Tracker Interlock and Monitoring (TIM) Board Test

TIM basic function test summary

Test name Method Test result
NTC temperature measurement Put all the NTC sensors together, plug in the DB25 female, and read the temperature data. Check the temperature values of each sensor from the server side.  
Humidity measurement Put all the humidity sensors together, plug in the DB25 female, and read the humidity data. Check the humidity value of each sensor from the server side.  
Hardware alarm circuit (hardware interlock) Put the NTC sensors in different temperature environments (temperature environment state can be set). Check the high voltage and low voltage hardware interlock signal output status, and check the same information from the server side.  
Telecommunication Connect the TIM board to the DCS server using the RJ45 cable. Check whether the server will receive the data sent by the TIM (the data is parsed according to the communication protocol).  
RS422 communication The RS422 on the TIM board can be connected to PC via a USB-RS422 converter. The PC side opens the serial port tool to send data and observe whether the data is correctly transmitted back to the serial port tool.  
RS485 communication Reserved for chiller  

TIMArchitecture.png
TIM Architecture

TIM board schematics

TIM board schematics tim-20190901-v2.pdf
Version 3 TIM board schematics tim-20191026-v3.pdf

Connecters and cables needed for the TIM board test

DB25 connector (6)

Contains: NTC thermistor (9), HIH-4000 (1), DB25 female (1)

During the TIM basic function test, all the NTC and humidity sensors can be plug in the DB25 to read the temperature and humidity data. All sensors mounted on the Tracker plane and the temperature/humidity information sent to the TIM board via Patch Panel. Then the TIM board examines the data further and finally calculates the relative humidity and temperature. The temperature and humidity values of each sensor can be checked from the server-side.

The pin assignments of DB25

The interlock pin-out modified with swapping the pin 25 and 12 for the new version of DB25. For this reason:

Note that, only for the TIM v2 board the small flat ribbon swapping cable must be used.

DB25 connector pin-out for TIM_v3 click Tab1, for TIM_v2 click Tab2. To see the pin-out differences between v2 and v3 click Tab3.

Tab 1

DB25 pin-out for TIM_v3
Function Pin PinSorted ascending Function
SCT1_NTC1 GND 14 1 SCT1_NTC1 Signal
SCT1_NTC2 GND 15 2 SCT1_NTC2 Signal
SCT2_NTC1 GND 16 3 SCT2_NTC1 Signal
SCT2_NTC2 GND 17 4 SCT2_NTC2 Signal
SCT3_NTC1 GND 18 5 SCT3_NTC1 Signal
SCT3_NTC2 GND 19 6 SCT3_NTC2 Signal
SCT4_NTC1 GND 20 7 SCT4_NTC1 Signal
SCT4_NTC2 GND 21 8 SCT4_NTC2 Signal
NTC GND 22 9 NTC Signal
HIH-4000 (T&H) VCC 23 10 HIH-4000 OUT
HIH-4000 GND 24 11  
LV Control Signal 25 12 LV GND
    13  
   
DB25 schematic.png
DB25 v3 schematic

Tab 2

DB25 pin-out for TIM_v2
Function Pin Pin Function
SCT1_NTC1 GND 14 1 SCT1_NTC1 Signal
SCT1_NTC2 GND 15 2 SCT1_NTC2 Signal
SCT2_NTC1 GND 16 3 SCT2_NTC1 Signal
SCT2_NTC2 GND 17 4 SCT2_NTC2 Signal
SCT3_NTC1 GND 18 5 SCT3_NTC1 Signal
SCT3_NTC2 GND 19 6 SCT3_NTC2 Signal
SCT4_NTC1 GND 20 7 SCT4_NTC1 Signal
SCT4_NTC2 GND 21 8 SCT4_NTC2 Signal
NTC GND 22 9 NTC Signal
HIH-4000 (T&H) VCC 23 10 HIH-4000 OUT
HIH-4000 GND 24 11  
LV GND 25 12 LV Control Signal
    13  
   
DB25 v2 schematic.png
DB25 v2 schematic

Tab 3

Differences between the v3 and v2: pin 25 and 12 are swapped. For the temporary solution, the small flat ribbon swapping cable is using for the TIM_v2
DB25 pin-out diff.png
DB25 differences between v2 and v3

DB9 connector

Contains: NTC thermistor (2), DB9 female (1), wires

There are 2 kind of DB9 double connectors are used for different purposes.

DB9 connector for extra NTCs and HV interlock signal:

This double DB9 connector is used for the extra NTCs which for testing the ambient temperature and for High voltage hardware interlock signal. When the NTC sensors temperature state is set for different temperature environments, the high voltage (HV) and low voltage (LV) hardware interlock signal output status can be checked from the server side.

The pin assignments of DB9 for NTCs & HV interlock signal

Update: Dial switches were added on DB9 for the new version of the TIM board. For the TIM v3 DB9 connector pin-out click Tab1. For TIM v2 DB9 connector pin-out click Tab2. To see the differences between v2 and v3 click Tab3.

Tab 1

TIM_v3 DB9 pin-out for NTCs and HV interlock signal
Function Pin Pin Function
NTC1 Signal 1 6  
NTC2 Signal 2 7  
  3 8  
NTC GND 4 9 NTC GND
NTC GND 5    
HV1 21 26 HV1
HV2 22 27 HV2
HV3 23 28 HV3
HV GND 24 29 HV GND
HV GND 25    
   
DB9 NTC shematic.png
TIM v3 DB9 schematic for NTC&HV interlock

Tab 2

TIM_v2 DB9 pin-out for NTCs and HV interlock signal
Function Pin Pin Function
NTC1 Signal 1 6  
NTC2 Signal 2 7  
  3 8  
NTC GND 4 9 NTC GND
NTC GND 5    
HV1 21 26 HV1
HV2 22 27 HV2
HV3 23 28 HV3
HV GND 24 29 HV GND
HV GND 25    
   
DB9 v2.png
TIM v2 DB9 schematic for NTC&HV interlock

Tab 3

DB9 pinout diff.png
DB9_pinout differences between v2 and v3

DB9 connector for RS485 (1) and RS422 (1)

This DB9 connector is related to RS-485 and RS-422 signals. The RS-422 on the TIM board is connected to PC via a USB-RS422 converter. The PC side opens the serial port tool to send data and observe whether the data is correctly transmitted back to the serial port tool. Regarding RS-485 Network Connector (Pin1: Reference, Pin2: Data B+, Pin3: Data A-), it is reserved for the communication with chiller. for RS-422 and RS-485 signals click Tab2.

The pin assignments of DB9 for RS485 and RS422

Tim_v2 and v3 have the same pin assignments of DB9 for RS485 and RS422 .

Function Pin Pin Function
  1 6 GND
RS485_B Signal 2 7  
RS485_A Signal 3 8  
  4 9 GND
GND 5    
RS422_RXD+ Received Data 21 26 GND
RS422_RXD- 22 27  
RS422_TXD+ Transmitted Data 23 28  
RS422_TXD- 24 29 GND
GND 25    
   
DB9 RS schematic.png
DB9 schematic for RS422&RS485

Network cable

Standard ethernet cable

TIM software test instruction

Hardware connections

TIM board.jpeg
TIM board
1. Connect to the network cable, initial IP:128.141.189.231
2. Connect DB25 sensors
3. Connect DB9 (for NTC)
4. Connect DB9 (for high-voltage interlock signal output)
5. Connect debug serial port (not necessary)
6. Connect 24V power (after connecting other ports above)

TIM board starts to work now.

Connect to PC and collect data

1. Install the software "Modbus Poll" (Download modbuspoll_70167.rar) on a Windows PC. The PC must be in the same network segment as the TIM motherboard.
2. Open the software "Modbus Poll" and set the host computer connection parameters. Click Connection in the upper left corner, then click connect...
Modbus poll set.jpg
modbus poll set
3. Set the parameters as below and click OK
Modbus poll connection setup.jpg
modbus poll connection setup
4. Click on Setup in the top left corner, then click Read/Write Defintion, and set Quantity to 62, then OK, as shown below
Modbus poll readwrite definition.jpg
modbus poll readwrite definition
5. Now you will see the results on screen. The boxes are highlighted with different colours and each colours refers to the DB25 connectors on TIM.

MODbus TIMtemphumidity value.png
modbus poll display
TIM DB25.png

Control the system through web interface

1. Open Chrome and enter IP: 192.168.1.73
2. Account: admin Password: admin
web login.png
website login
3. Click the top left button web setup. Set the IP address and then click the bottom right button confirm. (we will translate them into English later). You need to use this IP address when you login next time.
web setup.png
website setup
4. Update the software
This is not needed right now. Detailed instruction will come later.
web update.png
website update
web update 2.jpg
website update
5. Reboot the system
web reset.png
website reset

TIM Hardware interlock test

Standalone test setup

Using the multimeter to test the high voltage (9V) and low voltage (5V) interlock signal
One of the pen put in the hole in the corner(grounding contact) Another pen put on the small pinholes. Read the voltage.
When you hold the temperature sensors in your hand (temperature higher than 30 C), the voltage will turn to 0.
hardware.jpeg
hardware

Logic table for TIM hardware interlock

HT: high temperature limit.
LT: low temperature limit

  States IO HV/LV Notes
1 Both sensors within HT and LT 0 5/9  
2 Both sensors > HT, or both sensors < LT 1 0/0  
3 One sensor > HT; one sensor < LT 1 0/0  
4 One sensor within HT and LT; one sensor > HT or < LT 1 0/0  
5 Both sensors missing, short cut, damaged 1 0/0  
6 Only one sensor missing, short cut, damaged 1 0/0 This will be improved in the next version. A switch will be used to allow TIM to work with only one sensor. (For the current version, we will have to manually connect a NTC to the two pins on DB25.)

Set the temperature limit

1. Choose a proper temperature range. (HT stands for "high temperature limit", LT stands for "low temperature limit" )
2. Lookup NTC reference manual to find out the resistance value corresponding to the temperature limit.
3. Calculate the threshold voltage
equation.jpeg
R_{HT} is the resistance value corresponding to the HT (high temperature limit), with unit kOhm
R_{LT} is the resistance value corresponding to the LT (low temperature limit), with unit kOhm

Make sure (LT1=LT2) > (HT1=HT2)
4. Adjust the voltage by using a screwdriver to rotate the potential knob corresponding to the voltage pair. You can measure the voltage by connecting the test point with the multimeter

tunevoltage.jpeg

"Dial switches" for the HV interlock modules

Each switch control a DB25 port. If one of the port is empty, the switch on the board should be turned off. There are 8 channels in version 3 (for 2 backup power supply crates: 2 extra channels are used to control the 2 spare crates). By default, the dial switches for channel 1~6 are in "ON" status, while the dial switches for channel 7~8 are in "OFF" status. For instance, If HV power supply crates #3 or #4 failed, the broken power crates can be unplugged manually from the corresponding tracker plane and connected #7 and #8 power crates to that tracker plane. Set channel #3 and #4 as "OFF", and channel #7 and #8 as "ON"
To make sure the hardware interlock function works well: While setting the right value (5V) on DB9, the dial switch must be turned off and the DB25 must be empty. Then set the dial switches "ON" position and can plug the DB25.

SW1 SW2 SW3 SW4 SW5 SW6
PP1_NTC1 PP1_NTC2 PP2_NTC1 PP2_NTC2 PP3_NTC2 PP3_NTC1
PP1_IO PP1_IO PP2_IO PP2_IO PP3_IO PP3_IO

TIM swithces positions.png

Communication protocol for TIM and DCS

communication protocol for TIM and DCS communication protocol for TIM and DCS

Explanation of the humidity calculation

Normally, the humidity is measured (calculated) with respect to the environment temperature measured by an NTC connected to DB9. In order to simplify the installation, we set the temperature to a fixed 15C, since there will be only 1~2 % shift for humidity calculation when the temperature varies between 10C to 25C.
Different channels of humidity sensors have a different equation. After calculation, we find out the error of using the average value is less than 1%. Now we use the average of the three sensors implement in one station and thus have slightly varying values on the different TIMs.
calculateofhumidityerror.jpeg
-- DiWang - 2019-08-29

Topic attachments
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PDFpdf Communication_Protocol_for_TIM_and_DCS_.pdf r1 manage 50.8 K 2019-10-08 - 16:43 DiWang  
PNGpng DB25_pin-out_diff.png r1 manage 300.6 K 2019-12-17 - 15:14 CandanDozen DB25 pin-out differences between v2 and v3
PNGpng DB25_schematic.png r1 manage 182.3 K 2019-12-17 - 11:24 CandanDozen DB25 schematic
PNGpng DB25_v2_schematic.png r1 manage 76.5 K 2019-12-17 - 13:27 CandanDozen DB25_v2_schematic
PNGpng DB25_v2_schematic_swappedribon.png r1 manage 500.1 K 2019-12-17 - 13:48 CandanDozen DB25 v2 schematic and swappedribon cable
PNGpng DB9_NTC_shematic.png r1 manage 186.4 K 2019-12-17 - 11:23 CandanDozen DB9_NTC schematic
PNGpng DB9_RS_schematic.png r1 manage 98.0 K 2019-12-17 - 11:23 CandanDozen DB9_RS schematic
PNGpng DB9_pinout_diff.png r1 manage 117.0 K 2019-12-17 - 15:11 CandanDozen DB9 differences between v2 and v3
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PNGpng DB9_v2_NTC_schematic.png r1 manage 43.3 K 2019-12-17 - 13:27 CandanDozen DB9_v2_schematic
PNGpng MODbus_TIMtemphumidity_value.png r1 manage 189.8 K 2020-02-12 - 14:16 CandanDozen Temperature and humidity values from TIM through Modbus
PNGpng Modbus.png r1 manage 138.1 K 2019-10-15 - 12:02 DiWang  
JPEGjpg Modbus_poll_connection_setup.jpg r1 manage 25.3 K 2019-09-10 - 10:12 DiWang  
JPEGjpg Modbus_poll_display.jpg r1 manage 17.4 K 2019-09-10 - 10:23 DiWang  
JPEGjpg Modbus_poll_readwrite_definition.jpg r1 manage 52.8 K 2019-09-10 - 10:18 DiWang  
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PDFpdf tim-20190901-v2.pdf r1 manage 391.8 K 2019-10-08 - 15:09 DiWang  
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