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FGT Safety Review – 9/2/2009 BNL G. Visser
STAR Forward GEM Tracker Safety Review
Electrical
1
Gerard VisserIndiana University Cyclotron Facility
John T. AndersonArgonne National Laboratory
Benjamin BuckMassachusetts Institute of Technology
9/2/2009
FGT Safety Review – 9/2/2009 BNL G. Visser 2
Topics
• FGT electrical overview• GEM bias connections• Front end electronics• Cable plant• Readout crate, power supplies and modules• Other FGT electrical equipment• WSC field shaping bias connections
FGT Safety Review – 9/2/2009 BNL G. Visser 3
Overview I: Readout system integration schematic (simplified)
ethernet trig/clkDDL fiber
Wiener MPOD controller (1x)
ISEG 8 ch HV module (3x)
ARM (12x) (APV Readout Module) [IUCF]
ARC (2x) (APV Readout Controller) [ANL]
208 V 1 φ
Wiener crate (1x) (FGT custom) 6U x 220mm cards
8
2+2
FGT Cables24 FEE signal24 power & remote sense24 HV coax
Cable break connectors/boxes located just outside of west support cylinder, on TPC wheel. This point also serves as FGT detector ground tie (to TPC wheel).
Internal FEE signal cables: custom low-mass aluminum design with silicone & FEP extruded insulation
Estimated cable run 65 feet[ WSC → TPC sec 2/3 boundary → sec 2/3 tray out of magnet → 2nd level platform ceiling tray → 2C7/8/9 ]
SGIS (to kill all FGT power)
FGT Safety Review – 9/2/2009 BNL G. Visser 4
Overview II: GEM quadrant assembly and electrical connections
Bias divider boardFR-4, 20 x 275 x 0.8 mm
“Connector” boardFR-4, 65 x 45 x 0.8 mm
FEE board (2x)FR-4, 259 x 53 x 1.6 mm
Terminator boardFR-4, 32 x 38 x 0.8 mm
Anode strip board and ground plane
STA
R T
PC
alu
min
um s
truct
ural
par
ts(S
TAR
sys
tem
gro
und)
GEM bias patchSHV cable connectors
LV & signal patchBud #PN-1320-C64 x 58 x 35 mmPolycarbonate, UL 94HB
Ground wire18AWG stranded
FGT
cabl
es to
pla
tform
1
2
3 4
2
see detailed cable info on slide 7
Total power 6.9 W per quadrant (ref. slide 5, 6)
FGT Safety Review – 9/2/2009 BNL G. Visser 5
5kV type, SOA # S3838CVX104K30 or equivalent
cathode
GEM #1
GEM #2
GEM #3
anode strips
GEM bias system
iseg Spezialelektronik GmbH# EHS8060n
-6 kV [hardware limit (pot) shall be set at -5 kV]1 mA hardware current limit
20 mA current loop permit input
connectors: SHVgrounded (non-floating) output
(to break ground loop for noise/performance reasons)
6 kV typeSyfer # 1812Y6K00221MXT
platform
TPC west
Divider string power: 2.4 W maximum
Ohmite # OA101KE or # OX101KE
FGT Safety Review – 9/2/2009 BNL G. Visser 6
Front end electronics
FEE board (prototype)
Connector board prototype
APV chip w/ encapsulantSignal inputs
Connector is for prototype only;direct solder to cable for real board
Clock/trg buffers
Voltage regulators1.8 V to 1.25 V (2x)2 A max
Power: 1.5 W
Input supply: 0.45 A @ +1.25 V, 0.78 A @ -1.25 V
Materials: FR-4, copper, nickel/gold plating, SnPb solder, silicon, encapsulant (epoxy, silica, flame retardant)
Power (local): 1.5 W
Input supply: 0.94 A @ +1.8 V, 1.60 A @ -1.8 V, fused at source end of cable (ref. slide 8)
Remote sense on input supply; all terminals here fused with Raychem # nanoSMDC020F (0.42 A trip @ 25 °C, 24 VDC 100 A interrupt rating)
Output feed: 0.90 A @ +1.25 V, 1.56 A @ -1.25 V
Materials: FR-4, polyimide (cable clamp pieces), copper, nickel/gold plating, soldermask, SnPb solder, silicon, package molding compounds (epoxy, silica, flame retardant), stainless steel screws
FGT Safety Review – 9/2/2009 BNL G. Visser 7
Cable plant details
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2
3
4
Inner service combined signal/power cable 24x 6 feetManufacturer: Calmont Wire & Cable Co.P/N: tbd, custom designConstruction: 12pr 30AWG CCAW* / FEP, 10c 20AWG CCAW / silicone, overall Al foil shield, silicone jacketRatings: None, but constructed equivalent to UL 150V, NEC type CL2 or superior ( → pass UL-1581 vertical tray)Connector #1: NoneConnector #2: DB37, AMP # 5-747916-2 (rated 3 A, 1000 VAC withstanding; service here ≤ 1.6 A, 5 V)
GEM bias HV cable (for inner service and external) 24x 71 feetManufacturer: NK NetworksP/N: ?? – Cable is marked “NK NETWORKS 9943 C-50-2-1 MODIFIZIERT FRNC-B - DESY 16995 MT”Construction: ??Ratings: Details unknown but the cable is approved by and procured through DESY; said to be made to CERN & DESY specificationsConnector #1: SHV, Huber and Suhner # 11-SHV-50-2-5 / NE 133 (similar to RG-59 type except for cable diameters)Connector #2: same, except inner cable only one connector (soldered at detector)
External service signal cable 24x 65 feetManufacturer: BeldenP/N: 1424AConstruction: 12pr 24AWG Cu / foam PE, overall Al foil shield, PVC jacketRatings: UL style 2919 (30 V 80 °C); NEC type CMConnector #1: DB25, AMP # 5-747913-2 (rated 3 A, 1000 VAC withstanding; service here ≤ 0.1A, 5 V)Connector #2: same
External service power/sense cable 24x 65 feetManufacturer: BeldenP/N: 5307FE (selection is not final, may substitute a similar cable)Construction: 9c 18AWG Cu / PP (or PVC substitute), overall Al foil shield, PVC jacketRatings: UL 300 V 75 °C, 3.5 A per conductor; NEC type CMRConnector #1: Amphenol # 97-3101A-18-1S (rated 200 VAC, 13 A (test); service here ≤ 1.6 A, 5 V)Connector #2: Weidmüller # BCZ 3.81/09/90F SN BK BX or similar (UL rated 300 V 10 A; service here ≤ 1.6 A, 5 V)
*Note: CCAW = copper-clad aluminum wire (typically used for magnet wire in aerospace equipment). 10% copper cladding by volume. Termination will be by soldering (SnPb).
FGT Safety Review – 9/2/2009 BNL G. Visser 8
cPCI
Readout (and power) crate
Customized version of Wiener #6023 6U crate (which is used extensively at STAR)
Card depth 220mm (vs. VME standard 160mm)
Divided into 3 segments of 7 slots each:• MPOD controller and ISEG HV modules (3, double-width)• Two segments of 7 slots for readout boards,
interconnected with CPCI backplane; each slot has 13 power pins (+5) rated at 0.8 A each
Rear connection of cables to FEE, via transition modules
Internal power supplies:• 24 V 23 A (for HV modules); actual load ≤ 10.5 A• 2x 5 V 115 A (for readout boards); actual load ≈ 46 A
each
Dimensions: width 429 mm, height 172 mm, depth 215 mmWeight: 17.6 kg Rated mains input range: 100- 240VAC ± 10% (90...265VAC)Rated input current: Sinusoidal 16AInrush current: limited to rated input current (cold unit)Input fuse: external, intern on special requestIsolation (input – output) CE / EN 60950, ISO 380, VDE 0805, UL 1950, C22.2.950DC output power: 3kW maxOperation temperature: 0… 50°C ambient without deratingEfficiency: 75% ... 85% (depending on module type)
In this configuration, input current 10.9A @ 208V at maximum load. Actual for expected load (ref. next slide) 4.6 A @ 208V.
FGT Safety Review – 9/2/2009 BNL G. Visser 9
Readout modules
ARC module (APV Readout Controller)Power: 20 W
Input supply: 4.0 A @ +5.0 V, fused @ 6.3 A, Littelfuse 451 series*
Materials: FR-4, copper, nickel/gold plating, aluminum, package molding compounds, SnPb solder, ceramics
Power (local): 24 W
Input supply: 7.0 A @ +5.0 V (35 W), fused @ 10 A, Littelfuse 451 series*
Output feed (2x): 0.94 A @ 1.92 V, 1.60 A @ 2.41 V (5.64 W), remote regulated at +1.8 V, -1.8 V, ground isolated
Output fusing: On rear transition board at cable connectors. Littelfuse 451 series, on each line.
Materials: FR-4, copper, nickel/gold plating, aluminum, package molding compounds, SnPb solder, ferrites, ceramics
SIU
P1
P1
P2
34
(ref. slide 4,7)
DAQ fiber
trigger
ARM (APV Readout Module)
cPCI
*Note: 300 A 32 VDC interrupt rating
FGT Safety Review – 9/2/2009 BNL G. Visser 10
Other electrical equipment
• Two small blowers to be mounted on west end ring of the STAR magnet, Orion Industries # OAB800AN-11-1B or similar• Shaded-pole 125 VAC motor, 18 W, will be fused and grounded of course• probably a flow or pressure sensor to be read out by slow controls (is not an
interlock)
• Gas system• Anticipate a few temperature and pressure sensors to be read out by RS-232
or 20 mA loop, wired with appropriate cable, e.g. 2C 20AWG CMG• Readout device in FGT electronics rack, connected to ethernet
• ethernet switch mounted in FGT rack or nearby
• optical fiber patch box (MIC box) in FGT rack for connection to DAQ room, all fibers NEC type OFNR
• STAR trigger/clock signal cable to TCD rack (1A1) – Belden # 8166, NEC type CM
• laptop computer in FGT rack for local operation of FGT controls
• DAQ computer (1) rackmounted in DAQ room
• WSC field-shaping bias system (detailed on next slide)
FGT Safety Review – 9/2/2009 BNL G. Visser 11
“Protection: Automatic current regulation protects the power supply against all overload conditions, including arcs and short circuits. Fuses, surge limiting resistors, and low energy components provide the ultimate protection.
Remote Controls: Common, +10 volt reference, interlock, current monitor, current program, voltage monitor, voltage program, HV enable/disable, and ground provided on a rear panel terminal block.
External Interlock: Open off, close on.”
Glassman EH10N10, -10 kV w/ current limit
WSC field-shaping bias system
Becomes a new permit to TPC cathode
Fixed operating point tbd, expect approximately -5.5 kV
Reynolds HV cable with series 531 connectors. Rated 10 kV operation, 100% tested to 15 kV, commercially assembled. Length approximately 50 feet, tbd.
Mating connector (Reynolds series 531) is an integral bonded part of WSC – TPC mechanical interface structure. Bias voltage runs in from there to shroud electrode on 20kV silicone high voltage wire.