version 1.1
10-04-97
During instrument design and fabrication a large volume of technical data pertaining to the ING of telescopes and related facilities is invariably required. We have attempted to incorporate the most important of these data into one manual in order to provide you with a single, coherent reference.
This manual, Instrument Specifications, details many of the requirements that experience has shown to be necessary for instruments at ING. Some reflect rigid conditions imposed by the telescope structure; others are of an operational nature. While the details are certainly negotiable, it should be remembered that our ultimate design goal is to provide not only an instrument which works well, but one which is equally maintainable at a remote site, under non-ideal conditions.
I would like to thank Dereck Salmon of the CFHT who kindly allowed large chunks of their original manuscript to be used as a basis for this manual.
S.Barker 15-11-96.
This manual, Instrument Specifications, is intended as a guide to engineers and scientists either designing a common user instrument or simply wishing to use their own instrument at the ING.
In order to ensure that instruments which arrive at the observatory can come on-line quickly and easily, both potential instrument builders and ING need a set of guidelines and checklists which establish the minimum list of requirements. This manual is intended to establish the more general points of such a list. More specific details will be included in the instrument contracts.
Again, as stated earlier, in this early version of the document we make no claims for its completeness. We are more than willing to receive and discuss constructive comments from your scientific and technical staff regarding its content and organization.
Instruments will be stored and operated in both the telescope dome environment and in heated laboratories. The design operating temperature range for instruments and associated equipment shall be from -5°C to +30°C at relative humidities ranging from 0% to 95%(condensing).
As noted in section 1.8.5, a heavy-duty, vinyl instrument cover is also required with the instrument.
The instrument shall be designed for operation at altitudes between sea level and 2500 m. Electronic circuitry should be designed to work at a maximum ambient temperature of 50°C due to the 25% reduction in air density at the summit. Power supplies should be derated by 50%. i.e a supply with a maximum rating of 100W should only be used to deliver 50W. High voltage systems should be rated for operation at an altitude of 2500 m or higher.
In an attempt to eliminate dome-induced seeing, the observatory has implemented a policy of reducing to a minimum all power dissipated at the telescope. Where feasible, power sources provided at various ING instrumentation panels should be used while the instrument is mounted to the telescope. It should be noted that instruments must still be provided with autonomous power supplies in order to meet the requirement of operation in a stand-alone mode.
Considerable attention should be given to minimizing power dissipation within the instrument. The instrument bid and detailed design should provide a detailed power budget.
The instrument should include a plenum over the major electronics components with a 50 mm diameter, 150 mm long hose connection for use in heat extraction.
For much of the year dust from the Sahara ('calima') is a problem at the Observatory. It must be assumed that any exposed surface or mechanism will be covered with dust. This problem is most acute at prime focus. As a consequence all bearings, slides etc should be sealed or fitted with covers. Where possible the instrument should be dust tight.
The Roque de Los Muchachos observatory presents some extreme environmental conditions for electronic systems. System designers must pay special care to environmental restrictions.
Electronics systems for use on the telescope shall be rated for operation between -5°C and +30°C, at relative humidities ranging from 0% to 95%(condensing). Storage shall occasionally be at relative humidities of 100%.
Electronics systems designed for the GHRIL enclosure should be designed to operate between 0°C and 30°C and humidities from 0% to 95%.
Electronics systems for use in the remainder of the buildings shall be rated for operation between +5°C and +30°C, at relative humidities ranging from 0% to 80%.
Cooling effectiveness is reduced due to the lower air density (~75%) at the observatory site. In general this may be accommodated by derating systems to work as though they were in a 50°C operating environment.
Chassis for telescope mounting shall be fully enclosed, with solid or screened panels and doors over all openings.
Standard, 19 inch rack mounting chassis are recommended. Nineteen inch racks are available at the cassegrain focus, the UES and GHRIL naysmyth platforms, and in all control rooms.
Access panels shall be equipped with quick release, captive hardware. Plastic hardware for these applications is not permitted. See the section on EMC for more details.
Use of Eurocards is highly recommended.
- 160 mm deep cards are standard at ING
- 3 and 6 unit heights are standard at ING
All circuit cards shall be positively latched in position to prevent them becoming unseated with vibration.
Commercially supplied circuit cards should be printed circuits.
Custom designed boards may be built using printed circuit or Wire Wrap techniques.
Due consideration must be given to the need to meet EMC directives which may be significantly harder to achieve with a wire wrapped solution. Serious consideration should also be given to the use of a double sided PCB utilising a ground plane.
All wire wrapped boards shall used a hard wired power bus.
All designs should use at least one 10nF decoupling capacitor per IC and one 100 microfarad electrolytic capacitor per circuit card.
If more than one board of the same design is to be delivered it is recommended that the circuit is laid out on a PCB.
All printed circuit and other wiring techniques will be done to appropriate industrial standards. In particular, "hobbyist" methods will not be employed.
All circuit cards shall have all connectors, integrated circuits, transistors, status displays, and other major components permanently labeled.
All IC sockets shall be of a high quality 'turned pin' type.
All electronic circuits shall be easily accessible for maintenance, troubleshooting, removal and replacement with an instrument mounted on the telescope, or mounted on its handling cart.
Circuits shall be of a modular design using circuit boards, and shall be easily removable from the instrument. The use of card cages, versus direct mounting of circuit boards, is recommended. Access to card cages should be through doors or panels which are hinged, or removable and use quick release hardware.
Circuit boards shall contain test points which shall be directly accessible on the board from the front of the card cage. An extender must not be required to access basic test points. However, an extender board must be supplied with all systems which require extending cards for detailed troubleshooting. The system must be capable of normal operation with any circuit card extended.
Connections to instrument circuit cards shall be made through a chassis mounted connector panel, and then to the circuit card. Direct connections from external devices to a local controller or circuit card are not permitted.
In general, rear connections to circuit cards are favored.
When connections are made to the front side of plug in circuit cards, provision must be made for extending the connection to permit operating the card on an extender.
In general, connections to the component face of circuit cards are not permitted.
All connectors shall be latched or screwed in position.
In recognition of the remoteness of the observatory, special considerations must be made for system maintenance. In general there is not sufficient time for units to be returned to the manufacturer for repairs during an observing run. This dictates the need to have `hot' spares on site and the capability to repair all aspects of the instrument.
The expected service life of the instrument will probably be in the order of 10 - 15 years. It must be possible to maintain and repair the instrument long after many of the components used have become obsolete.
LED or other status indicators on equipment are very useful. However, extraneous light at the telescope is not permitted. Any such indicators on telescope mounted instruments must incorporate a means by which the indicators may positively be turned off, or covered.
Self-powered instruments shall use 240 volt 50 Hz power connected through a single, standard 3 prong, grounded connection conforming to BS1363/A. A minimum of 1000 VA will be available at the telescope and control rooms.
All instruments using internal power supplies shall have easily accessible means of testing power supply operation. Some recommended solutions are LED's and test points. This is covered in detail in the section on diagnostics.
All power supplies should provide overvoltage, overcurrent and thermal overload protection and be capable of working under no load conditions.
An MTBF of 50000 hours or greater shall be specified. Where this is not possible an alternative MTBF shall be agreed with the project manager.
Capacitors must be of a 'sealed' type to minimise the effects of electrolyte evaporating.
All cables required for the operation and test of the instrument, both while on the telescope and while in a stand-alone mode, shall be provided with the instrument.
Hardwired cable or wire harness termination is not permitted. Both ends of all cables shall terminate in a connector. All devices such as motors, encoders, actuators, etc., shall be connected to the instrument through a connector at the device.
All wiring internal to electronics chassis, with the exception of panel controls and indicators shall be terminated at standard board interconnections or back plane connections.
Cabling between any electronic junction boxes and panels shall be constructed of insulated, multi-stranded, color coded conductors using a wire gauge appropriate to the expected worst case current loads bearing in mind the lower heat dissipation at altitude.
Cables fabricated with several individual conductors or conductor pairs must be contained within an exterior protective sheath, such as tubing, or webbing. When possible, standard, commercially available cable should be used in preference to making custom cable bundles. To prevent the weight of a cable from being supported by individual conductors within connectors, the cable sheath must be mechanically clamped to the backshell of the connector.
All heavy cables shall be strain relieved at the connectors. Heavy cables shall be provided with an additional mechanical strain relief attached to the cable sheath, separate from the connector.
All cabling between telescope-mounted instruments and the control rooms shall use the ING general purpose instrumentation cabling wherever possible. This is covered in section 2.12. Instruments using the instrumentation cabling shall incorporate the available cable shielding, with appropriate chassis and ground connections. Voltages on this cabling shall not exceed 50 volts peak.
Ribbon cable is generally not permitted outside of instrument chassis. It is not permitted as an interconnection medium between electronic chassis, or between chassis and panels or handsets.
Ribbon cable may be used within electronic chassis, but should terminate at a connector panel, where heavy duty connectors and cables can carry the signals to the external devices.
All connectors between electronics boxes, or between boxes and ING connections shall be clearly and permanently labeled on panels and on both ends of all cables. This labeling must be consistent with a simplified interconnection diagram provided in the electronics manual.
Minimum marking for a chassis is a connector number _ e.g. J4.
Minimum marking for a cable connector is a device and connector number _
e.g. BLUE WIDGET, J4.
Long cables which are permanently installed on the telescope, in control consoles, or in the building cable trays shall be marked to indicate the connections at both ends of the cable. Minimum marking is the connection on the present end, and the destination and connection on that end _
e.g. BLUE WIDGET, J4; TO GREEN PANEL, J1.
The following types of connectors are recommended for all new construction at ING. Other types of connectors may be in current use, but are discouraged for new construction. If other types of connectors are preferred in a particular application, ING must approve their use.
MS connectors
Use of military connectors, with quick-release bayonet locking is strongly recommended where connectors will be frequently connected and disconnected, subject to strain, or be subject to external forces.
MS connectors shall be of the crimp type, and shall have built in strain relief.
Multiple MS connectors at the same location must not be able to be connected improperly. This shall be implemented through use of varied connector types, or through alternate keying of the connector shells.
Use of screw-on type MS connectors, or solder type MS connectors is not permitted.
"D" connectors
Use of normal density "D" connectors (9, 15, 25, 37, and 50 pin) is permitted for connections which are not frequently connected and disconnected, and not subject to undue strain or external forces. Their use is discouraged in more severe environments.
Use of double density "DD" connectors is discouraged.
Protective shells and strain relief must be used on all "D" connectors. Standard brass connector shells provide very poor strain relief, and their use is discouraged. Alternatives should be investigated and used.
EMC screened shells shall be used.
"D" connectors shall be provided with either screw lock hardware or slide lock hardware to secure connectors to the connector panel.
Coaxial connectors
Standard BNC and 00 gauge "LEMO" connectors are recommended.
Crimp BNC connectors are preferred over solder type.
Cable and shell type shall be matched so that an effective strain relief is provided.
ZIF (Zero Insertion Force) connectors
Use of ZIF connectors is recommended when connectors are built into mating hardware, and must align and mate when the hardware is assembled.
Contact ING for approved types of ZIF connectors.
Plastic connectors
The use of plastic connector shells, backshells, and strain reliefs is not permitted outside of instrument chassis.
Use of mass terminated plastic connectors is not permitted outside of instrument chassis under any circumstances.
Strain relief
All connectors used outside of chassis shall have an effective method of strain relief, so that loads are not taken on individual conductors.
Cable reinforcement at strain relief points, using jackets or sleeves, is encouraged.
Physical connections
All connector hardware shall be captive.
All connectors used outside of chassis shall have a positive means of physically securing the connector to the mating connector on the chassis. Twist locks, screw locks, slide locks, and other hardware provided by the manufacturers is usually sufficient.
All chassis mounted connectors shall be supplied with a captive hood incorporating a conductive foam insert.
The ING is continually upgrading the telescope facility to improve image quality. To this end all non-essential sources of heat on or around the telescope should be eliminated. To further these efforts contractors are required to provide a detailed heat budget for both the complete instrument and for individual devices.
Instruments shall be designed with diagnosis and troubleshooting in mind. Diagnostic design planning is critical in meeting operational goals of minimum equipment downtime. The following guidelines should be considered in the planning stages when designing new subsystems.
Subsystem power supply voltage levels should be monitored with threshold circuits driving lighted indicators such as LEDs. The indicators should be clearly visible at the front of the subsystem enclosure and marked with the nominal voltage of the corresponding power supply. An unlighted indicator signifies that the corresponding voltage is below tolerance. A switch may be provided to activate the indicators if the equipment is mounted in a location which precludes illumination. Power supply voltage monitor test jacks should also be provided on the front of the subsystem enclosure. The subsystem power switch and primary fuse should also be accessible from the front of the enclosure. All of these features may be placed behind doors or panels.
Subsystem modules or boards should have visible fault indicators. They may be located behind a cover or panel, but should be easily accessed. Module fault indicators should show positive illumination only when a fault is detected. Transient or intermittent module faults should have latching indicators with manual resets. Fault indicators should be specific to the module on which they are located. Test points and test jacks helpful in fault identification should also be easily accessed without physically removing a module or extending it from its normal operating environment.
Modules that communicate with intelligent systems should incorporate fault identification status reporting. Modules with on-board intelligence should have some degree of internal self-test capability. If self-testing cannot function as an operational background task, it should be easily initiated from an accessible select switch with a visible pass/fail indicator. As with non-intelligent modules, fault identification should be a quick, in-place means of locating a failed module for immediate replacement.
Modules with an embedded microcontrollers should be able to reliably inform a troubleshooter if the problem is within that module.
All equipment should automatically signal failure to the next highest level of control equipment. The message protocol employed should be industry standard if possible and clearly identify the faulty sub-system.
For non-networked systems a dedicated engineering RS-232 port is required for running diagnostics and trouble shooting boards with embedded microprocessors. The low level software should provide a flexible set of diagnostic routines. See the section on low level software for more details.
For more complex networked systems, engineering facilities shall be available through the network with adequate diagnostic software provided.
It should be noted that ING has a strong preference for all new systems to be networked, thus allowing remote logon and diagnosis of faults.
If the module has its own DC power supplies or on-board regulators, test points or LED indicators should be provided for easy voltage checks without removing the module from its crate. If LEDs are used they should be driven by thresholding circuits which depend on the measured voltage only and illuminate if the voltage is within tolerance.
A visual activity indicator is useful. It should be tied to a significant event in the system, such as completion of a cycle, access by a remote machine, etc. It should be designed so that either constant on or constant off indicates abnormal behavior, which flashing indicates cyclic access.
If the embedded microprocessor module communicates with a host computer, a watchdog timer is required. The timer monitors the communication interval with the host and informs the host if the interval is exceeded without the controller initiating an exchange. The host can then issue commands to attempt to "wake up" the module or issue a reset when all else fails. A means of allowing the host computer to request communications echos is required for isolating faults to a module. This can be a purely diagnostic function if the application is time critical.
If a commercial board is used that has a 'fault' indicator then it must not give a false indication. i.e if it requires software initialisation then this must be done or if the indicator is not used then it should be disabled.
The following recommendations are made to contractors for choosing ING instrument electronic control systems and hardware.
The ING requires, wherever possible, the use of commercially available, off the shelf components, parts, subassemblies, circuit boards, interface PCB's, controllers, computers, etc. Consideration should be given to the expected lifetime of any product and solutions chosen which have a possible upgrade path to cater for obsolete parts.
It is recognised there are some areas of all instruments, where commercial units are unavailable. There exists a grey area where the provider, for internal reasons, may decide to fabricate a solution rather than purchase it. It is ING's experience that these decisions delay projects, add to the project's expense, and cause maintenance problems later in the life cycle of the product, and are to be avoided.
ING engineers should be involved at the specification stage when deciding which systems to use.
In situations where commercially available, off the shelf solutions are not available, the circuit or system should be a duplicate of an existing ING solution, if at all possible, although the need to avoid designing in obsolete parts must also be considered.
The following is the list of solutions in preferred order:
1.Duplicate of commercially available solution in use at ING.
2.Commercially available solution.
3.Duplicate of a non-commercial solution available in use at ING.
4.Original contractor designed solution.
The following hardware is currently in use on-site and will be supported:
NB This list is constantly changing and the ING should be actively involved in any hardware specification.
VME systems :
mvme147/167 cpu cards
oregon XXX stepper motor control
XICOM x220,x240 i/o modules
galil motion control
DR11W
memory
omnicomp graphics display
frame grabber
Power supplies
An extensive range of 3u rack mounted Vero style supplies is used.
PCB's should be designed to comply with BS6221 part 3 which details such things as minimum track width for the required current and track clearances for voltage isolation.
All PCB's shall have a silk screened component identification.
All PCB's shall use a solder resist coating.
All double sided PCB's shall use PTH technology.
The EMC performance of electronic equipment at ING is important for several reasons. The enviroment sometimes has very low humidity, allowing large electrostatic charges to develop. Any equipment delivered should be capable of withstanding an electrostatic discharge to any exposed part without failing. Adequate precautions should be taken when designing enclosures, interconnections and grounding.
Additionally, care should be taken to design for adequate compliance. A large number of electronic systems work in close proximity at the observatory and care must be taken to ensure they do not interfere with each other. Portable radio transmitters may be used close to instrument controllers and adequate screening and filtering should be used to prevent unexpected operation.
ING expects equipment to be designed and tested to BSEN 50082 part 1 for immunity and BSEN 50081 part 1 clause B for radiation.
It is the developers LEGAL responsibility to comply with the EMC Directive.
ING require a test certificate to be delivered as part of the handover documentation.
ING has adopted BS60950 as an appropriate standard. This details things like minimum safety earthing, cable insulation thickness and minimum clearances from high voltages. It is the instrument developers LEGAL responsability to comply with safety standards, including the Low Voltage Directives, Machinary Safety Directive, Plug and Socket Directive.
Motion control assemblies refer to any electro-mechanical system which physically moves under control of a remote control panel or computer.
Most motion control systems have physical limits beyond which they must not be driven. If not capable of continuous, unimpeded operation they must be protected by electrical limit switches.
Direct acting switches, which sever motor power, are preferred over indirect switches, which operate through electronic logic.
End of travel switches which do not themselves remove motor power require mechanical or other means of device protection if the mechanism is driven at full speed into the mechanical stops.
"Soft" limits operating through the computer, which are backed up by direct acting, "hard" limit switches are both acceptable and desirable.
All end of travel switches must be capable of unassisted reverse motion off the limit switch. For d.c. motor-driven devices this is most easily achieved by means of diodes across the switches.
There should be no way of driving a system, which is on an end of travel limit switch, farther into the limit. This applies to both manual and computerized operation.
Because of the risk of light leakage opto-switches shall not be used.
Devices with a few discrete positions.
Keep the drive system simple.
Use of stepper motors and encoding and position control with switches is generally acceptable. The use of inductive proximity switches is preferred to microswitches.
A mechanical registration system, such as a spring loaded detent roller shall be built into multiposition systems to assure accurate positioning with the motor powered off.
Bi-directional operation, to minimize operating time is desirable.
Devices which require fine positioning but which do not need to be actively and continuously servo controlled.
These devices should be capable of operation in either direction.
Stepping motor systems shall be designed to operate at greatly reduced holding power, or with power off when not moving. The system shall not move when power is removed or applied. In particular, the phases energized at power-on must be identical to those at power-off.
Stepping motor systems should be operated with either an absolute encoder or an incremental encoder and zeroset mechanism. Mechanical limit switches do not generally provide the required long-term accuracy.
Commercial stepping motor controller modules are acceptable provided that they permit low or no power holding operation.
A servo system is a control system which drives its motor based on direct feedback from a position or velocity encoder.
It is important that servo control assemblies minimize heat near the optical path and in the image detection areas. Motors and amplifiers should be powered only when movement is required. Remote location of high-powered servo amplifiers is preferred if reliable operation can be demonstrated.
Due to the electrical noise associated with the telescope environment, control loops should be kept as short as possible.
Cables must be well shielded and good grounding techniques employed to prevent interference with detector signals.
Consideration must be given to the structural configuration of the environment to prevent servo operation from exciting structural resonances.
Servo systems with mechanical travel restrictions must have adequate limit switch protection.
Commercial servo system solutions which provide limit protection through micro-controllers must be protected by an additional layer of direct-acting, hardware limit switches.
R.F. generated by servo amplifiers or computers must be shielded so as not to interfere with astronomical detectors.
The ING currently supports DC motor servo control solutions from Galil. VME modules are preferred.
1.3.18.1 Connectors
RS232 - The connector on the instrument shall be a 25pin "D"style connector.
Ethernet - Connections between the instrument and the ING network shall be via a UTP RJ45 connector.
Mechanisms which require occasional local control (eg changing filters or gratings) should have a local control panel allowing adequate control of the mechanism. For safety reasons remote operation of the mechanism should be interlocked out while it is being worked apon.
Software that is intended to be supported by the ING shall be developed in accordance with the ING document 'ING Software Standards Overview' SOF-STD-1 V0.1.
ING document 'Testing and delivery of software for ING' SOF-STD-4 V0.1 details the test and acceptance procedures which will be carried out on new software which is to be supported by the ING.
Optical components shall be mounted in cells which are removable from the instrument. Removal shall be possible while the instrument is on the telescope or on its handling cart.
Cell mounting hardware and geometry shall be such that optical alignment is maintained during installation and removal of the cell from the instrument.
All optical coatings shall be sufficiently robust to withstand repeated cleanings. In particular, the use of soft (non bake-hardened) antireflection coatings is NOT acceptable.
All alignment fixtures and specialized alignment tooling shall be provided with the instrument.
All optical elements shall be identified by a component label and an arrow indicating the direction of light propagation engraved on the edge of the optic.
Where requested by ING, large optics shall be provided with engraved markings at their optical centers, or with other identifying marks required for alignment.
Mounting hardware for delicate or unusual optics shall be provided with appropriate warning labels, identifying the nature of the caution to be taken.
e.g. CAUTION : CRYSTAL OPTICS
FRAGILE SURFACE COATINGS
EXPOSED CROSS HAIRS etc ...
When designing mechanical components for the ING the designer must communicate with the engineers of the ING mechanical engineering section. This ensures that a 'Concurrent Engineering ' approach is taken and that any requirements listed below are not mis-interpreted.
1.6.1 Mechanical interface and space envelope.
Mechanical interface and space envelope drawings can be obtained from the ING mechanical engineering section. Instruments and associated equipment must be wholly within the space envelope. Interface and space envelope drawings should be obtained at the start of the design project. The ING can then ensure you have the latest drawings and will provide you with updated drawings if interfaces or space envelopes change during your design project.
1.6.2 Access
The designer must make provision for access to mechanisms whilst the instrument is mounted on the telescope. This allows engineers to work on minor breakdowns and fault find without the need to remove the instrument from the telescope. For this purpose it must be possible to operate the instrument with the covers removed.
1.6.3 Operating angles
Instruments, together with all associated equipment, shall be capable of operating on the telescope at elevations from 90 (zenith) to 10 degrees and 360 degrees rotation at all angles of elevation.
1.6.4 Weights and moments
Because of the many foci at the ING it is not practical to list all data in this document. However it is the designers responsibility to obtain permissible weights and moments from the ING mechanical engineering section for the relevant foci.
Additionally the weight of an instrument and its CofG position must be identified on a permanent mark or label on the instrument. It is not always desirable to keep the weight of an intrument to a minimum, since if the weight is too low this causes large amounts of balast to be required in order to balance the telescope. Similarly if the weight is too high large ammounts of balast may be required. If weight is a problem the instrument supplier may be required to supply balast.
1.6.5 Actuator and encoder mounts
Proprietary devices such as motors, solenoids and encoders shall be mounted, with sufficient access and appropriate fastening, so as to permit quick removal and replacement whilst the instrument is on the telescope.
Cabling to all devices must terminate with an accessible connector, so as not to inhibit removal, should the unit fail and require replacement, whilst on the telescope.
1.6.6 Indexing of travelling components
Mechanisms which are driven between fixed locations shall incorporate a precise mechanical stop which will define its position. Mechanisms shall not be positioned solely by motors controlled by the opening and closing of limit switches. Limit switches can be used to remove power from a motor when a device has driven to or beyond its stop position.
1.6.7 Materials
Aluminium alloy is the preferred material for instruments. However, other materials should not be discounted provided that the designer can justify the use. Thread inserts, such as helicoils, shall be used in parts manufactured from aluminium when it will be necessary to fit or remove screws on a regular basis e.g. if it is required to assemble components prior to fitting to telescope or to fix access panels in place.
1.6.8 Fasteners
Note: I will change the British Standards below for ISO standards when I can find them.
All fasteners shall conform to the following or equivalent:
Rivets are non-preferred and the designer may be required to justify the use of such fasteners.
All screws must be locked using one of the following methods:
Stainless steel fasteners are acceptable in low stress applications. Black finish steel fasteners are acceptable. Zinc plated carbon steel fasteners should be electroplated. Zinc dipped plating is not acceptable. Cadmium plated fasteners must not be supplied.
1.6.9 Finishes
Aluminium components internal to the instrument shall be shot blasted and black anodised. External aluminium surfaces shall be black anodised.
For surfaces other than aluminium, two pack epoxy paints are acceptable.
Preferred colour black. Light spray paint is unacceptable.
Cadmium must not be used.
1.6.10 Identification
The instrument shall have a permanent label attached with the following details:
1.6.11 Deliverable Documentation
Procedures for assembly and dismantling must be supplied with the equipment.
All technical drawings and illustrations shall be provided on computer media in Autocad compatible format and as either:
i) 8½" x 11" or 11" x 17" original drawings on mylar or velum
or ii) as larger drawings on :
(a) A3, A2, A1, A0 size drawing stock of mylar or velum.
or (b) reproducible sepia blueprints of original mylar or velum drawings in the sizes specified above.
All drawings shall be numbered.
Manuals shall be provided in typewritten form in English on A4 stock.
Manuals shall be provided on computer media in a format compatible with the IBM PC version of the Microsoft WORD6 word processing software.
Each manual shall contain, apart from the text :
i) a Title or Cover Page
ii) a Table of Contents
iii) a List of Illustrations
iv) an Index
Each document page shall contain a page number and a release date or version number.
Drawings :
An overall assembly drawing or 3-view cutaway drawing shall be provided showing all major subassemblies.
A complete set of dimensioned assembly and detail drawings sufficient to fabricate any component of the instrument, shall be provided.
All parts shall be numbered and dimensioned.
Commercial parts shall be identified on the drawing together with:
i) the manufacturer's name
ii) the part or model number
iii) the quantity required
The drawing standards used must be clearly identified on the drawings.
All special symbols shall be identified in a separate symbol table provided as an instrument drawing.
Manuals:
A mechanical assembly and maintenance manual shall be provided. It shall contain :
i) an overview of the instrument operation
ii) instructions for the mechanical assembly, and disassembly of all major modules.
iii) all specialized assembly procedures
iv) a list of all specialized tools required for instrument maintenance or adjustment
v) a list of all commercial parts used in the instrument, including, for each :
- a drawing reference numbers indicating the assembly in which the part is used.
- the manufacturer's name, address, telephone number, and telefax number.
- the model or part number.
- a data or manufacturer's specification sheet.
- the supplier's, name, address, telephone number, and telefax number.
Source code listings for all modules shall be provided both as hardcopy, and on magnetic media readable by the ING target system.
All modules shall be documented and fully commented. Each module shall contain as a comment header to the source code :
i) a listing of all modules called from the module
ii) a listing of all modules which call the module
iii) a brief explanation of the module's purpose
iv) a listing of all module inputs
v) a listing of all module outputs
vi) a listing of all module error conditions
vii) a definition of all module variables, constants and arrays.
The software package shall include explanatory text and diagrams detailing :
i) the purpose and scope of the software package, including
references to operational theory, if appropriate.
ii) program flow indicating the interactions between modules.
iii) error conditions and codes, and likely sources of the errors.
Drawings :
A system block diagram detailing signal flow, major subsystems and functions shall be provided.
A drawing detailing overall system component layout, cable interconnections, connector identifications, and cable names shall be provided.
Detailed wiring interconnection diagrams shall be provided for each cable, showing:
Detailed electronics circuit diagrams shall be provided for all circuits, indicating :
All changes or jumpers on circuit boards shall be highlighted
All signal paths and power runs shall be clearly identified, and signal directions indicated
All circuits shall be supplied in an electronic format. ING have a strong preference for the ORCAD schematic design package.
All references to signals and connections from and to other drawings or devices shall be clearly identified
Circuit timing diagrams shall be provided.
Logic notion should be consistent with the device manufacturer's symbols. The use of "inverted" logic symbols is not acceptable.
Diagrams should be on size A (A4) or B (A3) sheets suitable for binding in a manual.
Manuals:
A written systems and operational description shall be provided
A detailed written description of circuit cards and subsystem functions, including critical signals and timing shall be provided.
Source and binary listing of the contents of all PROMs or programmable logic devices shall be provided.
A list of all commercial components shall be provided, including :
i) a drawing reference number indicating where the part is used
ii) the manufacturer's name, address, telephone number, and telefax number
iii) the model or part number.
iv) a data or manufacturer's specification sheet
v) the supplier's, name, address, telephone number, and telefax number
Drawings:
A loop block diagram for all servo systems shall be provided indicating components, summing points and signal paths.
Open and closed loop gain and phase response curves (transfer functions) shall be provided for all servo systems. Bode plot approximations are acceptable whenever system poles and zeros are adequately spaced.
Flow diagrams showing the interrelation and timing of all "firmware" routines shall be provided.
Manuals:
A written control system overview, detailing system operation shall be provided.
A written firmware system description providing a detailed explanation of the operation of each code module, including required inputs and all possible outputs shall be provided.
A complete, documented and commented firmware listing in assembly or higher level language shall be provided.
For servo systems, the transfer function of each loop component, together with system open loop and closed loop transfer functions shall be provided in the form of algebraic expressions.
Drawings:
A complete set of optical specification drawings sufficient to fabricate all custom optics, or other commercial optical components shall be provided.
An overall optical assembly drawing showing all optical components and systems, the directions and positions of major optical rays, and the direction of any available adjustments shall be provided.
Spot diagrams detailing critical device performance over the design field and spectral range shall be provided.
Manuals:
Optical alignment instructions detailing in particular any preferred procedures, and the use of alignment fixtures and tooling shall be provided.
An optical efficiency budget giving the efficiency of each surface, and an overall optical efficiency for the instrument shall be provided.
A list of mirror and anti-reflection coatings for each surface, shall be provided, detailing :
i) the manufacturer's name, address, telephone number, and telefax number
ii) type of coating and its specifications
iii) optical efficiency of coatings, including any efficiency tracings available.
A list of all custom optical components detailing all necessary manufacturing specifications shall be provided.
A list of all commercial optical components shall be provided, including :
i) the manufacturers name, address, telephone number, and telefax number
ii) the model or part number
iii) a datasheet or copy of catalogue entry
iv) the supplier's name, address, telephone number, and telefax number
1.8.1 Instrument
Instruments shall be provided with lifting points above the instrument CofG. positioned so that the instrument naturally hangs at the angle at which it is mounted to the telescope.
Individual items weighing more than 20kg are not man liftable, hence lifting equipment must be supplied.
1.8.2 Storage and Handling
Instruments shall be supplied with all necessary handling equipment required to maintain, transport and fit the instrument to the telescope. The designer must consider instrument changes and maintenance requirements when designing this equipment.
When designing lifting equipment the space envelope from the hook to the instrument must be considered.
If a dolly is to be supplied as the means of transporting or fitting the instrument to the telescope then a light weight handling dolly is preferred. This should have four castors two direction locking and two with brakes. Rolling resistance must be considered, hence a hard tyre is preferred. The dolly should support the instrument in the same orientation as the instrument will be in when mounted to the telescope following the instrument change. The dolly should not restrict access to the instrument and it must be possible to perform all electro mechanical functions whilst on the dolly since maintenance and trouble shooting is likely to take place on the dolly.
The dolly shall be designed to allow lifting of the dolly with and without the instrument.
In order to reduce shock loads to the instrument optics whilst being transported on the dolly, the designer may consider it necessary to mount the instrument to the dolly with shock isolators.
All handling equipment (including dolly) must be proof loaded and supplied with a proof load certificate.
1.8.3 Handling electronics equipment
It is preferred for all electronics to be mounted on the instrument. If it is not possible to mount the electronics to the instrument then the use of standard 19" racks is permitted.
1.8.4 Weight and moment
The weights and CofG positions of the dolly alone and dolly with instrument must be identified on the dolly as a permanent mark or label.
1.8.5 Cover
The instrument shall be provided with a vinyl dust cover. The cover shall have the name of the instrument in 100mm high letters permanently marked on it.
1.8.6 Identification
All handling equipment shall have a permanent label attached with the following details:
1.8.7 Materials
Carbon steel is the preferred material for handling equipment. However, other materials should not be discounted provided that the designer can justify the use. Thread inserts, such as helicoils, shall be used in parts manufactured from aluminium when it will be necessary to fit or remove screws on a regular basis e.g. if it is required to assemble components prior to fitting to telescope or to fix components in place.
1.8.8 Fasteners
Note: I will change the British Standards below for ISO standards when I can find them.
All fasteners shall conform to the following or equivalent:
Rivets are non-preferred and the designer may be required to justify the use of such fasteners.
All screws must be locked using one of the following methods:
Stainless steel fasteners are acceptable in low stress applications. Black finish steel fasteners are acceptable. Zinc plated carbon steel fasteners should be electroplated. Zinc dipped plating is not acceptable. Cadmium plated fasteners must not be supplied.
1.8.9 Finishes
All handling equipment shall be yellow.
Aluminium components shall be anodised yellow or painted with an appropriate etch primer paint system.
For carbon steel surfaces, two pack epoxy paints shall be used. Light spray paint is unacceptable.
Cadmium must not be used.
The vendor must provide training sufficient to allow ING technical staff to:
It is a requirement that new systems delivered to La Palma have a documented set of spares which will typically include:
All equipment delivered to ING shall be CE marked.