[]{#__RefHeading___Toc176166606 .anchor}DØ SMT

[]{#__RefHeading___Toc176166607 .anchor}HDI Recovery System

RunIIb Silicon Group

**September 10, 2007**

**Addendum to April 4, 2006 document**

System Contact

Linda Bagby

DAB X3100

bagby@fnal.gov

DØ SMT [1](#__RefHeading___Toc176166606)

HDI Recovery System [1](#__RefHeading___Toc176166607)

Introduction [3](#introduction)

Low Voltage Power Supply System [4](#low-voltage-power-supply-system)

Power Distribution [4](#power-distribution)

Filter Network [6](#filter-network)

Equipment Location [6](#__RefHeading___Toc176166612)

Movable Counting House [6](#movable-counting-house)

Cathedral Area [7](#cathedral-area)

Central Calorimeter Cryostat Face
[7](#central-calorimeter-cryostat-face)

Equipment Specifications [8](#equipment-specifications)

Wiener Power Supply [8](#wiener-power-supply)

Interlock Chassis [8](#__RefHeading___Toc176166618)

Safety System [10](#__RefHeading___Toc176166619)

Movable Counting House Rack Safety
[10](#movable-counting-house-rack-safety)

Low Voltage Power Supply System [11](#low-voltage-power-supply-system-1)

Adapter Card [11](#adapter-card)

#  

# Introduction

The DØ HDI Recovery system is a system designed to recover portions of
the SMT detector that are not currently operating as expected. Readout
problems with the SVX2 readout chip have been an ongoing challenge for
some time. In August, 2006, approximately 50 HDIs were lost due to high
DVDD currents. We believe that wire bonds providing DVDD to the SVX2
readout chip are broken. The recovery system, mainly consisting of a new
active Adapter Card and power supply, will provide a voltage level boost
to control lines responsible for the correct readout of a SVX2 chip
facilitating recovery of the data from remaining SVX2 chips with
unbroken power bonds on the HDI in question. We seek operational
readiness clearance for unattended operation of the SMT HDI Recovery
system.

# Low Voltage Power Supply System 

The SMT HDI Recovery system is composed of a commercial Wiener power
supply, an external filter network, an Interlock chassis, and a fuse
panel. The purpose of the system is to provide power to the newly
designed active Adapter Card.

## Power Distribution

The Wiener PL508 unit is specifically designed to provide power over
long distances. In order to facilitate easy access, the power supply and
interlock chassis are located in the movable counting house. The fuse
panels and filter networks are mounted in the Cathedral area of the D0
collision hall. The Power Distribution cards and Adapter cards are
mounted on the face of the calorimeter central cryostat. Figure 1 shows
the system block diagram.

Figure 1: SMT HDI recovery System

![](media/image1.wmf){width="5.684027777777778in"
height="4.315277777777778in"}

Four modules provide power to each quadrant consisting of up to 30
Adapter Cards. Each Adapter Card requires a maximum of 300mA of current
for a total of 9A per power supply module. 150 feet of 4 AWG Powerflex
cable is used from the power supply to the fuse panel to minimize the
voltage drop. 4 AWG (85A) cable is capable of handling the 30A maximum
current available from the supply. In case of catastrophic failure, 60A
in-line fuses are installed on the positive side of each power supply
module as shown in Figure 2.

Figure 2: In-line 60 Amp Wiener module fuses.

![](media/image2.jpeg){width="3.928472222222222in"
height="2.946527777777778in"}

The 4 AWG cable is terminated at the in-line fuse site with a Thomas and
Betts Gray square terminal (gray) with a crimp die suitable for 6 AWG
cable. This die was used to provide higher crimp pressure due to the
high strand count of the Powerflex cable. Thomas and Betts recommended a
crimp pull strength of at least 140lbs. The crimp was tested on a sample
piece of cable using a strain gauge to 160 lbs. The crimp held firmly.
The contact area of the 0.375 in. square lug is 0.28 sq. in. The
ampacity is 107A/sq. in. which complies with the 1000 A/ sq. in. maximum
Fermilab safety guideline.

The lug termination at the fuse panel has a contact area of 0.2 sq. in.
The ampacity of this connection is 150A/sq. in. which does not exceed
the 1000A/sq. in. guideline. The right-angle, tin-plated, 0.125" copper
bar used to connect the 4 AWG lug to the 50 A barrier strip completely
accommodates the lug connection surface. The surface area of the bus bar
that comes in contact with the barrier strip is 0.492 sq. in. The
ampacity of this connection is 61 A/sq. in. which also meets the safety
guideline. Figure 3 shows the connections inside the fuse panel located
in the cathedral of the D0 experiment.

Figure 3: Cathedral Fuse panel connections.

![](media/image3.jpeg){width="3.848611111111111in"
height="2.852777777777778in"}

10AWG (35A) cable is used to connect the barrier strip to the 3A fuse
bank bus bar. The 22 AWG remote sense lines are also fused at 3A within
the fuse bank. 10 AWG is used to connect the 3A fuse to the filter card
described in the next section. The output of the filter card then goes
to the Power Distribution card mounted on the face of the Central
Calorimeter. Molex Mini-Fit Sr. 50A pins are used to bring the power
into the card via 10 AWG cable. 5A pins, de-rated to 3.3A due to the
parallel pins configuration, are used to distribute the 5V power to as
many as 10 individual Adapter Cards via a 22 AWG twisted pair. The 10
twisted-pair 22 AWG cable bundle has a 5A current capability. The
Adapter Cards use 3A rated pins. Part numbers are available upon
request.

## Filter Network

The filter network was design to minimize noise pickup in the readout
system and is used in the Layer Zero system at DZero. This same filter
design is used in this system. The filter consists of two baluns and a
2.2uF capacitor shown below in Figure 4. The first balun provides
common-mode rejection while the second is used in band-reject mode. Each
supply line to the Adapter Card is connected to a separate filter
network. The #8112 balun is rated for a maximum current of 5.6 Amps
which causes a 35C temperature rise. Due to the 3 Amp fuse upstream of
each filter, the baluns will not experience more than 3 Amps of current.
A complete description of the filter design is available at

<http://d0server1.fnal.gov/users/bagby/www/LV_PS/a1050923.pdf> .

Figure 4: Power Supply Filter Network

![](media/image4.png){width="5.9944444444444445in"
height="1.7333333333333334in"}[]{#__RefHeading___Toc176166612
.anchor}***Equipment Location***

The following sections describe the location of the equipment for the
HDI Recovery System.

### Movable Counting House

Figure 5 is the rack layout of the Wiener Power supply and Interlock
chassis in rack M209 located on the second floor of the movable counting
house. Typical installation practices are followed which allows for air
space above and below the power supply.

Figure 5: M209 Equipment location.

![](media/image5.jpeg){width="1.4597222222222221in"
height="1.9465277777777779in"}

### Cathedral Area

The fuse panels are located on the west and east side of the cathedral
area inside the Dzero collision hall. A clear Lexan cover prevents
foreign objects from falling inside the unit. The filter networks are
mounted under the fuse panel and are also covered with a shield as shown
in Figure 6.

Figure 6: Cathedral Fuse Panel and Filter Installation

![](media/image6.jpeg){width="2.6597222222222223in"
height="3.546527777777778in"}

### Central Calorimeter Cryostat Face

The new Adapter Cards are mounted between the Calorimeter Central
Cryostat (CC) and the Calorimeter End Caps (EC). The power distribution
cards are mounted in various positions on the CC as shown in Figure 7.
Kapton tape is used to cover exposed surfaces on both types of cards.

Figure 7: SMT HDI Recovery Power Distribution Card and Adapter Card.

![](media/image7.jpeg){width="2.5597222222222222in"
height="1.9194444444444445in"}

# Equipment Specifications

## Wiener Power Supply

The Wiener PL508 power supply provides separate floating voltages for
each of the four quadrants (SE:SouthEast, NW:NorthWest, SW:SouthWest,
NE:NorthEast). The same type of supply is used in the Layer Zero system
to provide equipment commonality. A spare module (U6) is provided for
quick recovery in the event of a module failure.

Table 1 shows the power supply module capacity and operating parameters.
Two trip levels are associated with each module's output current. The
first trip level is called I Max, and the second level of protection is
the I Limit. The I Max current level is the maximum current for a good
status indication. If more current is requested than the I Limit set
point, the output voltage will fail. There are three voltage trip
parameters for each module. An upper (Over V) and lower (Under V) window
is set around the target voltage (Output V). If the output voltage goes
below Under V or above Over V, the supply will turn off. The third
voltage trip level is the Over Voltage Protection (OVP) value. If the
module output voltage rises above the OVP value, the output will
crow-bar.

Table 1: Wiener Module Specifications

  ---------- --------------- --------- ------- -------- ------- ------- --------
  Power      Module          Output V  I Limit Under    Over V  I Max   OVP(V)
  Supply     Specification   (V)       (A)     V(V)     (V)     (A)     

                                                                         

  U0:        2-7V, 115A,     0         5       0        3       4       6
             550W                                                       

  U1: VCC_SE 2-7V, 30A, 210W 5.5       6.1     4.8      5.6     6       5.9

  U2:        12-30V, 11.5A,  0         5       0        15      4       6
             280W                                                       

  U3: VCC_NW 2-7V, 30A, 210W 5.5       6.1     4.8      5.6     6       5.9

  U4: VCC_SW 2-7V, 30A, 210W 5.4       6.1     4.8      5.5     6       5.9

  U5: VCC_NE 2-7V, 30A, 210W 5.55      6.1     4.8      5.65    6       5.9

  U6: SPARE  2-7V, 30A, 210W 0         6.1     0        5.2     6       5.3

  U7:        5-10V, 80A,     0         5       0        5.5     4       6
             600W                                                       
  ---------- --------------- --------- ------- -------- ------- ------- --------

The Wiener supply is operated via the mainframe front panel, RS232, or a
CAN bus interface. The system has been integrated into the experiment's
EPICS system and is monitored with a software application. U0, U2, and
U7 will not be used in the system.

The module mainframe is fused on the 120VAC input with a 15 Amp fuse. A
solid state relay is used to control application of AC power to all
modules housed in the mainframe. This relay is used as part of the
interlock system described in the next section.
[]{#__RefHeading___Toc176166618 .anchor}

## Interlock Chassis

The Interlock chassis provides a means of disabling the Wiener
mainframe, thus all power supply modules, in the event of a detector
cooling fault (GLYCOL) or detection of smoke (VESDA) in the west and
east cathedral area. Figure 8 is the schematic drawing of the interlock
chassis. This unit was originally designed for the Layer Zero system and
modified to provide an interlock to the new SMT HDI Recovery Wiener
supply.

A set of mechanical contacts, from the Glycol cooling system and the
VESDA fire system, enables power to relays K1 and K2 thus closing a
solid state relay on the AC line of the Wiener power supply. In
addition, a fault out indication is sent to the RMI thus disabling the
AC power via the Pulizzi box. Permit, chassis power, and fault condition
status are indicated on the front panel of the chassis by LEDs as well
as through the 1553 RM.

Figure 8: Interlock Chassis Schematic Diagram.

![](media/image8.wmf){width="5.4944444444444445in"
height="4.177777777777778in"}

![](media/image9.wmf)

[]{#__RefHeading___Toc176166619 .anchor}

# Safety System

## Movable Counting House Rack Safety

Figure 9 illustrates the block diagram of the safety system in rack
M209. This is a standard installation for all DZero racks in the
counting house. The configuration shown will interrupt AC power to the
Wiener and Interlock Chassis in the event smoke is detected in relay
rack M209. In addition, if the Interlock chassis detects an external
interlock, the Wiener power will be interrupted by two mechanisms. The
first mechanism is a direct interlock into the Wiener while the second
is via the Pulizzi.

Figure 9: Counting House Safety System

![](media/image10.wmf){width="6.178472222222222in" height="6.15625in"}

***Electronics Safety***

### Low Voltage Power Supply System

The SMT HDI Recovery system is protected against all possible fault
situations with the Wiener Power Supply and the Interlock chassis as
well as features on other system electronics such as the Interface Board
and the Adapter Card.

1.  Fuse in AC power line in the Wiener power supply.

2.  Solid state relay in the Wiener 120 VAC power line.

3.  Fuses in SVX2 power lines on the Fuse Panel.

4.  Two current and three voltage trip levels in the Wiener Power
    supply.

1\. The 15A AC line fuse, providing main power to the Wiener, protects
the system from faults on the mainframe side of the system.

2\. The solid state relay on the AC power main of the Wiener provides an
external trip mechanism for removing power from the system in case of
GLYCOL cooling or VESDA trips. The philosophy behind the cooling system
interlock is that the silicon sensors should not be allowed to get too
hot (and burn up) or too cold (humidity condensation). VESDA provides a
shutdown trip in the event smoke is detected in the cathedral area of
the collision hall.

3\. A series of fuses in the power lines up to the adapter card protect
the cabling and the Adapter Card. The fusing will be above normal
operating levels.

4\. Internal Wiener trip levels provide a two level current trip (Imax,
I Limit) and a three level voltage trip (Under Voltage, Over Voltage,
and OVP).

### Adapter Card

The replacement Adapter Card (HEP015 Rev 2) is a six-layer copper/FR4
circuit board that is a direct drop-in replacement for the HEP015 Rev
1.5 board. It is largely the same except for the addition of a power
connector, four TTL ICs and five FET switches. It\'s purpose is to
recover non-working HDIs in which one SVX chip has a fused or broken
DVDD wire bond. It does this by applying +5V power to the SVX chip,
through the FET switches, to four of the data lines, which in turn power
the SVX\'s DVDD net via the chip\'s protection diodes.

The +5V twisted pair enters the Adapter Card via a Molex 7055-30001
2-pin connector rated for 3 Amperes per pin. The pins are .025\" square.
The mating connector part number is 50-57-9402 (shroud) and the part
number for the contacts is 16-02-0104. The following two connectors are
the same as in the original Adapter Card: The connector to the
low-mass-cable (and HDI) is a Hirose FH21-30S-1DS rated 0.5A per pin.
The connector to the 80-conductor gray cable (and Interface Board) is a
3M N10280-52E2VC. All six layers of the new Adapter Card are 1 oz.
copper.