06/03/2002ivan hruska ep/ate1 lv brick for tilecal overview design summary results from 2nd...

06/03/2002 Ivan Hruska EP/ATE 1

LV brick for TILECALLV brick for TILECAL

OverviewOverview Design summary Results from 2nd radiation tests in PSI Villingen Bulk supply Plans for future



New brick design - LT sample extensionNew brick design - LT sample extension



U1LT1681

14 VCC

2 OVLO1 SHDN

55V

REF

6FS

ET

3TH

ERM

7SY

NC

8SS

4SG

ND

10VC

9VFB

15PGND

13SG

12IM

AX

11SE

NSE16

BG17

BLKS

ENSE

19TG

18BS

TREF20

VBST

D1

MURS160T3

U2

IR2110SMD1LO2COM

3VCC

6VS

7VB11 VDD12 HIN13 SD

8HO

14 LIN15 VSS

GND

C3

150pU3

1VDD12VIN+3VIN-4GND15 GND2

6 VOUT-7 VOUT+8 VDD2

R12k

GND

C4150p

R22k

R310k

GND

R4

10k

GNDGND

T1

IRFS9N60A2

1

3

AGND

AGND

R52kR62k

R710k

C5

150p U5

1VDD12VIN+3VIN-4GND15 GND2

6 VOUT-7 VOUT+8 VDD2

AGND

R8

10k

C6150p

GNDGND

GND

U7

LTC1698

1VD

D 2CG

3PG

ND4

GND

5 OPTODRV

6VC

OMP

7MARGIN8VFB9OVPIN10PWRGD11ISNSGND12ISNS

13ICOMP

14VA

UX

15 SYNC

16FG

U4A

LM6142

23

1

84

U4B

LM6142

65

7

84

R9

10k

R11

52k3

GNDGND

R10

10k

B1

BIMETAL

THERMAL CONTACT

12

C7

82p

GND

GND

C8

100N

C9

100N

GND GND

R13

0.03

3

GND

R14

3k

R15

10R C10

3n3

R16

1k

GND

GND

AGND

R17

22R R182k2

C12

100ND2

LL4148

C13

100n

R19

2k

R20

2k

R21

2k

R22

2k

R23

2k

R24

2k

AGND AGND

AGND

GND

C14

1M

L247uH

C15

1M

C16

1M

GND GND GND

GND

GND

R12

0.033

GND

GND

C17

68M2

1

L31mH4

GND

C18

100n

C19

100n

GNDGND

C20

100n

GND

R27

1k8

GND

R29

100

R30

100

C21

47n

R31

3R9

R32

3R9

R33

100

R34

100

GND

C22

47n

AGND C23

68M

AGND

T3IRF3710

21

3T4

IRF3710

21

3T5

IRF3710

21

3T6

IRF3710

21

3

AGND

C24

1n

C25

1n

R35

10R

R36

10R

AGND AGND

L4

2.35uH

C26

68M2

1 C27

68M2

1 C28

68M2

1 C29

68M2

1

AGND AGND AGND AGND

AGND

R43

R033

R50

6k8

R51

2k2

AGND

R52

10k

R53

1k5

AGND

R54

6k8

R55

2k2

GND

GND

GND

R56

100

R57

100C35

47n

C30

47n

R58

100

R59

100

R60

3R9

R61

3R9

INITIAL PAGE: OF:

COMPANY:

COUNTRY:27.3.2002

21.10.2002LV ISOLATED BRICK FOR TILECAL

1 1

4

CERNGENEVEGENEVESWITZERLAND

IVAN HRUSKA

CITY

PROJECT:REV: DATE: ENG:

ADDRESS:

U12

6N137

2

3

8765

R62

100

AGND

R63

1kC37

68M2

1

AGND

C38

100n

AGND

U13A

LM6142

23

1

84

U6B

LM6142

65

7

84

D13

8ETH

06S1

NC

2A

3C

D38E

TH06

S1NC

2A

3C

J1

HDR_4

1234

J3

HDR_6

123456

J2

HDR_15

123456789101112131415

J4HDR_

212

J5HDR_

212

R37

1kR38

1k

GND

C1 100n

C33

100n

C2

100n

C34

100n

C32

100n

T2

IRFS9N60A2

1

3C3

6

3n3

R40

3k

R41

10R R42

1k

R44

1k

R45

1k

GND

R46

1k

L5

1mH4

C39

220n

C40

220n

C41

150p

C42

150p

AGND AGND AGNDAGND

L6

2.35uH

D4LL41

48

D8

LL4148

D9

LL4148

D7LL4148

D5

MURS160T3

D6

MURS

160T

3

D10MURS160T3

D11 MURS160T3

U13B

LM6142

65

7

84

R67

2k

R68

2k

AGND

R69

10k

C43

1n

AGND

R70

1k5

R71

180

AGND

R72

100

R73

3k

L71mH4

D12

MURS160T3

D14

MURS

160T

3

C11

68M2

1C31

100n

C44

100n

C45

1n

R39

10R

C46

1n

R74

10R

C47

100n

GND

D15

P6KE

18

GND

D16

P6KE

18

D17

P6KE

18

AGND

D18

P6KE

18

AGND

R25

330k

R26

1k

J6

HDR_15

123456789101112131415

GND

U8

117

34

1

2U9

117

34

1

2

U10

117

34

1

2

GND

GND

R28

100

R47

220

PAYTON150

1

347

8911

12

13

14

16

19

T72N2222A

5VSEC

5VSEC

9VSEC

INCURMEASINCURGND

INCURMEAS

9VSEC

5VSEC

9VSEC

5VPRIM

VCCPRIM

OUTCURRMEASOUTCURRGNDOUTVOLTMEASOUTVOLTGND

OUTCURRMEAS

OUTCURRGND

OUTVOLTGND

OUTVOLTMEAS

INCURGND

SENSE_LOW

5VREF

TRIM

OUTPUT_GND

SENSE_HIGH

TRIM

5VREF

VCCPRIM

9VSEC

5VPRI5VPRI

VINVIN

VCCPRIMVCCPRIM

5VPRI

OUTPUT_GND

VCCPRIM

MAX 16 MA

MAX 0.6 MA

UNDE

RVOL

TAGE

OVER

VOLT

AGE

0.398 X UOUT



New design - based on New design - based on PSI results from June PSI results from June ‘02‘02

PCB design ready - 8 pieces produced

Still in debugging procedure - check of all possible effects

New custom made flat transformer

New rectifying MOSFET Efficiency 90% till 30A !



Experience from debuggingExperience from debugging Debugging of prototype

With first type of transformer & IRF MOSFET we reached only 75% of efficiency

Problems with EMI in surrounding of LT1681 original schematics changed to improve situationredesign of PCB needed-shielding/grounding

Tested water cooling via alumina bars works well

butwrong thermal contact for some components - co-

planarity of barssoldering of alumina bars to the semiconductors

High side driver power circuit addedadditional winding on transformer


LV brick for TILECAL LV brick for TILECAL

Power dissipation from MOSFET driversPower dissipation from MOSFET drivers need of external boost of secondary driver

25% overload for primary no-change

survived TID & SEE in PSI in the same conditionspossible to cool in final setup

New components exchanged & checkedNew components exchanged & checked New flat PCB transformer - custom made by Payton -

SMD New MOSFET from VISHAY - low Rdson < 3.5mohm



Temperatures of components measured Temperatures of components measured all ~ 30degC excluding

MOSFET drivers primary 55degCsecondary 50 degC

MOSFETs45degC when full power

Transformer - PAYTON75 degC

Some of hot chips can be cooled


LV brick for TILECALLV brick for TILECALEfficiency of TILECAL brick vs output current

PAYTON transformer & IRF3710 5V constant output

0102030405060708090100

0 5 10 15 20 25

Current [A]

Effic

ienc

y [%

]

Load characteristics of TILECAL brick with PAYTON transformer & rect. MOSFET SUM110

5V constant output

010

20304050

607080

90100

0 50 100 150 200

Input Power [W]

Effic

ienc

y [%

]

Efficiency measured with IRF -> 86 % (only to 20A - cooling problems)

with VISHAY SUM110 -> 90% - 30A (power components ~45 degC)



Not yet completely solvedNot yet completely solved High side driver power when low PW ratio - very low

output power Resonance of transformer in some regimes of

operation



Design of small cooling Design of small cooling systemsystem

Impossibility to test the brick only with air cooling

Used heatsink from ‘01 design Tank with water & pump - no

heat exchanger Need of additional & cheap

cooling systems for radiation tests in:

PSI TCC2



Radiation testsRadiation tests Planned test in PSI delayed by 3 months Not sufficient flux in PSI during Nov’02 Test performed 2.2.2003 - see special presentation

Lateral SEE Test of MOSFETs (comments to my TMB presentation )

SEE test of new rectifying MOSFET SEE Test of high side driver chip IR 2213 Optocoupler for synchronous rectifying New linear regulators ( LM117 - reduction of costs ~

40CHF/brick ) Crowbar ( transil ) Bipolar latches for remote control



Results and plansResults and plans We have verified and selected most

of components for the design To get missing information we are

preparing additional component test + NIEL test + board test

Design changes according to results from SEE,TID & electrical tests (EMI)

new PCB design should be very close to the

prototype



Remote controlRemote control Design of remote control

PCB based on 2001 design and new ideas how to use ELMB for power supply

ELMB is not reliable component in radiation - SEEs

Idea of “electronic shielding” by using bipolar latch verified

Good results from SEE test of latches

Discrete DAC for voltage trim


LV brick for TILECALLV brick for TILECAL Power & cable measurementsPower & cable measurements

Selected cable (USA15->UX15) ~ 2.20CHF/m Tests of real resistivity of whole circuit in preparation

complete connector & cable setup Bulk supplyBulk supply

Detailed specification prepared Because of changes of voltage drop -> sense wires or

negative resistance required Cooling and deployment preliminary solved

9 crates is possible to place to one 52U high rack Need of only ~2.5 rack for all 64 channels Cooling is sufficient



Example of rack with 9 crates of bulk power supply in USA15

3 boxes can have maximum power dissipation ~ 3kW

1.5kW dissipation from 3 crates

Power coming from top bus bars - 75A/ phase

Not yet solved power distribution inside racks

Consultations with Paul Maley & J. Inigo - Golfin

52U RACK

27 outputs/rack

total input power 45kW

Current 75A/phase

4U empty space

15kW section input/ 1.5kW power dissipation

Turbine & rack control 4U

3 x AC/DC 1700W output converter in 4U3 x AC/DC 1700W output converter in 4U3 x AC/DC 1700W output converter in 4U



Air deflector

Heat exchanger

Fan tray

Heat exchanger

Fan tray

Heat exchanger

Fan tray



ConclusionConclusion Design of new PCB

component placement electrical test radiation test

Additional radiation test of some components SEE test for MOSFETs & chipset statistics NIEL test

Cooling unit for radiation tests needed Ordering of prototype of bulk supply Test of cabling system ( USA15-> brick)

06/03/2002ivan hruska ep/ate1 lv brick for tilecal overview design summary results from 2nd...

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