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LHC LVPS Procurement - Status

LHC LVPS Procurement - Status. Reported by: Chris Parkman, PH-ESS February 10, 2006 Tests by: Bruno Allongue, Philippe Fontaine, Edgar Dos Santos (PH-ESS) Francis Anghinolfi (PH-MIC), Mark Beharrell (IT-CO) Georges Blanchot (PH-ATE), Alexander Singovski (CMS ECAL) Acknowledgements to:

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LHC LVPS Procurement - Status

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  1. LHC LVPS Procurement - Status Reported by: Chris Parkman, PH-ESS February 10, 2006 Tests by: Bruno Allongue, Philippe Fontaine, Edgar Dos Santos (PH-ESS) Francis Anghinolfi (PH-MIC), Mark Beharrell (IT-CO) Georges Blanchot (PH-ATE), Alexander Singovski (CMS ECAL) Acknowledgements to: Federico Faccio (PH-MIC) László Ábel, Dante Gregorio (FI-PI)

  2. Technical approval • Wiener • Approval given with reservations • Magnetic field tolerance • EC conformity • OPC Server • Procurement underway • First release order issued • CAEN • Approval suspended • Electrical conformity • Environmental conformity • EC conformity • OPC Server • Procurement started • Accepting requests from experiments • Technical reports in preparation PH-ESS LVPS Procurement

  3. Wiener • Electrical - approved • Maraton, “F8” & “F12” • CE conformity (“Maraton” will be tested by TÜV in March) • Magnetic field tolerance • 1100 Gauss rather than 1200 • Bimetal thermal cut-out changed – to be tested • Radiation tolerance - approved • TID & SEE (spec: 140Gy over 10 years, 2*1011 p/cm2) • October 2005 Uppsala proton tests showed no effects up to 5.03*1010 p/cm2 • Probable failure of non-radiation tolerant AC/DC/PFC • December 2005 PSI proton tests showed no effects up to 2*1011 p/cm2 • NIEL (spec: 1012 n/cm2 over 10 years) • January 2005 Prospero neutron tests showed no effects up to ~6*1012 n/cm2 • OPC server • Qualified approval for the “Maraton” • (monitoring only over Ethernet) • Full “F12” functionality over Ethernet (sample end March) • Full functionality over Ethernet & CAN (sample two months after approval of “F12”) PH-ESS LVPS Procurement

  4. μP μP 3. “Maraton”12ch 50A DC-DC(3kW) 1. AC-DC (w. PFC) 230VAC, single phase 385VDC 2. Control & monitoring Ethernet ATLAS TRT, LHCb High radiation & magnetic field tolerance Water cooled OPC Server PH-ESS LVPS Procurement Spec A LHCb ATLAS-TRT

  5. μP ALICE Low radiation & magnetic field tolerance Water cooled “PL500-F12”12ch 50A DC-DC 230VAC, single phase Ethernet OPC Server PH-ESS LVPS Procurement Spec A ALICE

  6. μP CMS ECAL Neutron radiation & high magnetic field tolerance Water cooled “PL500” 6ch 100A DC-DC CMS-ECAL 230VAC, single phase CAN OPC Server PH-ESS LVPS Procurement CMS Spec B Radiation is present at a level below 4Gy and 1011 1 MeV equivalent neutrons/cm2 over 10 years, of which approximately 10% are above 20MeV. Stray magnetic fields are present at a level up to 180mT.

  7. No radiation or magnetic field tolerance μP ATLAS Pixels Air cooled “PL500-F12”12ch 50A DC-DCATLAS Pixels 230VAC, single phase Ethernet OPC Server PH-ESS LVPS Procurement Spec A ATLAS - Pixels

  8. CAEN EASY • Electrical • Out of spec • Power factor • EMC • Efficiency • Noise and ripple • CE conformity • Need approval by independent laboratory - “auto-declaration” is insufficient • Magnetic field tolerance • In spec - 2000 Gauss • Radiation tolerance • Tests so far • October (PH-ESS) – TSL Uppsala - proton tests showed TID effect and SEE • December (PH-ESS) - PSI - proton tests identified particularly sensitive area on boards • January (Atlas Muons/CAEN) - Casaccia - gamma tests showed TID effect • January (Atlas Muons/CAEN) - TSL Uppsala - proton tests to refine diagnosis and test replacement components also tests of HV boards • Planned tests • February (PH-ESS) - Prospero - neutron tests end February (PH-ESS) • February or March (ATLAS Muons/CAEN) - Pavia - gamma tests on test samples for TID effects March (PH-ESS/CAEN) - PSI - tests on sample boards to verify solution to SEE • May (PH-ESS) - TSL Uppsala - final verification (repeat of October tests) • OPC server • Number of problems identified by IT-CO • Solutions promised on March time-scale PH-ESS LVPS Procurement

  9. CAEN – Electrical issues: actions • Power factor • The tender calls for a minimum Power Factor of 0.95 (since relaxed to 0.85) • The measured value for the A3486 when delivering 3500W was 0.75 • With the addition of the harmonic trap (passive filter) a Power Factor >0.9 was measured at 3500W output power and 0.7 at 1730W • CAEN will “tune” the passive filter to cover a wider range of loads, and/or put the two channels in series (two notch filters) • Mains harmonic rejection • The A3486 was found to be non-conformant to the EN61000-3-2 Specification at all loads, however with the addition of the mains filter, the conditions of EN61000-3-2 were met at all loads. • Use the passive filter (CAEN are not envisaging active power factor correction) • Efficiency • The specification calls for an overall efficiency (power out/power in) of better than 70% at loads from 10 to 100% of full load • The A3486 and A3009 show overall efficiencies of less than 60% at all loads. The A3486 had an efficiency of 88% at an output of 3500W, the A3009 66% at maximum possible output (the nominal output was not attainable) - thus giving an overall efficiency of some 58%. • PH-ESS showed the major losses to be apparently associated with the transformer (on the A3009). • CAEN to investigate further • Other parameters • On the A3009 measured, the voltage turn-off (fall) was not to specification (5mS) and the current limit could not be tested since it was not possible to reach the nominal output current (~8.8A instead of 9A), also the over-voltage protection did not function as specified (apparently no crow-bar) • CAEN are looking to a firmware solution PH-ESS LVPS Procurement

  10. CAEN – Radiation tolerance: actions • Six components identified as sources of problems • Pulse width modulator - UCC3580 • The UCC3580 will be replaced the non-pin compatible UC3525 (as used successfully in Casaccia and Uppsala on an ATLAS HV board) • New versions of the aux DC/DC (CAEN code: DC5) and of the drivers (CAEN code: DRIVXA and DRIVXC) in preparation • MOS driver TC4427 – transformer input driver • Replacement being proposed (LM5111 or TC4424), has apparently performed well (tests in Uppsala, Week 4) • EEPROM - control circuits • Pin compatible replacement being proposed. • 6 x Schmitt-trigger inverter 74HC14 – general use • Components from Fairchild seem particularly sensitive – change to other maker • Operational amplifier LM393 used as a comparator • Remove completely – redundant monitoring function • Opto-couplers HPL0630 – SEEs inducing spurious resets to the microprocessor controller • Implement a low-pass filter on the reset line to reduce spikes, demonstrated during tests in Uppsala, Week 4 PH-ESS LVPS Procurement

  11. CAEN – OPC server • Hardware persistency (§5.3) • Error states in the CAEN HW did not persist across power cycling the HW. • Voltage set point not preserved (§5.4) • Under investigation – waiting for new OPC Server release. • Fault tolerance (§5.5.2) • A specific start-up sequence results in incorrect OPC quality values for some of the items. CAEN to retest. • Data (Device) Source Access (§5.5.3) • The OPC server reads from a cache in the 1527 rather than the Easy modules. • Human readable configuration file (§5.5.4) • IT-CO to check again. • Stability & performance (§5.5.5) • Random server crashing. Work in progress • Diagnostic Facilities (§5.5.6) • Requires a new release of the OPC server. • IT-CO (Mark Beharrell) is waiting for the next OPC server release before continuing his tests. Provisional schedule – end-February. PH-ESS LVPS Procurement

  12. μP μP μP μP CAEN LVPS layout EASY crate (w. crate controller) 12ch 9A DC-DC OPC Server 6ch 16A DC-DC 4ch 25A DC-DC 2ch 50A DC-DC Ethernet 1ch 100A DC-DC Control & monitoring 48VService 400VAC, 3-phase 400VAC, 3-phase AC-DC 48VDC Filter PH-ESS LVPS Procurement Spec A Spec B CMS LHCb - VELO ALICE - TOF ATLAS - Muons

  13. Procurement • Status • First Wiener release order being processed (~2.7MCHF) • Second release order in preparation • Requests accepted for first CAEN release order • Schedule • Wiener • Wiener will inform us of their production possibilities - next week • Faced with large orders for LVPS and crates • Any prioritisation between individual orders will be made by users with PH-ESS • Deliveries likely to be late summer… • CAEN • Long lead-time components ordered against informal notification of requirements • Despite delay in approval, ordering may proceed, but no payment before technical acceptance • Prioritisation difficult given large quantities ordered outside CERN contract • Deliveries likely to be late summer… PH-ESS LVPS Procurement

  14. Please use the PH-ESS request form whenever possible Allows request to be tracked For specials Emaillvps-info@cern.ch Catalogue Existing requests with status Add items PH-ESS request form PH-ESS LVPS Procurement

  15. Changes, Options, Parts

  16. Wiener - changes • Inclusion of OPC server licence in price – no separate licence • All monolithic power supplies • Maraton control and monitoring module RCM • 0R00.0000 -> 0R00.0001 • Crate for 6 Primary Rectifier Modules • 0B07.000 -> 0B07.001 - addition of screw terminal block at rear PH-ESS LVPS Procurement

  17. Thanks to Vincent Bobillier & Georges Blanchot Wiener parts in CERN Stores PH-ESS LVPS Procurement Amphenol connector for 385VDC input to Maraton power converter

  18. Suggested cables for Wiener Maraton • Cable for 385VDC Primary Rectifier to Maraton • Cable for RCM to Maraton PH-ESS LVPS Procurement

  19. Wiener Options 1: over-voltage protection • CMS ECAL • A never-exceed output voltage achieved by the use of a non-linear transformer • ALICE • Limits the voltage at the end of the sense line (detector end) to a user defined value • This value is fixed at factory and cannot be adjusted by the user • A pure hardware limitation independent of the channel processor PH-ESS LVPS Procurement

  20. Wiener Options 2: CERN patch-panel • Approximate cost mounted on the 0B15.1200 power bin with connections to the Wiener rear-panel – 250 CHF • Customised paralleling, etc., possible - needs care (possibility of damage …) • Screens connected by clamping-bar in rack • Consider whether you would like the power bin delivered early to allow rack installations to proceed PH-ESS LVPS Procurement More on lugs Right-angled lugs available from the CERN Stores

  21. Right-angled lugs PH-ESS LVPS Procurement

  22. CAEN Options: Anderson Connectors v. Screw Terminals PH-ESS LVPS Procurement A3009 12 channels A3025 4 channels Screw terminals preferred

  23. Electrical & Environmental Tests

  24. Wiener Electrical tests

  25. Static regulation: Spec: 0.5% Test: 0.026%. Dynamic regulation: Spec: 10% of set voltage Test: 1% Efficiency: Spec: >70% Test: 72% Power factor Spec: ≥0.95 Test: 0.975 Noise and ripple: Spec: < 10mV at output terminals Test: ~30mv p/p at 200MHz Test: ~13mv p/p at 20MHz Turn ON time: Spec: >50ms, <100ms Test: 80ms. Turn OFF time: Spec: <5ms Test: 90ms EMC EN 61000-3-2 compliant “PL500-F12”12ch 50A DC-DCATLAS Pixels 230VAC, single phase Ethernet 0M11.0000 - Monolithic 3U 19" power box, 230V 50Hz PFC input, 12 channel DC output, 2-8V, 90W nominal, 11.5A max, 10A continuous, Ethernet control. OPC server licence. OPC Server Wiener PL500 “F12” electrical tests - overview PH-ESS LVPS Procurement In discussion with Wiener

  26. Static regulation: Spec: 0.5% Test: 0.034%. Dynamic regulation: Spec: 10% of set voltage Test: 8%. Efficiency: Spec: >70% Test: 75.2% Power factor Spec: ≥0.95 Test: 0.997 (full load) Test: 0.945 (one channel, full load) Noise and ripple: Spec: < 10mV at output terminals Test: 15mv p/p at 200MHz - 8mv p/p at 20MHz Turn ON time: Spec: >50ms, <100ms Test: 75ms. Turn OFF time: Spec: <5ms Test: 2.5ms. Current limit protection: Spec: 110% of rated current Test: 55.4A adjustable Over voltage protection: Spec: 125% of set voltage Test: 6.2V EMC EN 61000-3-2 compliant Wiener Maraton electrical tests - overview PH-ESS LVPS Procurement 3. “Maraton”12ch 50A DC-DC(3kW) 1. AC-DC (w. PFC) 230VAC, single phase 385VDC 0M22.0003 - 3U 19" power box, 385VDC input, 12 channel DC output, 2-8V, 300W nominal, 55A max, 50A continuous, analogue controlled interface. Water cooled, no magnetic screening. 2. Control & monitoring Ethernet

  27. Wiener radiation tests

  28. Probable cause – irradiation of the AC/DC/PFC module (non-radiation tolerant) Wiener Maraton – Uppsala October 2005 • Spec. 2*1011 p/cm2 PH-ESS LVPS Procurement 5.03 1010 p/cm2

  29. Wiener Maraton – PSI December 2005 • Spec. 2*1011 p/cm2 PH-ESS LVPS Procurement 5.03 1010 p/cm2

  30. CAEN Electrical

  31. EMC (conditions: loaded to 1728W - 36A, 48V) Non compliant with h5, h7, h11, h13, h17, h19 Power Factor 0.74 (spec. ≥0.95) The system exhibited non negligible level of common mode noise The environment was not optimum (no LISN, no ground plane). Static regulation Spec: 0.5% Test: < 0.5% of set voltage Dynamic regulation: Spec: 10% of set voltage Test: <10% of set voltage Efficiency Spec: >70%, 10-100% load Test: overall system 57% + loss in DC cable. AC/DC converter (A3486): 88%. DC/DC converter (A3009, A3025…): 65%. Noise and ripple: Need additional measurements (30m of cable with loads capacitance of 300uF) Turn on OK. Turn off > 5ms. Current limit protection: <110% of rated maximum current. Impossible to reach the nominal value. Overvoltage protection: In case of overvoltage , error message “OVV” on SY2527 screen but no drop of output voltage. No crowbar CAEN A3486/A3009/A3025 electrical tests - overview PH-ESS LVPS Procurement

  32. CAEN Radiation Tests

  33. 9.3 1010 p/cm2 CAEN A3009 - Uppsala October 2005 PH-ESS LVPS Procurement

  34. CAEN A3009 - Uppsala October 2005 PH-ESS LVPS Procurement

  35. CAEN A3009 - Uppsala October 2005 PH-ESS LVPS Procurement

  36. CAEN A3009 - Uppsala October 2005 PH-ESS LVPS Procurement

  37. 1.09 1011 p/cm2 CAEN A3025 - Uppsala October 2005 PH-ESS LVPS Procurement

  38. CAEN A3025 - Uppsala October 2005 PH-ESS LVPS Procurement

  39. CAEN A3486 - Uppsala October 2005 PH-ESS LVPS Procurement Restart beam 1.44 1010 p/cm2 6.17 1010 p/cm2

  40. CAEN A3009 - PSI December 2005 Power solid state fuse + microprocessor A B C D PH-ESS LVPS Procurement E Input diode Switching transistor Service solid state fuse + EEPROM ?

  41. A PSI December 2005CAEN A3009 - Area A: Ch. 2 Vout PH-ESS LVPS Procurement

  42. A PSI December 2005CAEN A3009 - Area A: input power current PH-ESS LVPS Procurement

  43. A PSI December 2005CAEN A3009 - Area A: input service current PH-ESS LVPS Procurement

  44. D PSI December 2005CAEN A3009 - Area D: communication PH-ESS LVPS Procurement

  45. E PSI December 2005 CAEN A3009 - Area E: communication PH-ESS LVPS Procurement

  46. A PSI December 2005CAEN A3050 - Area A: Ch. 1 Vout PH-ESS LVPS Procurement

  47. A PSI December 2005CAEN A3050 - Area A: input power current PH-ESS LVPS Procurement

  48. A PSI December 2005CAEN A3050 - Area A: input service current PH-ESS LVPS Procurement

  49. B PSI December 2005CAEN A3050 - Area B: Ch. 1 Vout PH-ESS LVPS Procurement

  50. B PSI December 2005CAEN A3050 - Area B: input service current PH-ESS LVPS Procurement

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