Electronic Systems Support LHC LVPS Procurement - Status Reported by: Chris Parkman, PH-ESS February 10, 2006 Tests by: Bruno Allongue, Philippe Fontaine,

Electronic Systems Support

LHC LVPS Procurement - Status

Reported by: Chris Parkman, PH-ESSFebruary 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)

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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

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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”)

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ATLAS TRT, LHCb

OPC Server

OPC Server

Water cooled

Spec A

LHCb

ATLAS-TRT

2. Control & monitoring

385VDC230VAC, single phase

1. AC-DC (w. PFC)

Ethernet

3. “Maraton”12ch 50A DC-DC

(3kW)

High radiation & magnetic field tolerance

μP

μP

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OPC Server

OPC Server

ALICE

230VAC, single phase

“PL500-F12”12ch 50A DC-DC

μP

Ethernet

ALICE

Spec A

Water cooled

Low radiation & magnetic field tolerance

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CMS ECAL

CAN


“PL500”6ch 100A DC-DC

CMS-ECAL

μP

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.

Spec BCMS

OPC Server

OPC Server

Water cooled

Neutron radiation & high magnetic field tolerance

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ATLAS Pixels


Ethernet

ATLAS - Pixels

Spec A

OPC Server

OPC Server


ATLAS Pixels

μP

Air cooled

No radiation or magnetic field tolerance

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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

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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

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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

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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.

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400VAC, 3-phase

CAEN LVPS layout

48VDC

1ch 100A DC-DC

2ch 50A DC-DC

4ch 25A DC-DC

6ch 16A DC-DC

12ch 9A DC-DC

400VAC, 3-phase

FilterAC-DC

μP

μP μ

P

48VService

EASY crate (w. crate

controller)

ALICE - TOF

LHCb - VELO

ATLAS - Muons

CMS

Ethernet

OPC Server

OPC Server

Control & monitoring

μP

Spec A Spec B

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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…

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PH-ESS request form

Please use the PH-ESS request form whenever possible

Allows request to be tracked

For specials [email protected]

Catalogue

Existing requests with status

Add items


Changes, Options, Parts

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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

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Wiener parts in CERN Stores

Amphenol connector for 385VDC input to Maraton power converter

Thanks to Vincent

Bobillier & Georges Blanchot

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Suggested cables for Wiener Maraton Cable for 385VDC Primary Rectifier to Maraton

Cable for RCM to Maraton

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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

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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

Right-angled lugs available from the CERN Stores

More on lugs

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Right-angled lugs

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CAEN Options: Anderson Connectors v. Screw Terminals

A3009 12 channels A3025 4 channels

Screw terminals preferred


Electrical & Environmental Tests


Wiener Electrical tests

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Wiener PL500 “F12” electrical tests - overview 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


OPC Serve

r

OPC Serve

r


ATLAS Pixels

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.

Ethernet

In discussion with Wiener

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Wiener Maraton electrical tests - overview 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

2. Control &

monitoring

385VDC230VAC, single phase

1. AC-DC (w. PFC)

Ethernet

3. “Maraton”12ch 50A DC-DC

(3kW)

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.


Wiener radiation tests

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-0.5

0

0.5

1

1.5

2

2.5

3

3.5

Fluence

Vo

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Ouput Voltage 1

Ouput Voltage 2

Wiener Maraton – Uppsala October 2005 Spec. 2*1011 p/cm2

5.03 1010 p/cm2

Probable cause – irradiation of the

AC/DC/PFC module (non-

radiation tolerant)

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0

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1

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Fluence (p/cm2)

Vo

ut

(V)

Time (S)

DV=12mV

Wiener Maraton – PSI December 2005 Spec. 2*1011 p/cm2

5.03 1010 p/cm2


CAEN Electrical

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CAEN A3486/A3009/A3025 electrical tests - overview

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 Radiation Tests

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Caen A3009 Output voltage

-0.5

0

0.5

1

1.5

2

2.5

3

3.5

4

Fluence

Vo

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V out 1

V out 2

V out 3

9.3 1010 p/cm2

CAEN A3009 - Uppsala October 2005

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-0.5

0

0.5

1

1.5

2

2.5

3

3.5

4

Fluence

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V out 4

V out 5

V out 6


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-0.5

0

0.5

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1.5

2

2.5

3

3.5

4

4.5

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V out 7

V out 8

V out 9


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-0.5

0

0.5

1

1.5

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2.5

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V out 10

V out 11

V out 12


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CAEN A3025 Output voltage

-0.5

0

0.5

1

1.5

2

2.5

3

3.5

Fluence

Vol

tage

Ouput Volt 1

Ouput Volt 2

1.09 1011 p/cm2


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CAEN A3025 Ouput voltage

-0.5

0

0.5

1

1.5

2

2.5

3

3.5

Fluence

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Ouput Volt 3

Ouput Volt 4


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CAEN A3486 Output voltage

-0.5

9.5

19.5

29.5

39.5

49.5

Fluence

Vo

ltag

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Ouput Volt 1

1.44 1010 p/cm2 Restart beam

6.17 1010 p/cm2

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CAEN A3009 - PSI December 2005

AB

C

D

E

Input diode

Switching transistor ?

Power solid state fuse + microprocessor

Service solid state fuse +

EEPROM

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0

0.5

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3

Fluence (p/cm2)

Vou

t (V

)

Time (S)

Stop beam

Impossible to switch ON all channels:"UNV" error message.COM OK.

PSI December 2005CAEN A3009 - Area A: Ch. 2 Vout A

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Fluence (p/cm2)

Iin (A

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Time (S)

Stop beam

Impossible to switch ON all channels:"UNV" error message.COM OK.

PSI December 2005CAEN A3009 - Area A: input power currentA

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0

0.05

0.1

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0.2

0.25

0.3

0.35

0.4

0.45

Fluence (p/cm2)

Iin S

erv

(A)

Time (S)

Stop beam

PSI December 2005CAEN A3009 - Area A: input service current

A

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Fluence (p/cm2)

Co

mm

un

icat

ion

Time (S)

Unpluggedand recover



PSI December 2005CAEN A3009 - Area D: communication

D

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Fluence (p/cm2)

Co

mm

un

icat

ion

0 30 50 70 90 110 130 140 150 160 180 180 180 200

Time (S)

Reset and stop beam

Unplugged=> Reset

Start beamand Unplugged

Stop beamUnplugged and recover


PSI December 2005 CAEN A3009 - Area E: communication

E

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Fluence (p/cm2)

Vo

ut

(V)

Time (S)

DV=38.5mV

"Unplugged"Reset to recover communication

PSI December 2005CAEN A3050 - Area A: Ch. 1 Vout A

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10

Fluence (p/cm2)

Iin

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0

1

2

3

4

5

6

7

8

9

10

Time (S)


PSI December 2005CAEN A3050 - Area A: input power currentA

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0.05

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0.25

0.3

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0.4

Fluence (p/cm2)

Iin

ser

v (A

)

Time (S)


PSI December 2005CAEN A3050 - Area A: input service currentA

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Fluence (p/cm2)

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Time (S)

DV=63mV

PSI December 2005CAEN A3050 - Area B: Ch. 1 Vout B

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Fluence (p/cm2)

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PSI December 2005CAEN A3050 - Area B: input service current B

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Time (S)

PSI December 2005CAEN A3050 - Area B: input power current B

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Fluence (p/cm2)

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Time (S)

DV=58mV

PSI December 2005CAEN A3050 - Area C: Ch. 1 Vout C

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PSI December 2005CAEN A3050 - Area C: input power current C

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Fluence (p/cm2)

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Time (S)

PSI December 2005CAEN A3050 - Area C: input service current C

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UNV + Unplugged==>Reset Unplugged==>Reset



PSI December 2005CAEN A3050 - Area D: Ch.1 Vout

D

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2

4

6

8

10

12

Fluence (p/cm2)

Iin (A

)

Time (S)





PSI December 2005CAEN A3050 - Area D: input power current

D

57

10

Feb

. '0

6 -

cp

PH

-ESS

LV

PS

Pro

cure

men

t

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

0.45

0.5

Fluence (p/cm2)

Iin (A

)

Time (S)





PSI December 2005CAEN A3050 - Area D: input service current

D

58

10

Feb

. '0

6 -

cp

PH

-ESS

LV

PS

Pro

cure

men

t

0

0.5

1

1.5

2

2.5

Fluence (p/cm2)

Vou

t (V

)

Time (S)

Stop beamReset

Unplugged==>Reset Unplugged

Start beamUnplugged

Unplugged==>Reset

PSI December 2005CAEN A3050 - Area E: Ch.1 Vout

E

59

10

Feb

. '0

6 -

cp

PH

-ESS

LV

PS

Pro

cure

men

t

0

2

4

6

8

10

Fluence (p/cm2)

Iin (A

)

Time (S)

Stop beamReset


Start beamUnplugged

Unplugged==>Reset

PSI December 2005CAEN A3050 - Area E: input power current

E

60

10

Feb

. '0

6 -

cp

PH

-ESS

LV

PS

Pro

cure

men

t

0

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0.4

0.45

Fluence (p/cm2)

Iin (A

)

Time (S)

Stop beamReset


Start beamUnplugged

Unplugged==>Reset

PSI December 2005CAEN A3050 - Area E: input service current

E

Documents

Electronic Systems Support LHC LVPS Procurement - Status Reported by: Chris Parkman, PH-ESS February 10, 2006 Tests by: Bruno Allongue, Philippe Fontaine,