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P3K Palomar Infrastructure

P3K Palomar Infrastructure. Balance Adaptations Larger Cass weight load from instrument & electronics Electrical Service Upgrades Higher electric service requirements at Cass, Computer Room and AO Lab Cooling of Cass Electronic Racks Removal of ~6 kW of heat from below primary mirror.

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P3K Palomar Infrastructure

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  1. P3K Palomar Infrastructure • Balance Adaptations • Larger Cass weight load from instrument & electronics • Electrical Service Upgrades • Higher electric service requirements at Cass, Computer Room and AO Lab • Cooling of Cass Electronic Racks • Removal of ~6 kW of heat from below primary mirror J.Zolkower

  2. Cass Mounted System Weights • P3K AO Cass System Weights • P3K Bench 3900 lb • P3K DM rack 1 525 lb • P3K DM rack 2 525 lb • P3K Ctrl rack 1 258 lb • P3K Ctrl rack 2 348 lb • Cables 475 lb • Glycol system 260 lb AO System Total 6291 lb • With Heaviest AO Instrument • P1640 / Cal 380 lbs (est) • P1640/ Cal elec. 450 lbs (est) • Total w/ Instrument 7120 lbs • ~1700 lbs more than current maximum • Current AO Cass System Weights • AO Bench 3820 lbs • AO Rack 1 415 lbs • AO Rack 2 345 lbs • Cables 85 lbs AO System Total 4665 lbs • With Heaviest AO Instrument • P1640 340 lbs • P1640 elec. 400 lbs Total w/ Instrument 5405 lbs J.Zolkower

  3. Balance Adaptations J.Zolkower • P3K Cass mounted component weights exceed current balance adjustments via moving counterweights • New balance adaptations required: • Additional ~700 lbs of lead added to weight boxes on Tube upper ring • Implementation of up to three ‘dummy’ electronic cabinets: • 2 cabinets loaded with 475 lbs of weight, the third with ~200-300lbs • To be applied with lower weight Cass instrument / electronic configurations • Status: Design concept complete. • Risks: Additional load on tube may effect telescope pointing model. No structural concerns have been identified.

  4. Electrical Service Upgrades Power Requirements • Computer Room Electronics (2 Racks) • Total Rated Power : 11,870 W • Total measured continuous measured: 3500 W • Continuous + Intermittent measured: 5400 W • Cass Cage mounted Electronics (4 Racks) • Total Rated Power: 8900 W • Total continuous measured: 6250 W • Continuous + Intermittent measured: 7210 W • Current AO system measured: 1035 W • Highest power AO instrument P1640 ~ 500W • P1640 Cal power TBD • Chiller in Coude • 220 V / 3 Phase / 42 amp service ~ 10,000 W J.Zolkower

  5. Electrical Service Upgrades J.Zolkower Required Electrical Upgrades • Computer Room Electronics • Add 3x 120V / 30 Amp Receptacles (ready for connection) • Cass Cage • Add 3x 120V / 30 Amp Receptacles • Add Load Center in Cass Cage • Insufficient paired conductors available in exiting wrap-up to provide required power (electromagnetic field cancellation concerns) • A new, auxiliary wrap-up will be used to bring required power to Cass • This auxiliary wrap-up will also be used to & from transport glycol to Cass • AO Lab • Add 3x 120V / 30 Amp Receptacles, Contactors (ready for connection) • Coude(Chiller location) • Add Breakers, Disc. contactors, and Junction Box

  6. Power Dissipation / Mirror Temperature Current AO power ~ 1000 W J.Zolkower

  7. Cass Rack Power Allocation These racks to be cooled ~6100 W J.Zolkower

  8. Cooling System Functional Parameters • Basic Functional Requirement • Provide system for cooling of Cass mounted electronics in order to minimize the heat dissipated to environment below the primary mirror and dome air. • Operating parameters: • Ambient temperature range: -10ºC to +30ºC • Target Coolant temperature: 3ºC below ambient • Cooling fan air flow: Constant speed • Coolant Mix: 35% Propylene Glycol • Coolant Temperature Range: -13ºC to +27ºC • Facility Chilled water temp: 5ºC to 10ºC (seasonal range) • Thermal modeling of electronic rack heat exchangers by Thermatron to confirm heat exchanger design within proposed operating parameters and define performance requirement of chiller J.Zolkower

  9. Chiller Specification • Requirements for Cass Electronics Cooling • Total heat load: 6100 W • Max. coolant flow rate: 16 GPM • DM Racks: 3x 2 gpm x 2 Racks = 12 gpm • Cass 1 Rack: 2x 2 gpm x 1 Rack = 4 gpm • Coldest required supply coolant temp: -13ºC (3º below lowest ambient) • Warmest required supply coolant temp: +27ºC (3º below highest ambient) • Chiller Construction / Installation for Cass instrument cooling • Water cooled chiller: exhaust chiller heat through facility chilled water • 7.5 ton capacity chiller from Opti-temp to be installed in Coude lab • Delivery scheduled for Oct 4, 2010 • Chiller Construction / Installation for AO Lab: • Acquired Neslab System III Liquid to Liquid Heat Exchangers (no cost to project) • Ready for installation after clean-up and testing • Cooling requirements are less stringent when operating in AO lab, so refrig of process coolant not req’d • No need to move chiller from dome floor to AO lab or long plumbing runs J.Zolkower

  10. DM Rack Cooling System Layout Cage inside Cage outboard J.Zolkower

  11. Electronic Rack Heat Exchanger Delivery of 10 pcs Week of Sept. 20, 2010 J.Zolkower

  12. Cooling Fan Speed Control Proposed solution from Degree C • Accepts up to nine fans • ·Synchronizes rotational speeds of 4-wire fans to • eliminate “beat” noise and vibration • · Monitors speed of 3-wire fans • · Simultaneously controls up to two types of fans • · I2C and RS232 communication interfaces • · Field configurable through serial interface • · Programmable alarm thresholds & fan curve • · Open collector alarm output • · One onboard/ two external temperature sensors • · Non-volatile memory to store configuration • · Power & Alarm LEDs with external connections • · Software selectable 3.3/5V logic operation • · Isolated Fan and Logic power domains • · Single/Dual power input • · Inrush current limiter for “hot swap” • · Fan failure detection and prediction Delivery of 10 pcs Week of Oct 18, 2010 J.Zolkower

  13. Electronic Rack Cooling • Work completed • Spec and order Heat Exchangers • Spec and order Fan Trays & Speed Controller • Packaging of DM racks • Design & and pre-sourcing of rack plumbing, hose ass’y, manifold & attachment hardware • Work Remaining • Packaging of Cass 1 control rack • Installation of HX, fan trays, plumbing into racks • Testing of in-rack cooling system prior to electronic integration • Risks • More than 72 fans @ >100 cfm flow; Coolant flow @ 16 gpm • Will instrument be sensitive to vibration from fans or coolant flow? J.Zolkower

  14. Cooling System Control • System Supervisor Requirements Document: • http://www.oir.caltech.edu/twiki_oir/bin/viewfile/Palomar/Palm3000/P3KInfrastructure?rev=1;filename=P3K_Cooling_Supervisor_Concept_9-17-10.doc • Campbell Scientific 3000 data logger/controller • The Campbell data logger and control system has a versatile set of analog and digital inputs and outputs that are programmed with a simple interface and is in use at 4 location already at Palomar Observatory. • Parameters to be monitored: • Ambient air temperature and dew point at cabinet location. • Cabinet internal air temperature • Cabinet wetness • Fan Speed • Emergency stop status • Sensor Bypass configuration (overrides) • Chiller coolant temperature (at chiller) • Chiller coolant flow rate (at chiller) • Chiller enable state • Cabinet skin temperature • Cabinet coolant flow rates (TBD)

  15. Cooling System Control Modes of operation: • Constant temperature set point (AO Lab operational mode) • Controller maintains a constant internal air temperature • Ambient Temperature Tracking (Telescope operating mode) • Controller maintains a temperature relative to the ambient temperature • Dew point avoidance (Telescope operating mode) • Controller maintains a temperature relative to dew point for improved safety during high dew point conditions.

  16. Cooling System Control • Work completed • Hardware spec & ordered • Initial design complete • Initial software design complete • Work Remaining • Bench testing to begin after receipt of hardware (Oct 1) • Complete System integration and test

  17. Auxiliary Wrap-up Routing South Polar Axis Routing Turning Guide Attached at yoke bottom center To Coude J.Zolkower

  18. Auxiliary Wrap-up Routing Dec Axis Tube East Arm J.Zolkower

  19. Dec Axis Wrap-up Concept East Arm Spool Attached To Tube (Tube not shown) Dec axis Igus Cable Carrier Guide trough (cutaway) Attached to East Arm

  20. Cass Plumbing & Electric Routing Duct for hose routing Electric Load Center Cooling distribution manifold South side

  21. Cooling Distribution Manifold B&G Balance Valve • 2 Required • Cass Cage • AO lab Parker Quick Coupling Stainless Steel Manifold J.Zolkower

  22. Cooling / Electrical System Distribution • Work completed • Distribution Manifold design • Spec and pre-source of distribution manifolds, controls, valves, and pre-fabricated hose ass’y • Work Remaining • Design of Auxiliary Wrap-up • Spec & procurement of Aux Wrap-up components • Installation of Chiller in Coude (electric & plumbing) • Installation of Neslab at AO Lab • Procurement of manifolds, controls, valves, and pre-fab. hose ass’y • Installation of Distribution Manifold in AO Lab and Cass Cage • Installation of Auxiliary Wrap-up • Complete System integration and test • Risks • Aux Wrap-up varying effect on balance. Need to analyze. J.Zolkower

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