DAQ/CC/machprogram.dld /t /o /Parallel
    The program can also be run with a GUI by typing only "ispvm".

    A successful verify run looks like this:

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  • UPC Firmware Programming