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

1818

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

2222

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

2525

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

2626

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