TileCal Power Supply System Maintenance LVPS & HVS1
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1 TileCal Power Supply System Maintenance LVPS & HVS1 B. Palan / FZU Prague Tue 11 Dec 2007 LVPS Meeting
2 LVPS & HVS1 Maintenance Continuous technical & engineering support and service to maintain all TileCal power supply systems (LVPS & HVS1) 100% functional for physics experiments during 10 years of operation. USA15 control room Access any time Safe but supervised area High Voltage System for PMTs 16 TESLA HVS1 (16x16= 256 of 830VDC channels) Low Voltage PS 24 TESLA HPS1 (3 x 200VDC PS) (64 channels, 6 x HPS1 per partition) 64 AUX Boards control card (1x per 4 LVBOXes, 16 per partition) 4 DSS - LVPS Interlock board (1 per partition) ATLAS PIT cavern Radiation, magnetic field Very Limited access 1-2 times/year 8 200V and AUX Star Boxes 256 LVBOXes 11 Dec 2007 B.Palan 2
3 HVS1 Maintenance (1) TESLA HVS1 16ch -830V/-950VDC PS for photomultipliers Motherboard chassis for 8 cards (16 channels) 2ch HV card One HVS1 unit is supplying 16 drawers. Remote control by MODBUS protocol (RS422), in Scada/PVSS. Interlocked by DSS-LVPS Interlock card, switched ON when LVPS ON. Used only during cosmic tests in Dec 2007 B.Palan 3
4 HVS1 Maintenance (2) Qty: 16x HVS1 chassis, 128x 2ch HV cards installed in USA15 Spares: 2 chassis (one in 512, one Prague), 8 x 2ch HV cards (6%) Produced by TESLA-CZ in 2001/02. No more support from them. Tested with 16 HV dummy-loads in Prague during Possible maintenance support from FZU/Prague. Testing/Burnin place with 16 HV dummy-loads in Prague. Found problems during operation: -Chassis 3 broken PS protection fuses 1.5A/250V -2ch HV card 4 broken output HV fuses 100mA/1000V 8 damaged TRACO DC/DC 1W converters Critical components are TRACO converters - datasheet isolation I/O 3kV - problems/damages in 1kV Possible improvements for easier maintenance: -add pcb fuses on each 2ch HV card -only one 2ch card OFF when problem, not all 16ch. 11 Dec 2007 B.Palan 4
5 HPS1 Maintenance (1) TESLA HPS1 200VDC PS for LVPS boxes 3ch x 200VDC /7.5A/1.7kW Remote control by MODBUS protocol (RS422) in PVSS. One 200V channel supplies four LVBOXes. Only few units tested with 3 dummy-loads in Prague in Interlocked by DSS-LVPS Interlock card, switched ON to start LVPS boxes. Some units extensively used in 2006, Dec 2007 B.Palan 5
6 HPS1 Maintenance (2) Qty: 24x HPS1, 72 x 200VDC channels installed in USA15 Spares: 2ch per partition of 64 drawers (12.5%), no other units avail. Produced by TESLA-CZ in Time limited support from them. Only few units tested with 3 dummy-loads in Prague during Proposed maintenance support from FZU/Prague. Testing place with 3 dummy-loads in Prague and at CERN. Found problems during operation: -Control SW caused by HW, reprogrammed all new ATMEL firmware -Hardware min 10 Vout channel cards broken in 2006 min 10 broken power diodes in DC/DC conv (new D) min 6 broken output fuses 20A/500V -Noise/interference found 17MHz conducted current noise, ferrites + LC filter (not yet solved) Need close supervision, especially after power cut. 11 Dec 2007 B.Palan 6
7 AUX Board Maintenance (1) Custom made auxiliary power and control board for 4 LVBOxes V2.4 with modified ELMB FirmWare It supplies 4LVBOXes with Startup pulse, ELMB chip Power, ELMB_MB inside LVBOX CanBus communication with SW Control in SCADA/PVSS. Interlocked by DSS-LVPS Interlock card, switches ON LVPS. Extensively used during commissioning tests in 2006/ Dec 2007 B.Palan 7
8 AUX Board Maintenance (2) Qty: 64x units, 256 channels installed in USA15 Spares: 20 AUX Boards v2.4 (31%) Custom design produced in Each installed board qualified on AUX_Board tester at CERN. Found problems during operation: 6 AUX boards returned from PIT various reasons, Startup power DC/DC converters, Transformers channel fuses, channel output transils etc. 6 transformers, 2 overheated themselves (Clairtronic) Need close supervision and maintenance, specially after power cut. 11 Dec 2007 B.Palan 8
9 DSS-LVPS Interlock Board Maintenance Custom made interlock and control board for 64 LVBOXes One card is interlocking/enabling - 64x LVBOXes - 16x Aux Boards - 6x HPS1 200V PSs - 4x HVS1 800V PSs DSS signal from cooling system ON/OFF LVPS Qty: 4x units, each for 64 drawers installed in USA15 Spares: 1 unit (25%) Custom design produced in No special tester made. Basic and simple electronics. Found problems during operation: No major problems. No special attention but supervision after electricity power cut. 11 Dec 2007 B.Palan 9
10 200V and AUX Star Boxes Maintenance Custom made distribution boxes of 200V and AUX signals around calorimeter One card is interlocking/enabling - 4pcs on main barrel - 4pcs on extended barrels Passive interconnections only. But limited access, and irradiated. No required maintenance, only passive interconnections between LVBOxes and USA15 Instruments (HPS1, AUX Boards). Functionality verified during commissioning. May show problems towards the end of maintenance (aging of screwed pins, contact resistance) 11 Dec 2007 B.Palan 10
11 LVBOX Maintenance (1) Custom made DC/DC power supply for TileCal drawers Inside 8 Bricks, DC/DC modules, 1 x 3.3V, 3 x 15V, 4 x 5V (2048pcs) ELMB Motherboard canbus remote control 4 boxes creates one power branch supplied by one 200V channel supply, and one AUX board. Radiation tolerant up to 20krad TID, 2.15E+12 n/cm^2 neutron fluency, Able to work up to 200gauss mag.field. v final modifications, 300kHz SW Freq., OVP on each brick, OCP, startup sequence in 3 groups, HV or DIG side safe shdn, ELMB power cycle non-influence. ELMB_MB v6.5.3 five V levels sense line measurements improved 11 Dec 2007 B.Palan 11
12 LVBOX Maintenance (2) Qty: 256 (v6.5.4) installed in the ATLAS PIT, limited access Spares: 44 boxes (17%) Custom produced at CERN in All production testers, QA long term qualification at b512. Bricks - pinfield tester, burnin tester ELMB_MB tester LVBOXes QA station Each qualified box has run during min 3 hours. Found problems during operation: -34 returned boxes (January November 2007) stopped working - Bad assembly, modification, failed components -27 redo calibration Limited access (1-2 per year), operative change of failed boxes, Special attention (radioactive) during repair. 11 Dec 2007 B.Palan 12
13 LVPS & HPS1 Maintenance Center Proposed Bld175 (also as TileCal drawer repair center) Move equipment from 512 -> 175 after production (Feb-April 08) Install all required testers Brick - Pinfield tester, Burnin station ELMB_MB - tester AUX Board - tester LVBOX - QA station with 3 dummy loads and 2 drawers Bring together all applied necessary crimping tools, screws, spare active/passive electronic components, spare cables, etc. Be able to repair any LVPS/HVS1 components Brick, ELMB_MB, Fuse_board, AUX board, HPS1, HVS1.. What about CanBus power supplies maintenance? 11 Dec 2007 B.Palan 13
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