11 ssd power and cooling on the cone star integration workshop howard matis may 16, 2008 star...
TRANSCRIPT
11
SSD Power and Cooling on the Cone
SSD Power and Cooling on the Cone
STAR Integration WorkshopHoward MatisMay 16, 2008
STAR Integration WorkshopHoward MatisMay 16, 2008
22
The SSDThe SSD
33
The SSD is a working detector
The SSD is a working detector
44
BackgroundBackground
Important for the HFT physics program It is being upgraded to be fully compliant with
DAQ1000 The SSD NIM paper had 41 people We are trying to do the upgrade with
Experienced but unattached SSD engineers A few young scientists (software) Several “highly experienced” physicists (hardware) Manpower and resources limited
Have designed an upgrade path with very finite resources and to fit existing STAR upgrade funds
Important for the HFT physics program It is being upgraded to be fully compliant with
DAQ1000 The SSD NIM paper had 41 people We are trying to do the upgrade with
Experienced but unattached SSD engineers A few young scientists (software) Several “highly experienced” physicists (hardware) Manpower and resources limited
Have designed an upgrade path with very finite resources and to fit existing STAR upgrade funds
55
OutlineOutline
Overview Electrical past Electrical future Cooling past Summary
Overview Electrical past Electrical future Cooling past Summary
66
Existing Cables on the Cone
Existing Cables on the Cone
20 groups of cables feeding ladder on each end Readout on each end Only need to bias
detector on one end Each group contains
either 3 round cables going to
a rectangular connector (sense, LV, HV)
2 round cables (sense, LV)
20 groups of cables feeding ladder on each end Readout on each end Only need to bias
detector on one end Each group contains
either 3 round cables going to
a rectangular connector (sense, LV, HV)
2 round cables (sense, LV)
77
Cable Bundles along the Cone
Cable Bundles along the Cone
BundleBundle
(picture taken during Removal of SVT from STAR)(picture taken during Removal of SVT from STAR)
88
Readout chainReadout chain
30 MHzBLVDS bus
Ribbon cable (1m)
shielded cable (2m)
Readout board
3 MHzon a ladder
10 ADC boards
Two Shielded Cables per side
99
Existing Space on the Cone
(one side)
Existing Space on the Cone
(one side)System cable type quantity diameter
Area Rectangular
Total Area Rectangular
mm cm2 cm2
slow control + DAQ shielded twisted pair (68x) 2 25.0 6.3 12.5
Ladder power Sense (4x AWG 24) 20 10.0 1.0 20.0LV (6x AWG 18) 20 10.0 1.0 20.0HV Bias (2x AWG 24) 10 5.0 0.3 2.5
air cooling air cooling hose to end of cone 10 12.7 1.6 16.1air cooling hose to outside the cone 10 12.7 1.6 16.1
Total cm2 87.3
(Rectangular Area Area assuming cable is a square with the diameter of the cable)(Rectangular Area Area assuming cable is a square with the diameter of the cable)
Low voltage cable may be smallerLow voltage cable may be smaller
1010
Previous Coolinghttp://www.star.bnl.gov/public/ssd/STAR_technique/ssd_cooling_s
ystem_doc_2.pdf
Previous Coolinghttp://www.star.bnl.gov/public/ssd/STAR_technique/ssd_cooling_s
ystem_doc_2.pdf
Cooling at a ladder level
Air is taken from inner STAR 10 outputs go to East 10 outputs go to West
16 watt/ladder 1/2” tubes with outer
layer protection at exit of the cone (~3/4”)
Kinked hoses big problem
Cooling at a ladder level
Air is taken from inner STAR 10 outputs go to East 10 outputs go to West
16 watt/ladder 1/2” tubes with outer
layer protection at exit of the cone (~3/4”)
Kinked hoses big problem
1111
Existing Cooling DiagramExisting Cooling Diagram
1212
Air from inner field cage
Output to Vortex
1313
Features of Existing Cooling System
Features of Existing Cooling System
Input air temperature defined by IFC TPC air temperature Noticed more temperature failures on SSD
as hall temperature increased Design provides symmetric heat load on
east and west TPC Large cooler, very loud - Vortex Hoses easily crimped 20 tubes on each side in the vicinity of
the SSD end 10 tubes go under the cone
Input air temperature defined by IFC TPC air temperature Noticed more temperature failures on SSD
as hall temperature increased Design provides symmetric heat load on
east and west TPC Large cooler, very loud - Vortex Hoses easily crimped 20 tubes on each side in the vicinity of
the SSD end 10 tubes go under the cone
1414
Problems with existing cooling
Problems with existing cooling
Input air temperature Is inner field cage controlled to 20 C as per
original specifications? Need a source of cool air
Hoses kink easily Find stiffer hose that meets safety
requirements
Vortex very noisy (acoustical) Find new blower
Input air temperature Is inner field cage controlled to 20 C as per
original specifications? Need a source of cool air
Hoses kink easily Find stiffer hose that meets safety
requirements
Vortex very noisy (acoustical) Find new blower
1515
Cooling in new designCooling in new design
Need cooled incoming air Symmetric cooling from east and west side
Cool evenly Similar heat load on both sides of the TPC 10 inputs and 10 outputs on each end
Total of 20 at each end
New electronics might take more power Complete design so can calculate heat load
Assume can find BNL approved hoses which don’t kink at 0.5”
Need cooled incoming air Symmetric cooling from east and west side
Cool evenly Similar heat load on both sides of the TPC 10 inputs and 10 outputs on each end
Total of 20 at each end
New electronics might take more power Complete design so can calculate heat load
Assume can find BNL approved hoses which don’t kink at 0.5”
1616
Cables for Old/New DesignCables for Old/New Design
1717
SSD UpgradeSSD Upgrade
Power Need to finish design to determine how much power Reducing gauge of power wires requires a new power supply
Data Two optical cables for each ladder (one per side)
Slow Control 28 wire copper cable or Two optical links per ladder (one per side)
need person to design (not budgeted for in SSD proposal) Air Cooling
One tube on each end - sized to 1/2” aperture of SSD Must have a source of cool air Need a person to do a system design Coordinate with HFT
Power Need to finish design to determine how much power Reducing gauge of power wires requires a new power supply
Data Two optical cables for each ladder (one per side)
Slow Control 28 wire copper cable or Two optical links per ladder (one per side)
need person to design (not budgeted for in SSD proposal) Air Cooling
One tube on each end - sized to 1/2” aperture of SSD Must have a source of cool air Need a person to do a system design Coordinate with HFT
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Proposed Designs on one end of the Cone*
Proposed Designs on one end of the Cone*
*Warnings:Need more resources to implement optical for slow controlNeed to study if smaller cable diameter can be toleratedCooling design necessary to fix hose requirements
*Warnings:Need more resources to implement optical for slow controlNeed to study if smaller cable diameter can be toleratedCooling design necessary to fix hose requirements
System cable type quantity diameterArea
Rectangular
Optical Total Area
Rectangular
Cable Total Area
Rectangular
Minimal Total Area
Rectangular
mm cm2 cm2 cm2 cm2
DAQ Optical Fiber 20 3.0 0.1 1.8 1.8 1.8
Slow Control shielded twisted pair (28x) 20 20.0 4.0 80.020 3.0 0.1 1.8 1.8
Ladder power Sense (4x AWG 24) 20 10.0 1.0 20.0 20.0
20 4.8Beldon 5304UE (unshielded) 0.2 4.5
LV (6x AWG 18) 20 10.0 1.0 20.0 20.0
20 5.8Beldon 7930A (unshielded) 0.3 6.6
HV Bias (2x AWG 24) 10 5.0 0.3 2.5 2.5
10 3.4Beldon 9452 (shielded) 0.1 1.2
air cooling air cooling to end of cone 20 12.7 1.6 32.3 32.3 32.3
contingency 0.15 11.8 23.5 7.2
Total cm2 90.1 180.0 55.4
Howard Matis:
Jim Proposes remove unshielded option.
Fix left adjustment
Howard Matis:
Jim Proposes remove unshielded option.
Fix left adjustment
1919
Mechanical MountsMechanical Mounts
Must maintain original attachment to the cone
Must maintain original attachment to the cone
2020
Integration QuestionsIntegration Questions What is new design of the cone? What is the bend radius of pipes and cables
allowed by the IST or FGT? What is the path of the cables on the cone to the
SSD? Who is assigning space on the cone and drawing the
design? Air manifolds - location Bend radii of cooling hoses
How to route cables and pipes on the cone? How to cables and pipes from cone to ladders? Where to get cold air? Can SSD be cooled from one end? Who will do this?
What is new design of the cone? What is the bend radius of pipes and cables
allowed by the IST or FGT? What is the path of the cables on the cone to the
SSD? Who is assigning space on the cone and drawing the
design? Air manifolds - location Bend radii of cooling hoses
How to route cables and pipes on the cone? How to cables and pipes from cone to ladders? Where to get cold air? Can SSD be cooled from one end? Who will do this?
2121
Integration Questions (cont.)
Integration Questions (cont.)
Need space for the RDO boxes on the magnet end
Use existing SSD rack on South Platform Need space for new air cooler (North
Platform?) and hose Cables in trays and festoon not
significant change from before Plenty of space in DAQ room Must keep SSD mechanical mounts on
cone
Need space for the RDO boxes on the magnet end
Use existing SSD rack on South Platform Need space for new air cooler (North
Platform?) and hose Cables in trays and festoon not
significant change from before Plenty of space in DAQ room Must keep SSD mechanical mounts on
cone
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Summary of SSD UpgradeSummary of SSD Upgrade
Ladders refurbished - same silicon New ladder ADC and transmission to
RDO Board New RDO and connection to DAQ
Room Using standard STAR DAQ1000 electronics
New cooling system Keep existing power cables
Ladders refurbished - same silicon New ladder ADC and transmission to
RDO Board New RDO and connection to DAQ
Room Using standard STAR DAQ1000 electronics
New cooling system Keep existing power cables
Howard Matis:
Wrong place
Howard Matis:
Wrong place
2323
SummarySummary
Rectangular size of previous cables on the cone 97.3 cm2 (counting both air hoses)
Rectangular size of current design (with contingency) 180 cm2 – copper slow controls 90.1 cm2 – optical slow controls (Needs engineering)
To do items Approve SSD proposal and provide funds Complete technical design to determine heat load Coordination with HFT for cooling Support for design of slow controls and cable design Numerous integration issues
Rectangular size of previous cables on the cone 97.3 cm2 (counting both air hoses)
Rectangular size of current design (with contingency) 180 cm2 – copper slow controls 90.1 cm2 – optical slow controls (Needs engineering)
To do items Approve SSD proposal and provide funds Complete technical design to determine heat load Coordination with HFT for cooling Support for design of slow controls and cable design Numerous integration issues
Howard Matis:
Jim proposes remove 55.4 cm2
Howard Matis:
Jim proposes remove 55.4 cm2
2424
Repair StatusRepair Status
May 2008May 2008
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Current SituationCurrent Situation
SSD in Nantes All Ladders tested No dead ladders
Ladder 7 fixed by replacing ADC and connection board
SSD in Nantes All Ladders tested No dead ladders
Ladder 7 fixed by replacing ADC and connection board
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Current Testing - Need 20 ladders
Current Testing - Need 20 ladders
•Six very good ladders•Seven Ladders with one bad hybrid (half module)
•Those ladders may be fully “good” if the bias of the module is forced.
•Nine Ladders with several bad modules•Some need to have the bias forced
•Because of problem with JTAG chain, configuration can be determined with present software
•Some improvement can be done•Four of these Ladders with a real high voltage trip. Can be good if capacitors replaced
•Will result in 10 very good ladders ladders
•Six very good ladders•Seven Ladders with one bad hybrid (half module)
•Those ladders may be fully “good” if the bias of the module is forced.
•Nine Ladders with several bad modules•Some need to have the bias forced
•Because of problem with JTAG chain, configuration can be determined with present software
•Some improvement can be done•Four of these Ladders with a real high voltage trip. Can be good if capacitors replaced
•Will result in 10 very good ladders ladders
Howard Matis:
Fix slide
Howard Matis:
Fix slide
2727
Summary with NO repairSummary with NO repair
2828
CommentsComments
Currently STAR software requires both n side and p side for a track Efficiency different if can allow only one side
6 chips (ALICE128) are programmed by a JTAG chain
When there is a break, then chips cannot be programmed correctly Current test software cannot bypass Can be bypassed using STAR Slow Controls
Problem can be improvedCan bypass and then lose 128 strips
Currently STAR software requires both n side and p side for a track Efficiency different if can allow only one side
6 chips (ALICE128) are programmed by a JTAG chain
When there is a break, then chips cannot be programmed correctly Current test software cannot bypass Can be bypassed using STAR Slow Controls
Problem can be improvedCan bypass and then lose 128 strips
2929
High CurrentHigh Current
Capacitors are added to isolate power lines
Probably due to bad capacitor Should be repairable How to locate bad capacitors Use infrared imagery
Capacitors are added to isolate power lines
Probably due to bad capacitor Should be repairable How to locate bad capacitors Use infrared imagery
3030
Picture of ModulePicture of ModuleCapacitorsCapacitors
3131
Infrared scanInfrared scan
Power offPower off Power onPower on
Power offPower offPower onPower on
Bad CapacitorBad Capacitor
3232
SummarySummary
Efficiency good now Better than 90%
Will improve
Efficiency good now Better than 90%
Will improve