Introduction%20(5')

1
Design review of LV power supply for
TILECAL Introduction

• Introduction (5')
• Power supply system overview (15')
• Technical requirements (30')
• DC-DC converter box (90')
• Bulk power supply cabling (45')
• Remote control auxiliary circuits (45')
• Conclusions

2
Design review of LV power supply for
TILECAL Introduction - General overview

• Where is TILECAL in ATLAS ?

3
Design review of LV power supply for
TILECAL Introduction - General overview

• TILECAL sub-detector of ATLAS
• 64 pieces of metallic structure mounted to the
  circular shape
• 2500 t of iron
• 2 extended barrels central barrel
• scintillator plates optical fibers
• electronics integrated inside calorimeter in UX15
• HV regulator for PMTs
• ADC and signal preprocessing
• Trigger calibration
• LV Power supply
• electronics in USA15
• HV supplies, LV bulk supplies, data
  concentrators, trigger, calibration, auxiliary
  circuits

4
Design review of LV power supply for
TILECAL Introduction - General overview

• Granularity TILECAL naming conventions
• Calorimeter
• 2 in central barrel one in each extended barrel
• 256 superdrawers / calorimeter
• Superdrawer
• 64 superdrawers per circle
• 2 drawers
• 3 m long in total
• Patch panel
• Finger
• Feeds magnetic field between central extended
  barrel
• Space for power supplies

5
Design review of LV power supply for
TILECAL Introduction - General overview

• TILECAL electronics - superdrawer sides
• HV side
• there are 45 PMTs in barrel superdrawer and 32 in
  extended barrel superdrawer
• One HV supply for superdrawer
• Each PMT has its own linear HV regulator
• possibility to set individual voltage
• Digitizer side
• ADC
• Data preprocessing
• Trigger
• Adder
• Calibration testing

6
Design review of LV power supply for
TILECAL Power supply - system overview

• LV Power supply
• powers superdrawer
• 8 output levels required
• Total output power 380W
• Environment
• radiation
• magnetic field
• water cooling
• placed in each finger of TILECAL
• includes remote control measurement
• Bulk 200VDC supply AUX circuits in USA15

7
Design review of LV power supply for
TILECAL Power supply - system overview

• Structure
• 8 DCDC converter bricks / Power supply box
• 64 Power supply boxes / one circle of TILECAL
• 2 circles on central barrel 2 extended barrel
  circles -gt 256 Power boxes/ TILECAL
• 4 Power boxes / Power Branch -gt 64 x 200VDC
  cables -gt 64 Bulk power supply outputs in USA15
• 2048 DCDC converter bricks / TILECAL
• Auxiliary circuits same structure
• CANbus
• 1 CAN branch / 16 Power Boxes
• 16 CAN branches / TILECAL
• 256 ELMB modules / TILECAL

8
Design review of LV power supply for
TILECAL DC/DC converter box - Design
considerations

• Possible solutions
• PS outside UX15
• D Big loses , thick cables, ripple, EMC, low
  efficiency, sense wires etc.
• A No radiation, no mag.field, any dimensions
• PS integrated inside TILECAL
• Commercial DCDC bricks
• D Radiation tolerance -gt High price
• A Compact design, high efficiency
• Commercial DCDC bricks Linear regulators
• D Radiation tolerance
• A Limitation of amount of bricks, lower
  efficiency
• Commercial DCDC bricks Switching regulators
• D Radiation tolerance
• A One/two brick only, medium efficiency
• Custom made radtol DCDC bricks
• D Time of development
• A High efficiency, complete fulfill of
  requirements including remote control

9
Design review of LV power supply for
TILECAL DC/DC converter box - History

• Short history
• First prototype - Summer 1999
• based on few VICOR DCDC some linear regulators
• problems with EMI , ripple
• Second prototype - Autumn 1999
• improved design
• ripple OK
• non radtol
• Third prototype - Spring 2001
• based on one VICOR or MDI brick 5 switching
  regulators
• possible only for common ground with merge of the
  same levels
• radtol design of switching regulators
• prototype running incl. remote control
• Forth prototype - Autumn 2001 till now

10
Design review of LV power supply for
TILECAL DC/DC converter box - Final design

• Design requirements
• 8 independent DCDC converter bricks
• one for each output
• galvanic isolation of output from input
• to avoid grounding problems
• radiation tolerant design by using COTS
  components
• measurement integrated on brick
• possible use in other applications
• minimization of ripple in design
• Goals
• Design of radtol DCDC converter brick with price
  lt 200
• Design of reliable remote control by using ELMB
• Integration of components to the finger area
  incl. cooling

11
Design review of LV power supply for
TILECAL Design of radiation tolerant DCDC
converter

• Topology selection
• isolated switching converter with transformer
• flyback converter
• single transistor forward converter
• dual transistor forward converter
• half bridge converter
• full bridge converter
• resonant converter
• reasons
• widely used type of converter also for radtol
  apps
• leakage inductance loses compensated by topology
• possible use of existing sample design and
  chipset
• possible use of sync rectifier to reach high
  efficiency of conversion

12
Design review of LV power supply for
TILECAL Design of radiation tolerant DCDC
converter

• LT sample design
• LT1681/LTC1689 chipset
• 90 efficiency
• max 72 V input voltage
• 3.3 5V / 60W designs available as
• a free sample
• Improvements needed
• gt150V or as high as possible input voltage
• minimize loses in cabling system
• adding measurement of all parameters as required
• radiation tolerant design
• design must use only SMD components for automated
  manufacturing
• water cooling

• ripple without load 15mVpp
• with full load ( 50W) 100mVpp ( no output
  filter ! )

13
Design review of LV power supply for
TILECAL Design of radiation tolerant DCDC
converter

• Selection of input voltage
• Radiation constraints Uin lt ½ Ubr
• Minimum input current cable losses
• Result 200VDC 1/3 of Ubr of standard MOSFETs
• Design decisions vs magnetic field
• Minimum amount of magnetically sensitive
  components
• Magnetic coupling only for power
• No magnetic components in mission critical points
• Feedback
• MOSFET driver
• Current sense
• Safety margin design topology to survive
  external fields
• No destruction when field above some margin

14
Design review of LV power supply for
TILECAL Design of radiation tolerant DCDC
converter

• Selection of basic components
• primary secondary MOSFET
• main pair of switches
• must be SEE free
• from other measurements comes the empirical rule
• if Uwork lt 0.5Ubr there is NO SEE !
• Possible anisotropy vs SEE
• converter chipset
• LT chipset is bipolar
• high probability of SEE free behavior
• but possible TID effects
• feedback circuit
• optical coupling of primary secondary to
  minimize mag. filed problems
• special optically coupled amplifier found from
  AGILENT
• OP-AMPs with known behavior in radiation

15
Design review of LV power supply for
TILECAL Design of radiation tolerant DCDC
converter

• First design of new brick March 2002

16
Design review of LV power supply for
TILECAL Design of radiation tolerant DCDC
converter Radiation tests

• Radiation tests
• PSI proton beam June 2002
• TCC2 area on SPS May/June 2002
• PSI 2 November 2002 -gt February 2003
• INT Portugal NIEL test March 2003
• PAGURE gamma TID test April 2003
• PSI 3 May 2003
• TCC2 area May/July 2003

17
Design review of LV power supply for
TILECAL Design of radiation tolerant DCDC
converter Radiation tests

• TCC2 area on SPS May/June 2002
• Optically isolated amplifier with HCPL7840
  LM6142

18
Design review of LV power supply for
TILECAL Design of radiation tolerant DCDC
converter Radiation tests

• PSI proton beam June 2002
• Component test
• Tested MOSFETS for SEE
• Primary side of DCDC
• IRFP460 TO247
• IRFP9N60 TO263 (SMD)
• Secondary side of DCDC
• IRF260 TO247
• IRF3710 TO263
• Module test
• Original LT converter based on LTC1698 LT1681
• Half bridge converter with IRFP460, IR2110
  UC3526
• Optically isolated amplifier with HCPL7840
  LM6142

19
Design review of LV power supply for
TILECAL Design of radiation tolerant DCDC
converter

• First prototype of brick SMD technology

Problems EMI induced spikes to feedback
circuit Ground loops unstable behavior
PCB Resistivity of PCB in secondary
part High-side driver power problems
20
Design review of LV power supply for
TILECAL Design of radiation tolerant DCDC
converter Radiation tests

• PSI 2 November 2002 -gt February 2003
• Lateral test of IRFS9N60
• Test of LM317 voltage regulator
• Test of TRANSILs - crowbar
• Test of optocoupler 6N137 sync pulse coupling
  to rectifier
• Test of IR2110/2113 low/high side driver of
  primary MOSFETs
• Test of SUM110N06-04L - Rectification MOSFET
• Test of octal latches LS373,F373 reliable ELMB
  outputs

21
Design review of LV power supply for
TILECAL Design of radiation tolerant DCDC
converter Radiation tests

• INT Portugal NIEL test March 2003
• Component test
• Complex design test

22
Design review of LV power supply for
TILECAL Design of radiation tolerant DCDC
converter Radiation tests

• PAGURE gamma TID test April 2003
• Test of complex design
• Feedback path
• MOSFET drivers
• Sync rectifier - optical coupling
• Voltage regulators references

23
Design review of LV power supply for
TILECAL Design of radiation tolerant DCDC
converter Radiation tests

• PSI 3 May 2003
• Retest of SEE effects on MOSFETs
• Few new types added
• New schematics of test setup

BUT!!! IRFS9N60 tested in June 2002 after 4
months of annealing are working again !!!!
Result NO SEE but TID effects on MOSFETs Most
resistant IRFSL11N50A for primary IRF3710S
for secondary
24
Design review of LV power supply for
TILECAL Design of radiation tolerant DCDC
converter Radiation tests

• TCC2 area May/July 2003
• Final design test
• In preparation
• Leakless cooling unit installed on place
• Remote measurement under developement

25
Design review of LV power supply for
TILECAL Design of radiation tolerant DCDC
converter Semifinal design

• Second prototype May 2003

26
Design review of LV power supply for
TILECAL Design of radiation tolerant DCDC
converter Semifinal design

• Simulations
• PSPICE
• Filters AC transient
• Sense amplifier feedback circuitry DC
• MOSFET driver circuit transient
• Whole converter - transient
• Electronic design
• Dual transistor forward converter in three
  versions
• 3.3V version 5V version with synchronous
  rectification
• 15V version with diode rectifier
• All versions have the same PCB
• Difference is transformer, few values of
  resistors, rectifier
• Output power same 150W
• Final design - differences
• Small mechanical-cooling improvements
• Adding of 2 additional screws
• Special tool for better soldering of alumina bars
  needed
• Simplification of optocoupler circuitry

27
Design review of LV power supply for
TILECAL Design of radiation tolerant DCDC
converter Grounding, EMC Safety

• Grounding
• Secondary part isolated no DC loops
• Primary part has common ground inside Power
  Branch
• Minimization of cable voltage drop differences
  for branch units
• Symmetrical analogue inputs/outputs for steering
• Ground resistors to minimize ground currents
• Isolated auxiliary supply for steering for each
  Power Branch
• EMC
• Electrical shielding in transformer
• No capacitive coupling of primary switcher
• Minimizes EMI to secondary part ripple
• Shielding planes on PCB
• Minimizes EMI on PCB for better functionality
• Bead inductors for each functional block

28
Design review of LV power supply for
TILECAL Design of radiation tolerant DCDC
converter Grounding, EMC Safety

• EMC (cont.)
• Snubber networks on both primary secondary side
• Ringing suppression
• Wideband decoupling
• Parallel combination of few types of capacitors
  with different capacitance to cover wide band
• Input filter
• Low Pass with cutoff 3 kHz
• Output filter
• Buck filter
• Computed for ripple lt 50mVpp
• Low Pass frequency
• Additional filter to cut off conversion
  frequencies spikes
• 8 bricks will be covered by ferromagnetic - metal
  box
• Magnetic shielding
• Minimization of irradiation
• Bead ferrite rings on each output cable bundle

29
Design review of LV power supply for
TILECAL Design of radiation tolerant DCDC
converter Grounding, EMC Safety

• Safety
• Isolation
• Isolation gap between primary secondary part
• 500V isolation voltage standard
• Trasformer isolation
• gt1kV
• Covering
• Metal cover should be connected with power cable
  shielding
• Interlock
• Interlock pins are in main Power box connector
• If disconnected -gt Bulk supply trips off
• Fuses
• On the box will be used standard melting fuses
• Crowbar protection
• All brick outputs are protected by TRANSILs

30
Design review of LV power supply for
TILECAL Design of radiation tolerant DCDC
converter Mechanics cooling

• Mechanics
• Will use improved design from 2001
• Simple cube no grooves for cooling tubes
• More space inside due to flat design of bricks
• Possible to install some radiation shielding
  inside
• Ideas made in collaboration with FME Prague
• 2 x U pieces made by bended iron
• Machined by robot
• Includes all lugs for mount of parts plug-in
• Only 6 screws to mount together
• No isolation washers
• more space on heatsink
• Whole box made by using 3 pieces
• U-frame holder for heatsink, connectors etc.
• Heatsink
• U-shaped cover
• Box mockup ready
• Box cabling test

31
Design review of LV power supply for
TILECAL Design of radiation tolerant DCDC
converter Mechanics cooling

• Cooling
• Water cooled aluminium heatsink
• Hot components coupled straight via alumina bars
• Fitting by O-rings
• Leakless connectors for water
• Small cooling system for lab
• Used for the electronic tests of prototypes
• No heat exchanger

32
Design review of LV power supply for
TILECAL Coffee break

• Coffee break

33
Design review of LV power supply for TILECAL Bulk
power supply cabling

• Basic document
• Power and cable estimations
• Parameters of bulk supply
• Parameters of power cables
• Bulk power supply
• Technical specification
• Prototype in development
• Ready end of September 2003

34
Design review of LV power supply for TILECAL Bulk
power supply cabling

• Cabling
• 256 Power boxes / TILECAL
• 3 independent cable structures
• Power distribution
• Auxiliary cabling
• CANbus cabling

35
Design review of LV power supply for TILECAL Bulk
power supply cabling

• Cabling inside finger

36
Design review of LV power supply for TILECAL Bulk
power supply cabling

• Power distribution
• Power from 3phase line 3 x 240VAC
• Bulk supply generates 3 x 200VDC output
• One output goes over 150m of cable to UX15
• On the TILECAL barrel is distribution box
• Distribution box splits power to 4 finger Power
  boxes distance 10m each

37
Design review of LV power supply for TILECALBulk
power supply cabling

• Power cable
• Cable selected
• Small market survey done

38
Design review of LV power supply for TILECALBulk
power supply cabling

• Auxiliary cabling
• Same structure as for power cabling
• Cable not yet selected

39
Design review of LV power supply for TILECALBulk
power supply cabling

• CANbus cabling
• Different structure
• 16 nodes in branch
• Daisy chained
• Standard ATLAS CAN cable

40
Design review of LV power supply for TILECALBulk
power supply cabling

• Block schematics of cabling
• Description of blocks
• Visibility of potential ground loops