VME Crates: Technical Overview & Water Cooling Solutions for LHC Projects

1. LHC Crates 2005 Paul Harwood PH Electronic Systems Support Group (PH-ESS) Meeting Sept 1, 2004

2. Introduction • LHC crates contract • Supplier - Wiener (Plein & Baus) Gmbh • Schedule - Single annual order, 3 fixed deliveries • ESS handles – Contract, Ordering, Reception, Inspection, Inventory & database, Forwarding and Support. • 2004 deliveries • Deliveries 1 & 2 complete (32+38 crates) • Delivery 3 expected mid Nov (75 crates) VME crates

3. Technical overview • Crate configuration options • 6U / 9U • Local / Remote PSU • Air / Water cooled • Standard / Lab variant • Backplane options – VME64x, VME64xP, CPCI, Custom, J3… • Other – Fan tray depth, Slot depth, 6U/9U slot options • Communication – CAN as standard, TCP/IP & RS232 • Rad/Mag tolerant crates ’05 VME crates

4. Crate configurations 6U Remote Local 9U Remote Local VME crates

5. Crate variations • Initial plans were to provide a number of ‘standard’ crates • There are now 31 different types of crates & 36 PSU configurations on the inventory • For support & administrative reasons it is necessary that this list does not grow any more • Review the pre-existing options, there is almost certainly a suitable solution • Guidance can be provided of selection of the best solution VME crates

6. Water-cooling (PSU’s) • To date: • Pre-production prototypes evaluated by ESS • In collaboration with Wiener, several changes made to improve reliability & cooling efficiency • A few intermediate delivered to users • Have been recalled for the above modification • Considerations • Will require care with cooling water installation to achieve required flow rate (≈1 l/min) • Power supply is ‘shunted’ by rack heat-exchangers VME crates

7. Water cooling performance VME crates LHC w/c PSU – Cyan & dark violet curves. Note that the number of internal modules affects pressure / flow characteristic.

8. Cable management • In ‘remote’ PSU configurations, the loom of DC cables from the PSU to the crate required management, to ensure: • Minimum length (dynamic load requirement) • Full access to rear transition area • Minimize conflict with experimental cables in the rack • Ensure cables are undamaged by access operations • All remote PSU ‘bins’ will now include cable management (next slide) • Ensure that there are no conflicts with other services (water, experimental cables) VME crates

9. Cable management VME crates

10. Cooling • A number of instances of Slot 1 (2,3,4) cooling problems have been seen. • ESS\Wiener are investigating methods of mitigating this classic issue, including: airflow modification, assisted force cooling • In the meantime… • All crates are now supplied with Information sheets giving guidance on a few key aspects. • All 9U crates supplied in 2005 onwards will have a blanking panel fitted to the J3 area, if there is nothing ordered in this position. Users may remove this if required to fit a J3 backplane. This should improve the overall airflow in the crate. VME crates

11. 9U LHC Crate Variant 1 Water Cooled Power Supply 766mm Mains 6U Control in crate 726mm 840mm 1U 726mm Power AC/DC Connection J1 POWER 6Ux160mm Board WATER SUPPLY RP0 COOLED 9Ux400mm Board J0 9Ux220mm Board POWER 9U SUPPLY 6U SUBRACK J2 RP2 FAN TRAY 690mm Rad/Mag tolerant crates VME crates Hostile Safe • Prototype – 9U, no fan tray, VME64x • PSU water cooled with remote AC/DC & control board

12. Questions? • Any Technical Questions? VME crates

13. Ordering for 2005 • No major change from 2004 • Costs • Updated price list available from October • Normal annual increase from Wiener • PH-ESS will add a supplement to cover variations in the CHF/EUR exchange rate and transport (~2%) • Discuss your requirements with Paul Harwood • Technical • Information: www.cern.ch/ESS/crateProject/ • Delivery schedule (which batch?) • Deliveries in 3 batches May, August and November 2005 VME crates

14. Ordering for 2005 • Deliveries • In 2003/4 a considerable number of crates have been forwarded outside CERN, with increasing volumes this will no longer be possible • ESS will only now deliver by Internal Transport • Users must arrange their own onward shipping if necessary • Order amendments • Several instances of order amendments have occurred in 2004 • This is often expensive, and creates a large workload • Please ensure crate orders are correct at the time of ordering • Spares • ESS do not hold spares for crates • Each experiment / user should evaluate their needs and ensure that spares are maintained as necessary VME crates

15. Timescales (deadlines) • Requirements (Sept - Dec) • Discussion of requirements / prices / delivery • Internal orders confirmed (End of Dec) • All requirements must be received by this date • Prepayment (January) • PH-ESS issue TIDs, which must be approved before order will be placed (by 31st Jan) • External order placed (Feb 1st) • PH-ESS issues release order to supplier • Deliveries • 12, 24, 36 wks after release order VME crates

16. Database • ESS maintains a database of LHC crates • Used for: • Finding crate components / prices • Order tracking & delivery information • Inventory (bar code labels) & owner info • Commercial & technical history • Actions recorded: • Order status, delivery date, warranty info, reception, testing, dispatch, fault records, repair…. • Users may now access this database • http://ess.web.cern.ch/ESS/ and select “LHC crates – Public” • Database is password protected for commercial reasons, please apply to ESS for access VME crates

17. Discussion • Any Questions? • Any other points to raise? VME crates