TF Joint Voltage Drop Instrumentation Robert Marsala (609) 243-2507 Hans Schneider (609) 243-2017...

TF Joint Voltage DropInstrumentation

Robert Marsala (609) 243-2507Hans Schneider(609) 243-2017

Engineering OperationsAugust 7, 2003TF_JOINT_Final_Design_Review.ppt

Bob Marsala, Hans SchneiderEngineering Operations

2

Voltage Drop Measurement Plan

• Instrumentation Must be Capable of the Following– Maintenance Testing

• Inject up to +/-220A into TF Coil and Measure the Voltage Drop at Every Joint

– Operational Testing• Measure the Voltage Drop at Every TF Joint During an Actual Shot

at Up to 72KA

– Common• Computation or Resistance, Trending, Alarms, Warnings


3

System Block Diagram

EPICSR=V/I (at 72kA or 200A)

Agilent 6671A220A @ 8V

1N4047275A200V

PolaritySwitching

Relay

Transorbs450J 50kA

340V200A

1 Ohm275W

Shunt40mV

@ 200A

CAMACCRATE

96Channels

ADC

#24AWG Two Twisted PairTeflon (1500V Between Conductors)Tefzel Outer Insulation(Spark Test to 10kV)

Voltage Dropx 72

Strainx TBD

Instrumentation Rack

Manual Control

Gain 72kA or 200A

Two Twisted Pair Per Flag

Shunt Voltage

TF Power SupplyHalmar Current

DisconnectSwitch


4

TF Joint Voltage Measurement Components

• 2 Voltage Probes on Each TF Joint

• Cables from all Probes (144) to Racks

• Instrumentation Consisting of– Quick Disconnect Panel– Isolated Programmable Gain Amplifier– CAMAC Transient Digitizer

• 200 A Source Hardware and Switch


5

TF Flag Joint Voltage Probes

Two Probes per Joint 144 Potential Data Points

Two Coax ProbesTo Measure

Voltage Drop


6

Probe Detail

Probe Terminated in a SMB Connector

Near Flag


7

Cable

• Janor Wire & Cable Corp• 2 Twisted Pairs per Cable with Overall Jacket

– One TP for Each of the Two Probes on a Joint

• #24 Conductors• ETFE Insulation• 10KV Isolation from Conductor to Outer Jacket• Terminations

– Flag End: SMB Mating Cable Spliced to Cable– Rack End: 4 Pin Locking Tripeg Molex Connector


8

Instrumentation

• Located in Two Racks on Midplane Level• Consists of

– Mother Boards (6)

– Quick Disconnect (12)

– Programmable Gain Isolation Amplifier (72)

– CAMAC Crate with Transient Digitizers

– Power Supplies

– 200A Source and Control


9

Quick Disconnect Modules

• Channels Can be Quickly Disconnected from the Amplifiers

• 6 Channels (12 Probes) Serviced by each of 12 Disconnects

• Uses Properly Spaced Banana Jacks on Mother Board and Banana Plugs on Disconnect Module


10

Quick Disconnect

BananaPlugs

MotherBoard

DisconnectBoard

BananaJacks


11

Programmable Gain Isolation Amplifier

• Amplifies and Isolates Voltage Across Joint• 12 Boards per Mother Board, 6 Mother Boards = 72 Boards• 5000V Isolation between Input and Output• Two Gain Stages (Each having a Gain of 1, 10, 100 or 1k)

followed by Unity Gain Isolation Amplifier • Overall Gain from 1 to 1 Million Controlled by Two Rotary

Switches on Control Panel– Nominal Gain: 100 for 72kA, 10,000 or 100,000 for 200A

• Board Designed to Measure Voltages from Both Probes of a Joint, but only Parts for One Probe are Installed (Cost)


12

Summary• 2 Voltage Probes on Each TF Joint

• Cables from all Probes (144) to Instrumentation Racks

• Quick Disconnects Provided to Open Probe to Amplifier Connections

• Capable of 72kA Operation or 200A Maintenance Operation

• One Probe from Each Joint is Monitored

• Isolation to 5000V

• CAMAC Data Acquisition

• EPICS Used for Calculations, Trending, Alarms and Warnings


13

Resistance Measurement System Benefits

• All 72 Joints Monitored at 200A and 72kA– Manual 200A & Automated 72kA Measurements

• Expandable & Upgradeable– Measure All 144 Probes & Automate 200A Measurements

• CAMAC Digitizer Upgraded to PCI Digitizer

– Addition of Strain Measurements• Design Signal Conditioning/Amp/Iso Board

• Least Cost (M&S) and Effort (Manweeks) System– Combo Amp/Iso Board Designed and Being Tested

– CAMAC Crate and 908 Digitizers Available


14

Mother Board• Each Mother Board Services 12 Joints (24 Probes)• 6 Mother Boards Mounted in Rack

– 3 Accessible from Front of Rack and 3 from Rear– Expansion to 8 Mother Boards is Provided (Strain or

Displacement)

• Only One Probe from a Joint is Actively Monitored– Capable of Expansion to Actively Monitor Both Probes

• Active Probe can be Selected by Plugging Cable Connector into a Second Connector on the Mother Board


15

Mother BoardSamtec SSW-120-01-G-D)mate TSS-120-04-G-D-RA

1

1.062

1.062

.531

1.250

2.000

2.000

70555-0073mate: 50-57-9404Molexref Pg 505/6Mouser 613

Amp 1-380999-0 mate: 1-480270-0

1.250

1.250

1.250

1.250

1.250

2.250 17.000

1.250

1.250

1.250

1.250

1.250

5.000

0.328 diameter

Samtec SSW-105-01-G-mate: TSS-105-04-G-D-RA

16.000

1

D9S


16

Iso-Amplifier Schematic

+15V2

U4BUF634/SO

3 6

7

4 1

-15V1

+24V

U2PGA204/SO

4

5

11

12

15

16

13

8

10

1

9

6 7

14

VIN-

VIN+

VO

SENSE

A0

A1

+VCC

-VCC

REF

VO1

VO2

VOSADJ

VOSADJ

Dig Gnd

J3

JUMPER

1

2

TP7

1

need 5ma

TP1

1

R12250k

Ret 2

R7249

+24V Return

+15V1

U1A0

+

C22

1uF@25V

Offset

+

C2322uF@35V

X1 Isolation AmpTP3

1

C90.01

R162k

C30.01

C160.01

U1PGA204/SO

4

5

11

12

1516

13

8

10

1

9

6 7

14

VIN-

VIN+

VO

SENSE

A0A1

+VCC

-VCC

REF

VO1

VO2

VOSADJ

VOSADJ

Dig Gnd

R8

10k

-15V2

R1510k

R1110k

U5T2-2D2415EH

15

1011

13

12

2324

+Vout

Out ComOut Com

-Vout

+Vin+Vin

-Vin-Vin

TP4

1+

C151uF@25V

U2A1

-15V1

+V1/-V1 Com

R5250k

5KV IsolationBarrier

C110.01

C100.01

J4

JUMPER

1

2 Dc/DC Conv

C10.001

U1A1

C50.01

+

C7

1uF@25V

U6

OPI1264C

2

1

4

3

U3ISO121BG

39

4020

38

19

18

2

1

22

21

3 23

4 24

37

17

VIN

GND2GND1

EXTOSC

SENSE

VOUT

C1-

C1+

C2-

C2+

+VS1

+VS2

-VS1

-VS2

COM1

COM2

R9

10k

J1

HEADER 5X2

246810

13579

+V2/-V2 Com

U8

OPI1264C

2

1

4

3

C60.01

C170.01

J6

JUMPER

1

2

U7

OPI1264C

2

1

4

3

R31M

+15V2

+C4

1uF@25V

R1010k

+V1/-V1 Com

+ C1922uF@35V

-15V2

X1,10,100,1000Amplifier

C140.01

U9

OPI1264C

2

1

4

3

C12.001

C210.01

R6

249

TP6

1

J5

JUMPER

1

2

R1

10k 1% 10,00VDC 5W (M750)

R13

10k

U2A0

-15V1

C80.01

R1410k

X1 Buffer

+ C2422uF@35V

C20.001

Input 2+

R41M

C20.0022

Input 2-

J2

HEADER 20X2

246810121416182022242628303234363840

13579111315171921232527293133353739

+15V1

Input 2-

R1751

Input 2+

R210k 1% 10,00VDC 5W (M750)

Out 2

+V2/-V2 Com

TP2

1

TP5

1

+C18

1uF@25V

+C13

1uF@25V

800 Hz Filter


17

CAMAC Crate

• CAMAC Crate with 3-908 Transient Digitizers Used to Store Voltage and Current Data

• EPICS Used to Calculate Resistance and for Trending/Status/Alarms

• Memory/Sample Rate TBD


18

Programmable Gain IsolationAmplifier Layout

Input Connector

Input Resistors

PG Amps

Isolation AmpBuffer

Opto Couplers

DC/DC Conv

Output and Control Connector

5000

V B

arri

er


19

Power Supplies

• All Programmable Gain Isolation Amplifiers Powered by +/- 15V Linear Supplies (2) for Ground Referenced Output and +24V Linear Supplies (2) for DC/DC Converters


20

200A Supply and Control

• Supply– Agilent 6671A– 220A @ 8V

• Control and Protection– Current Programmed via Pot on Control Panel– Polarity Switching Relays Controlled from Control Panel– Interlock to Prevent Switching of Polarity while Current

is Flowing in TF Coil– Protection Incase of Open Circuit

• Interlocked Switch to Apply 200A to TF Bus

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TF Joint Voltage Drop Instrumentation Robert Marsala (609) 243-2507 Hans Schneider (609) 243-2017...

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