There turned out to be a few analog signals for the vacuum system after all. The TP2/3 foreline pressure gauges were never part of the digital system, but we wanted to add them, as some of the interlock conditions should be predicated on their readings. Each gauge connects to an old Granville-Phillips 375 controller which only has an analog output. Interfacing these signals with the new system required installing an Acromag XT1221 8-channel A/D unit. Taking advantage of the extra channels, I also moved the N2 delivery line pressure transducer to the XT1221, eliminating the need for its separate Omega DPiS32 controller. When the new high-pressure transducers are added to the two N2 tanks, their signals can also be connected.
The XT1221 is mounted on the DIN rail inside the chassis and I have wired a DB-9 feedthrough for each of its three input signals. It is assigned the IP 192.168.114.27 on the vacuum subnet. Testing the channels in situ revealed a subtley in calibrating them to physical units. It was first encountered by Johannes in a series of older posts, but I repeat it here in one place.
An analog-input EPICS channel can be calibrated from raw ADC counts to physical units (e.g., sensor voltage) in two ways:
From the documentation, under the engineering-units method EPICS internally computes:
where EGUF="eng units full scale", EGUL="eng units low", and "full scale A/D counts" is the full range of ADC counts. EPICS automatically infers the range of ADC counts based on the data type returned by the ADC. For a 16-bit ADC like the XT1221, this number is 2^16 = 65,536.
The problem is that, for unknown reasons, the XT1221 rescales its values post-digitization to lie within the range +/-30,000 counts. This corresponds to an actual "full scale A/D counts" = 60,001. If a multiplicative correction factor of 65,536/60,000 is absorbed into the values of EGUF and EGUL, then the first term in the above summation can be corrected. However, the second term (the offset) has no dependence on "full scale A/D counts" and should NOT absorb a correction factor. Thus adjusting the EGUF and EGUL values from, e.g., 10V to 10.92V is only correct when EGUL=0V. Otherwise there is a bias introduced from the offset term also being rescaled.
The generally correct way to handle this correction is to use the manual "NO CONVERSION" method. It constructs calibrated values by simply applying a specified gain and offset to the raw ADC counts:
calibrated val = (measured A/D counts) x ASLO + AOFF
The gain ASLO="[(V_max_adc - V_min_adc) / 60,001]" and the offset AOFF="0". I have tested this on the three vacuum channels and confirmed it works. Note that if the XT1221 input voltage range is restricted from its widest +/-10V setting, the number of counts is not necessarily 60,001. Page 42 of the manual gives the correct counts for each voltage setting.