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B.Todd, M. Zerlauth, I. Romera, A. Castaneda. 0v1. Introduction. 2004 : LHC interlock systems = proto phase Fast, dependable , simple function XC9500 CPLD chosen for some parts of interlock system XC95288 in CIBU (Beam Interlock System) x 300 in LHC

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  1. B.Todd, M. Zerlauth, I. Romera, A. Castaneda 0v1

  2. Introduction 2004: LHC interlock systems = proto phase Fast, dependable, simple function XC9500 CPLD chosen for some parts of interlock system XC95288 in CIBU (Beam Interlock System) x 300 in LHC XC95288XL in CIBM (Beam Interlock System) x 34 in LHC XC95144 in CIP (Power Interlock Controller) x 36 in LHC AB/PO - each FGC has several 2005-9: Reliability campaigns XC95288 tested in PSI ½ LHC system used in SPS for 4 years Full LHC system started for 2 years All looking good  2009: R2E Warning regarding radiation in zones considered OK CNGS test campaign launched to quantify the risk Interlock Radiation Test Bench Machine Interlock Systems

  3. Electrical Architecture USER SYSTEM rack “some radiation” Worst “UJxx”-type In INTERLOCK rack “negligible radiation” Typical background at Sea Level Test / Repair before each Mission - accessible 2U Chassis VMEChassis 3 of 45 TE/MPE/MI - CERN Machine Interlocks

  4. Typical Hardware User Interface BIC (Front) TT40 BIC (Rear) TT40 4 of 45 TE/MPE/MI - CERN Machine Interlocks

  5. CIBD Specification Tracopower TXL-025-25S 5V, 5A, 25W • Device housed in shielded conductive case • Reliability analysis = redundant PSU = good Availability • Decoupling diode added • +3% trim to accommodate Vdiode • 400mA Fuse and filter added on input • EMC Tests done with CIBU/CIBD configuration • Very good results • https://edms.cern.ch/document/762174/ • Not the cheapest • excellent reliability = better than predicted • 4 failures to date = 10x better than datasheet 5 of 45 TE/MPE/MI - CERN Machine Interlocks

  6. CIBD – 5A 5V PSU 6 of 45 TE/MPE/MI - CERN Machine Interlocks

  7. CIBD – 5A 5V PSU ~12cm 7 of 45 TE/MPE/MI - CERN Machine Interlocks

  8. CIBD – 5A 5V PSU PROSPERO 235U core and a 238U reflector NEUTRONS Energy = 1MeV Fluence = 1E12 n/cm2 =Several 10’s Years LHC <1% Voltage change And CIBU OK down to 4.5V (guaranteed by design) PSU well protected - PSU 25W, we need <5W Degradation is expected & planned for 8 of 45 TE/MPE/MI - CERN Machine Interlocks

  9. User Interface Specification Device housed in conductive case with Burndy Connectors -great EMC -good reliability from connectors (many others already use these) Completely 5V -good reliability (more resistance to perturbation) Classic 7400 Series -mature technology -wide support Current Loop inputs -accommodate many different types of User System -DESY input circuit (M. Werner) RS485 Outputs -good integrity -mature Technology 9500 Xilinx CPLD for TEST and MONITOR -Manchester frames (Used General Machine Timing as a basis) -excellent dependability shown so far -not susceptible to program corruption 100% remotely testable 100% remotely monitorable 9 of 43 TE/MPE/MI - CERN Machine Interlocks

  10. User Interface 10 of 45 TE/MPE/MI - CERN Machine Interlocks

  11. User Interface Beam-2 Beam-1 11 of 45 TE/MPE/MI - CERN Machine Interlocks

  12. Test Areas 12 of 45 TE/MPE/MI - CERN Machine Interlocks

  13. Test Areas Beam-2 Beam-1 13 of 45 TE/MPE/MI - CERN Machine Interlocks

  14. Test Areas 14 of 45 TE/MPE/MI - CERN Machine Interlocks

  15. Test Areas Beam-2 Permit A Beam-1 Permit A Beam-2 Permit B Beam-1 Permit B 15 of 45 TE/MPE/MI - CERN Machine Interlocks

  16. Test Areas All use the SAME electronic circuit! It’s repeated four times Beam-2 Permit A Beam-1 Permit A Beam-2 Permit B Beam-1 Permit B 16 of 45 TE/MPE/MI - CERN Machine Interlocks

  17. USER PERMIT Paths The mission critical function for the CIBU; -relay USER_PERMITcorrectly Nothing else! All the BLACK lines are critical! 17 of 45 TE/MPE/MI - CERN Machine Interlocks

  18. USER PERMIT Paths The mission critical function for the CIBU; -relay USER_PERMITcorrectly 18 of 45 TE/MPE/MI - CERN Machine Interlocks

  19. The Irradiated Zones • USER_PERMIT Optocoupler • USER PERMIT Current Regulation Circuit • USER PERMIT RS485 Driver • USER PERMIT Schmidt Trigger • The WHOLE CIBU Test 3 Test 1 Test 4 Test 2 19 of 45 TE/MPE/MI - CERN Machine Interlocks

  20. Irradiation Parameters Irradiation Parameters 60MeV Protons – OPTIS at PSI 15MeV/cm2/mg in SiO2 – can cause SEE in plastic packages N.B. 1 x 1011protons cm-2 equivalent to 140 Gy “Representative of LHC Environment” – F. Faccio, M. Muhtinen 20 of 45 TE/MPE/MI - CERN Machine Interlocks

  21. The Irradiated Zones 21 of 43 TE/MPE/MI - CERN Machine Interlocks

  22. Test 1 – The Optocoupler Received a TOTAL DOSE of 62 Gy = 4.8 x 1010 pcm-2 10 Glitches observed – observation window open only ¼ of test - 40 assumed. Cross Section = 8.3 x 10-10for Optocoupler Glitches 22 of 43 TE/MPE/MI - CERN Machine Interlocks

  23. Test 1 – The Optocoupler usual transition times were observed during the test ~3.6us delay for TRUE to FALSE ~0.6us delay for FALSE to TRUE 23 of 43 TE/MPE/MI - CERN Machine Interlocks

  24. Test 2 – The Current Regulator Received a TOTAL DOSE of about 120 Gy NO Glitches observed Current regulation drifted by about 4% 24 of 43 TE/MPE/MI - CERN Machine Interlocks

  25. Test 3 – RS485 Driver Received a TOTAL DOSE of 496 Gy NO Glitches observed, No FALSE Transitions FAILED SAFE at 496 Gy, power cycle restored operation 25 of 43 TE/MPE/MI - CERN Machine Interlocks

  26. Test 4 – Schmidt Trigger Received a TOTAL DOSE of 1000 Gy (then experiment halted) NO Glitches observed, NO FALSE transitions 26 of 43 TE/MPE/MI - CERN Machine Interlocks

  27. Test 5 – Whole PCB Two PCBs tested ~140-160Gy - CPLD stopped sending data frames 27 of 43 TE/MPE/MI - CERN Machine Interlocks

  28. Overall Current Consumption Three PCBs tested at various points User Interface ID 1 = 180 Gy 28 of 43 TE/MPE/MI - CERN Machine Interlocks

  29. Overall Current Consumption Three PCBs tested at various points User Interface ID 682 = 1650 Gy 29 of 43 TE/MPE/MI - CERN Machine Interlocks

  30. Overall Current Consumption Three PCBs tested at various points User Interface ID 2 = 160 Gy 30 of 43 TE/MPE/MI - CERN Machine Interlocks

  31. CIBD and CIBU Conclusions • Critical Path of Beam Interlock System • - 8.3 x 10-10 Cross-Section for Glitches = use 1.6us GLITCH FILTER! • Good radiation tolerance • CPLD failed first at 150Gy – only for MONITORING • BUT once we got it back here – reprogrammed it and it worked! • Will monitor Glitch counters to indicate potential problems • Had plans for RAD HARD CIBU but on hold • Needs motivation, time and money! ($) • VME is weak? move BICs to ‘surface’ ($$$) • Critical Matrix CPLD is same as in CIBU (3.3V variant) … How does it handle? • VME PSU – redundant! • Can research a RAD HARD BIC (not including VME) • Needs motivation, time and lots of money ($$$$$) 31 of 43 TE/MPE/MI - CERN Machine Interlocks

  32. FIN Xilinx 9500/9500XL CPLD Testing CNGS 2009 TE/MPE/MI Radiation Working Group 21st August 2009 32 of 45 TE/MPE/MI - CERN Machine Interlocks

  33. Safety Critical path for PIC Max 16 Inputs / Patch Panel Max 96 Inputs / Total SIEMENS 319 CPU PROFIBUS MATRIX UNMASKABLE BEAM DUMP REQUEST OF THIS PIC MASKABLE BEAM DUMP REQUEST OF THIS PIC XILINX XC95144 CPLD used for redundancy and speed in beam dump request for Powering Interlock System (PIC) 36 CPLDs used in 36 different installations in the LHC (located in UAs, UJs and RRs) • Critical Path: Matrix for up to 96 inputs, generating 3 beam permit signals • Monitoring part: Read-back of Matrix configuration, Glitch Filters, CRCs, SW versions,.. Due to redundant designs throughout the system, CPLD failures would decrease primarily the AVAILABILITY of the machine, not the safety Machine Interlock Systems

  34. BIS CPLDS CIBU CIBM VME Chassis 1U chassis XC95288 = Not safety critical XC95288XL = safety critical 300 in LHC 34 in LHC Machine Interlock Systems

  35. Principle for Test-bench “CIRX” Machine Interlock Systems

  36. Principle for Test-bench “CIRX” Machine Interlock Systems

  37. Principle for Test-bench “CIRX” Machine Interlock Systems

  38. Principle for Test-bench “CIRX” Machine Interlock Systems

  39. Principle for Test-bench “CIRX” Machine Interlock Systems

  40. Principle for Test-bench “CIRX” Machine Interlock Systems

  41. Principle for Test-bench “CIRX” XC95144 x 32 XC95288XL x 32 41 of 27 Machine Interlock Systems

  42. Testbench Electronic Functionality XC95144 x 32 XC95288XL x 32 Machine Interlock Systems

  43. Testbench Electronic Functionality Machine Interlock Systems

  44. Testbench Electronic Functionality Machine Interlock Systems

  45. Testbench Electronic Functionality Machine Interlock Systems

  46. Testbench Electronic Functionality Machine Interlock Systems

  47. Testbench Electronic Functionality Machine Interlock Systems

  48. Testbench Electronic Functionality Machine Interlock Systems

  49. Testbench Electronic Functionality Machine Interlock Systems

  50. Testbench Electronic Functionality Machine Interlock Systems

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