Another re-fit, but this time the quadratic coefficient (beta) is set to 1.003e-6:

       R_0 (ohm)   Alpha (1/C)

RTD 0   79.7386   0.001863

RTD 1   78.6248   0.002359

RTD 2   81.3254   0.002211

RTD 3   74.6127   0.003509

RTD 4   80.6652   0.001988

RTD 5   78.5450   0.002127

RTD 6   77.0144   0.002268

RTD 7   83.0204   0.002288

       R_0 (ohm)   Alpha (1/C)

RTD 0   79.3962   0.002031

RTD 1   78.2874   0.002530

RTD 2   80.9775   0.002381

RTD 3   74.2947   0.003684

RTD 4   80.3199   0.002157

RTD 5   78.2106   0.002297

RTD 6   76.6825   0.002438

RTD 7   82.6645   0.002458

Measurements taken can be found here. An uncertainty of 1 C was assumed for temperature.

We noticed that the RTD temperature readings given on the Cymac were off, and traced the issue to miscalibration in the relationship between the resistance and temperature of each RTD (Callendar-Van Dusen eqn). Below is the table of values inferred from independent measurements of temperature and resistance to rectify this problem. This data was then fitted to better determine the coefficients present in the temperature-resistance relation:

       R_0 (ohm)   Alpha    Beta

RTD 0   80.8674   0.001315   4.273e-6

RTD 1   79.5704   0.001887   3.7873e-6

RTD 2   81.7334   0.002014   2.1724e-6

RTD 3   74.3060   0.003677   3.6022e-8

RTD 4   81.1350   0.001761   2.3598e-6

RTD 5   77.9610   0.002423   -7.5192e-7

RTD 6   78.7980   0.001373   6.2909e-6

RTD 7   83.8616   0.001890   3.3529e-6

Cleaned and baked the Cal Tech FROSTI legs and showed Luke the procedure on how to clean parts.

Upon finishing the FROSTI assembly last week, we ran into some electrical issues. An electrical short was found between two of the d-sub pins (2 and 8). It appears that the pins were somehow coming into contact with the aluminum surrounding them. This was causing the power supply to trip. The issue was seemingly fixed by adjusting the positioning of the cabling leading out of the reflector. When handling the device in the future, please make sure to keep the wiring as undisturbed as possible. The setup is rather fragile, and moving the cabling around could potentially reintroduce a short like this.

FROSTI assembly was completed today. The RTD and power wires were terminated at the DB-25 connectors and the legs were put on. It is currently placed in front of the stand-in test mass (~5 cm away). The FLIR has also been moved back to it's nominal position. As of now, it appears there are some shorts within the power cabling. This will be a focus of tomorrow's work.

Heater 1= 72.8; 80.6

Heater 2= 69.5; 80.8

Heater 3= 70; 83.2

Heater 4= 70.6; 78.7

Heater 5= 69.9; 80.6

Heater 6= 71.1; 78.2

Heater 7= 68.5; 76.8

Heater 8= 70.1; 82.8

FROSTI assembly began today. After a final set of RGA scans were taken, the vacuum chamber was vented and the reflectors were removed. The chamber was then resealed and pumped down again. 

Today we completed the installation of the Macor hardware and heater elements between the two reflector halves. Tomorrow we will route, bundle, and terminate the power and sensor cables. 

The FLIR and test mass stand-in have been transferred into the cleanroom. A software test will be run as soon as we get an ethernet cable long enough to reach into the cleanroom where the camera is set up. Once this is finished, the FLIR will be moved aside for construction of the FROSTI! When completed, the camera will be placed back into position for in-air optical testing.

Summary

Following Wednesday's cleanroom cleaning [333], we proceeded to vent the vacuum chamber, remove the heater elements and their mount structure, and install the FROSTI reflectors. The reflectors are the final components to undergo RGA testing before the FROSTI prototype can be assembled. After installing the reflectors, we pumped the chamber back down and initiated a 48-hour 125 C bake.

Vacuum Vent

At ~1:00 pm, we shut off power to all eight of the FROSTI heater elements. Prior to shutoff, all were operating in vacuum at roughly 300 C. We then waited approximately 30 minutes for the elements' temperatures to fall below 50 C.

At this point, we isolated the RGA volume from the main volume by closing both gate valves, leaving the RGA volume to continue to be pumped through the bypass line. We then backfilled the main volume via the needle valve connected to one of the 2.75" ports. Once the pressures had equalized, we removed the chamber lid via our usual procedure (requiring only a small amount of flathead-screwdriver prying) and extracted the heater element assembly.

Reflector Assembly

We then removed the FROSTI reflectors from their protective packaging (for the very first time) on the cleanroom tabletop. We tested the fit of the Macor and stainless steel hardware in the reflectors' tapped holes. The Macor standoffs and bolts appear to fit perfectly. However, the 1/4-20 tapped holes for joining the two reflector halves are too shallow by ~1/4". As a temporary fix, we used some on-hand stainless steel washers (which had already been cleaned and baked) to securely fasten the two halves together. In the final assembly we will replace these with slightly shorter 1/4-20 vented bolts.

Pumpdown and Bake

The two fastened reflector halves were placed inside the chamber, sitting on top of the two mounting legs (see attached photos). We then reinstalled the lid. In order to rough the main volume, we isolated the RGA volume from the pumpline (by closing the bypass line valve), shut down the pumps, and then backfilled the pumpline via the manual vent valve on the turbo pump.

Once the pressures had equalized, we opened the 6" gate valve separating the pumpline from the main volume and powered on the roughing pump. Once the main volume pressure fell below 0.5 Torr, we powered on the turbo pump as well. The main volume pressure reached 5e-6 Torr within ~30 minutes, consistent with previous experience, and was continuing to slowly fall.

Lastly, we initiated a 125 C bake-out of the entire system following our usual procedure. We plan to run this bake for 48 hours (i.e., through the end of the day Friday).

cleaning cleanroom and particle count

• 11:50 am: ran zero count test on particle counter
• 11:55 am: started particle count
  • zone 3:
    • 0.3 u: 1787
    • 0.5 u: 581
    • 1.0 u: 166
• zone 4:
  • 0.3 u: 623
  • 0.5 u: 290
  • 1.0 u: 124
• 12:17 pm: began surface check and wipedown, including softwalls
• 12:25 pm: started vacuuming the floor
• 12:36 pm: finished vacuuming the floor
• 12:44 pm: started mopping the floor
• 12:57 pm: finished mopping the floor
• 12:58 pm: started cleaning the buckets
• 12:59 pm: started mopping with IPA wipes
• 1:05 pm: finished mopping with IPA wipes
• 1:06 pm: changed sticky floor mats
• 1:08 pm: started particle count
  • zone 3:
    • 0.3 u: 1621
    • 0.5 u: 581
    • 1.0 u: 332
• zone 4:
  • 0.3 u: 1080
  • 0.5 u: 457
  • 1.0 u: 249

The replacement door for the HEPA garment cabinet arrived last week, and was installed on Thursday. However, it looks like there's a small gap between the door and where the hinge is attached to the cabinet frame. No screws were provided with the replacement door. If we want to perform any adjustments, we have to be very careful; the screws break very easily.

On Thursday we installed the power conditioning/distribution equipment and networking equipment in the new 1129 rack. The hardware is identical to the setup in the 1119 rack and includes:

• Tripp Lite SU5KRT3UTF - 208V, 5kVA on-line UPS with 120V transformer
• CyberPower PDU20M2F12R - metered power distribution unit, (14) NEMA 5-20R
• Ubiquiti USW-Pro-48 - 48 port 10Gbps network switch

The UPS is connected to a 208V NEMA 6-30R outlet in the overhead cable tray, which is on the building's "standby" (backup power) circuit. An 8-ft L6-30 extension cord has been ordered to permanently run the power cable through the cable tray.

The network switch will be connected to a Cat6 cable that was recently run by ITS from the 1119 rack, allowing the lab's LAN to be extended into 1129. This Ethernet link remains to be tested.

I ended the bake of the UHV system (that began on Monday) at 6:23 pm today by switching OFF both PID controllers. The heaters elements were run at max power (24 V DC / 200 mA per element) during this bake, and I left them powered at the same level.

At the time, the instrument readings were as follows:

• Left high-limit controller: 138 C
• Right high-limit controller: 128 C
• Left PID controller: 100 C
• Right PID controller: 100 C
• Main volume pressure: 8.17e-7 Torr
• RGA volume pressure: 4.63e-7 Torr

I reproduced Cao's CE beamsplitter code (see below for example plots). I received the current info on the beamsplitter parameters for A+ and A# from GariLynn also. The next steps are to perform a similar power loss analysis on the anticipated A# beamsplitter.

Below is the proposed schematic for FROSTI optical testing, chosen so enough space is allotted for prototype assembly.

Steps to be taken include:

1. Reconstruct FLIR staging apparatus
2. Move test mass stand-in to cleanroom
3. Mark FLIR camera position on cleanroom optical table at correct distance
4. Run ethernet cable into cleanroom
5. Move FLIR aside to allow for more assembly space
6. Upon assembly completion, reposition FLIR onto optical table again

Tentative plan is to begin setup early next week.

cleaning cleanroom and particle count

• 5:10 pm: ran zero count test on particle counter
• 5:14 pm: started particle count

  NOTE: initial counts are significantly above allowed limit. ~10 times larger than ISO class 5 standard in the smallest size range. Realized partway through ceiling tile changes that the power/lights for some of the hepa fans in the ceiling frame had been turned off. May explain this high number. Have since turned fans back back on.

  • zone 3:
    • 0.3 u: 109208
    • 0.5 u: 16337
    • 1.0 u: 581
• zone 4:
  • 0.3 u: 51340
  • 0.5 u: 9228
  • 1.0 u: 581
• 5:33 pm: started replacing ceiling tiles
• 6:25 pm: began surface check and wipedown, including softwalls
• 6:33 pm: started vacuuming the floor
• 6:45 pm: finished vacuuming the floor
• 6:45 pm: started mopping the floor
• 6:50 pm: finished mopping the floor
• 6:52 pm: started cleaning the buckets
• 6:53 pm: started mopping with IPA wipes
• 6:58 pm: finished mopping with IPA wipes
• 6:59 pm: changed sticky floor mats
• 7:00 pm: started particle count
  • zone 3:
    • 0.3 u: 5404
    • 0.5 u: 1413
    • 1.0 u: 41
• zone 4:
  • 0.3 u: 1704
  • 0.5 u: 332
  • 1.0 u: 166

Summary

Today I finished implementing an RTS model to read out the integrated FROSTI RTDs (temperature sensors) via the CyMAC. The model is named "MSC" and is located at cymac:/opt/rtcds/usercode/models/c1msc.mdl. We successfully tested it with the heater elements operating in vacuum at low power (12 VDC), finding them to reach an average steady-state temperature of 160 C.

From the cymac host, the MEDM control screen can be accessed with the terminal command "sitemap" (from any directory).

Measurement Technique

Each FROSTI heater element [299] contains an internal two-wire RTD placed near the front emitting surface, which enables the temperature of the blackbody emitter to be directly monitored. From the measured temperature and the emissivity of the uncoated aluminum nitride surface (known to be ~1 in the IR), the radiated source-plane power can also be estimated.

The resistance of each RTD is measured via a ratiometric technique. The RTDs are powered in series with a 1 kΩ reference resistor located inside the readout chassis [305], whose temperature is not changing. The signal is obtained by taking the ratio of the voltage difference across each individual RTD to the voltage difference across the reference resisitor. The advantage of this technique is that the ratio of  the voltage differences is insensitive to changes in the current through the resistors (since they are all in series; see [271] for wiring diagram).

Implementation Detail

The signal flow is shown in Attachment 1. The eight RTD signals enter through ADC channels 0-7, along with the reference resistor signal on channel 8. The first set of filter modules apply a calibration gain to convert the signals from raw ADU counts to units of input-referred voltage. The ratio of each RTD signal to the reference resistor signal is then taken. The second set of filter modules multiply the voltage-difference ratios by the resistance of the reference resistor, 1 kΩ ± 0.01%, to obtain the RTD resistances in physical units of ohms.

Finally, a freeform math module is used to invert the quadratic relation between each RTD's resistance and temperature. The final signals passed to the third set of filter modules are the RTD temperatures in physical units of degrees C. The temperatures of the tungsten RTDs are estimated assuming TCR coefficients of A=0.0030 C^-1 (±10%) and B=1.003E-6 C^-2, which were provided by the manufacturer.

One DAC channel is used to provide the excitation voltage for the RTD measurement, which is visible on the far right of the control screen. At its maximum output voltage of +10 V, the DAC can drive a maximum current of 10 mA.

After further modification of the RTD readout chassis (i.e. adding resistors, placing reference resistor in front of RTDs), here are the following direct measurements:

RTD 1: 0.484 V

RTD 2: 0.486 V

RTD 3: 0.503 V

RTD 4: 0.474 V

RTD 5: 0.495 V

RTD 6: 0.483 V

RTD 7: 0.476 V

RTD 8: 0.510 V

Reference: 5.847 V

Here are the Cymac signal readings:

RTD 1: 74

RTD 2: 67

RTD 3: 73

RTD 4: 45

RTD 5: 82

RTD 6: 75

RTD 7: 70

RTD 8: 71

Reference: 884

The one (possible) discrepancy here is the readout for RTD 4 via Cymac, since it's signal reading is ~30 counts lower than the others. I do not believe this is a wiring issue due to the direct measurements taken.

After updating the wiring in the RTD Chassis, a signal is now seen at each ADC input. However, there seems to be a discrepancy between the voltages I measured out with the multimeter (see below). Next steps include:

• Finish final debugging
• Calibrate ADC inputs with known voltage source (likely to use DAC).

Voltage Readings:

RTD 1: 0.576 V

RTD 2: 0.578 V

RTD 3: 0.598 V

RTD 4: 0.563 V

RTD 5: 0.477 V

RTD 6: 0.463 V

RTD 7: 0.456 V

RTD 8: 0.491 V

Reference Resistor: 5.463 V

Total Voltage: 9.665 V

Took more data today and the chamber and elements are showing an even lower HC level than we have gotten before. It is safe to say that the elements are not contaminated and out gassing HC into the chamber.

Heater 1= 73.6; 81.8

Heater 2= 70.4; 82.1

Heater 3= 71; 84.5

Heater 4= 71.5; 80

Heater 5= 70.5; 81.7

Heater 6= 72; 79.4

Heater 7= 69.2; 78.2

Heater 8= 71.1; 84.2

Below is the data for the most recent bake. I believe the chamber is cleaner than it is actually showing as the RGA data was still getting lower while the data was being taken. I will take the data again tomorrow just in case. Still, the data shows that the chamber is basically as clean as it was before bake 10 and this means further power testing can proceed.

Helium leak tested the chamber again today to check if the sealant changed anything. The two primary target flanges from last time have improved significantly with the flange from the RGA on the cross now being below 2e-14. While the turbo pump flange was leaking at a rate of 4e-13. Much better than what it has been before.

I performed another continuity test on the RTD chassis wiring, and everything seems to be set up correctly. The chassis should be ready for installation.