# Presentation: 171322

## Run IIb L1 CAL Installation

**Constraints**
**Transition System**
**Cabling**
**Run IIb Racks**
**Schedule Overview**
**Installation**
**Summary**

**Patch Panels on Sidewalk Test Stand**

**All photos and schematics shown in this talk and supporting documentation can be found at or linked from the following URL:  **
**	****www-clued0.fnal.gov/~alstone/D0Work/L1Cal/l1cal.html**

## Constraints

**TDR - Reuse Run I BLS trigger cables.**
**78 & 80 Ohm impedance, 130-180 ft in length.**
**Installed circa 1990.**
**Cannot access to cables at the CAL BLS detector platform end.**
**10-20 ft of slack at MCH1.**
**Congested space beneath floor boards.**
**No place to store cables between decommissioning of Run IIa & installation of Run IIb.**
**Exceptional difficulty in locating spares.**

**New electronics are more compact.**
**4 crates (new) vs 20 crates (old).**
**Cable congestion at ADF and TAB backplanes.**
**1280 BLS, 240 LVDS cables.**
**Channel mapping, strain relief.**
**ADF backplane connector mismatch.**
**Cannot plug 8-pin BLS trigger cable connectors directly into 20-pin ADF backplane connectors.**
**Cannot plug LVDS cable into ADF backplane without removing key.**
**ADF-to-TAB signal flipping.**
**TAB backplane connectors assume a different orientation of signals from ADF backplane output.**
**Cable access & channel debugging.**
**Use scope during physics data taking without disconnecting signal cables.**

## Run IIb L1 CAL Signal Overview

## MCH1 Configuration

** ****Color coding illustrates the current & new BLS trigger inputs.  **
** ****Ten racks of Run I trigger electronics. 128 BLS trigger cables are routed to each rack.**

**Current**

**New**

** ****Four patch panels in the bottom half of each crate provide the mechanical means to route and support the BLS trigger cables.**

## Patch Panel Card

**Two passive patch panel cards – stuffed printed circuit boards – mounted to each patch panel.  Only the monitor connectors are visible from the front of the patch panel.   Cables are connected from the back.  Need 80.**

**Output to ADF (Pleated Foil Cables)**

**Monitor connectors**

**Input from BLS**

**In line resistors**

## ADF Transition Card & Faceplate

**Two pleated foil cables carry analog TT signals from each patch panel card to the ADF Cards via the ADF backplane. **
**Three LVDS cables carry the same digital ouput of the ADF Cards to three different TABs via the TAB backplane.**
**Need 80 ATCs.**

## Cabling

**Each label has a unique, clear, concise and unambigious ****NAME****, ****ORIGIN**** and ****DESTINATION****.**
**BLS trigger cables will be labeled as they are disconnected from the old electronics.**
**Pleated Foil and LVDS cables will be labeled after they have been tested in conjunction with the transition system components.**

**Cabling**

## Cabling: BLS Trigger Cables

**Before Run I disassembly**
**Prepare map of dead and noisy BLS lines**
**Careful training for handling of BLS trigger cables**
**Disconnect cables from old electronics**
**Apply Run IIb labels**
**Remove cable ties and secure cables in the vertical cable trays**

**Run IIa**

**After installation of Patch Panels**
**Redress cables, connect to Patch Panel Cards, apply strain relief**
**Procedure documented in a D0 Note.**
**Note:  It is possible that some fraction of BLS trigger cables will need to be reconnectorized after the installation of the transition system.****  **

**Run IIb**

## Cabling: Pleated Foil Cables

- Rear View

- Side View

**Pleated foil cables are 10 feet in length.  The cables drape from the top of the ADF backplane so as NOT to block access to the power supply beneath the ADF crate.**

## Cabling: TAB Backplane

**240 LVDS cables are routed from 4 ADF backplanes to the TAB backplane.  Each cable is 5 meters long. **
**The cabling of the TAB backplane is reminiscent of a telephone switchboard.  Cables will have to cross to allow full access to the backplane, and to implement a strain relief system.**
**Each TAB (column) receives TT signals for a slice of phi for all of eta.  In this diagram, A-B-C-D refer to the four ADF crates.  Each SW input to the TABs gets a copy from three adjacent ADF boards.**

## Sidewalk Test Stand

**Wooden platform adjacent to MCH1 near DAB pit isolated from building ground.**
**Build the final Run IIb L1 CAL Trigger system with all active components.**
**Crates: 4 ADF, 1 TAB/GAB, 1 Readout, 1 Communication.**
**Online computer, L1 CAL Trigger control computer, BLS-to-ADF Transition System.**
**Safety system which allows for 24/7 operation.  ****pORC received 2 Sep 2005.**

**We intend to keep the sidewalk test stand up and running through and after the shutdown for quasi long term needs.**
**The TAB prototype,  communication & readout crates stay on the sidewalk.  We will use the spare ADF crate on the sidewalk.**
**Power distribution is customized for sidewalk.  Air cooling.**
**RMIs with smoke detection.**

## Pre-Installation

**Sidewalk Test Stand**
**Vertical slice of Run IIb signal path**
**Integrate into global readout**
**Monitor Run IIb data with current trigger & physics readout**
**24/7 operation approved**
**Cabling**
**Mock-up of BLS trigger cables**
**Very limited access before Run IIb installation in MCH1**
**Interrack wiring & strain relief drawings for Pleated Foil & LVDS cables done on sidewalk completed**
**Implement MCH1 procedures**
**Run IIb labelling scheme**
**Transition System**
**1 Patch Panel Card, 2 Pleated Foil Cables, 1 ADF Transition Card, 3 LVDS Cables are tested as a unit (80 in total, plus spares)**
**Only need full set of ATCs with LVDS cables for sidewalk operation**
**Finite set of BLS trigger inputs**
**12 Patch Panels assemblies on sidewalk**
**Remaining assemblies are in DAB3, ready for shutdown**

**Signal Electronics**
**Full set of ADF Crates & Boards tested & in hand at D0, with spare set-up at MSU**
**Full set of TABs & GABs at D0 **
**Communications & Readout**
**Crates & Boards in hand at D0**
**Infrastructure**
**Reuse MCH1 racks**
**Strip them to frames during early weeks of shutdown**
**AC distribution boxes in hand**
**Plugs directly into current MCH1 power**
**Cooling systems**
**Commercial parts ordered**
**Heat exchangers, hoses, valves**
**Custom parts built at D0**
**Pipes, plenums**
**RMIs, smoke detectors in hand**
**Custom cable support systems**
**Bulkhead panel for L1CalTrk**
**Panels for BLS trigger cable monitoring**

## Status of Rack Infrastructure

**AC distribution boxes plug directly into existing MCH1 power.  The Tygon hoses are in good condition.  Will install new heat exchangers, water manifolds, hoses, valves and flowmeters, and tie into existing water lines.  Saftey monitoring – smoke, air flow, water flow, water drip - for six racks with active components.  Cable support systems being built in-house.**

## Run IIb L1CAL MCH1 Rack Layout

**M103-105**
**= M110-112**

**Air & water cooling for ADF Crates.  Air only for TAB/GAB & Communications Crates.  Air, water and smoke interlocked with RMIs.  30 Amp Pulizzi for power distribution.**

## ORC: Sidewalk vs MCH1 Installation

**AC Distribution**
**In-house design**
**DC Distribution**
**ADF crate (<700W):  ****Wiener crate/PS combo**
**TAB/GAB crate (<300W):  ****Bench top supplies**
**Controls crate (<200W):  ****Run IIa crate/PS combo**
**Readout crate (<330W):  ****Houses VME/SCL card**
**Fire Protection**
**Standard RMI:  ****Smoke, Air Flow**

**AC Distribution**
**Commercial**
**DC Distribution**
**ADF crate:  ****Same**
**TAB/GAB crate:  ****Wiener PS, fuse panel**
**Controls crate:  ****Wiener crate/PS combo**
**Readout crate:  ****No VME/SCL card**
**Fire Protection**
**Standard RMI:  ****Smoke, Air Flow****, Water**

| http://d0server1.fnal.gov/users/bagby/www/L1defaultorc.htm |  |
| --- | --- |
| System | L1_Calorimeter ORC Documentation .pdf , . doc
Rack Layout.pdf 
AC Distribution .pdf  |
| ADF Crate | ORC Documentation .txt  |
| TAB/GAB Crate | DC Distribution .pdf
TAB_GAB Backplane Diagram .pdf  |
| Control Crate | ORC Documentation .txt 
Wiener Specifications .pdf  |
| Readout Crate | VME/SCL DC Distribution .pdf 
VIPA DC Distribution .pdf 
VIPA Backplane Mechanical Drawing .pdf 
VIPA Backplane Schematic .pdf 
VIPA Backplane Sense Fuse/Thermistor Specifications .pdf  |

**MCH1**

**Sidewalk**

## Component Status

| Item | Need | In Hand | Comments |
| --- | --- | --- | --- |
| Patch Panels | 40 | 44 | 12 assembled on sidewalk.  The rest are in DAB3. |
| Patch Panel Cards | 80 | 41 | 1 Patch Panel Card + 2 Pleated Foil Cables + 1 ADF Transition Card + 
3 LVDS Cables are tested as one unit (80 in total, plus spares). |
| Pleated Foil Cables | 160 | 192 |  |
| ADF Transition Cards | 80 | 64 |  |
| LVDS Cables | 240 | ~300 |  |
| ADF Boards | 80 | 100 | Fully tested. At D0. |
| ADF Crates, PS + Fan Tray | 4 | 5 | Plus spare power supply, fan tray.  Back-up crate at MSU. |
| TAB/GAB Crate | 1 | 2 | Prototype on sidewalk is back-up (with modified power supply) |
| Trigger Algorithm Board | 8 | 12 | All available.  Several TABs with 1 GAB in use at D0. |
| Global Algorithm Board | 1 | 3 |  |
| Communication Crate | 1 | 1 | At D0.  Sidewalk crate is back-up. |
| SCLD Board  | 1 | 2 | 1 at D0, 1 at MSU.  In use. |
| VME/SCL Board | 1 | 3 | 1 Final (in use) + 1 Prototype at D0.  1 Final at Nevis. |
| Readout Crate | 1 | 1 | Reuse MCH1 crate for Run IIb.  Spare readout stays on sidewalk. |
| Other Cables | 68 | All + spares | L2/L3 (27), SCLD (4), TAB-GAB (8), GAB-TFW (4), L1CalTrk (24) |

## Installation Overview

| Item | Start Date | Duration | Persons | Comments |
| --- | --- | --- | --- | --- |
| Shutdown | 1 Mar 2006 | 14 wks |  | L0 (L1CAL) dominates installation (commissioning) schedule. |
| Noise Studies | 2 Mar 2006 | 1 wk |  | Need Run IIa L1 CAL trigger. Decouple beam pipe. Etc. |
| Decable BLS Trigger Cables | 13 Mar 2006 | 1 wk | 2 Phys | Remove rack doors. Disconnect 1280 cables. Relabel. Store. |
| Remove Run IIa Electronics | 20 Mar 2006 | 2 wk | 2 Tech | Strip M102-113 racks to frames. Remove AC conduits. |
| Install Run IIb Services | 3 Apr 2006 | 3 wk | 2 Tech | Power, water, air, safety services.  Install patch panels.  |
| Reconnect BLS Trigger Cables | 17 Apr 2006 | 1 wk | 2 Phys | Redress. Strain relief. |
| Install Crates, TCC.  Power. | 24 Apr 2006 | 1 wk | 2 Tech | 4 ADF, 1 TAB, 1 L1CAL TCC. Reuse current Readout, Comm. |
| Pleated Foil, LVDS Cables | 28 Apr 2006 | 1 wk | 2 Phys | Route. Strain relief. |
| Other cabling | 1 May 2006 | 1 wk | 2 Phys | L2/L3 Optical. GAB-to-TFW. L1CalTrk Match. SCL. |
| System Checkout. ORC. | 8 May 2006 | 1 wk | 2 Tech, 
2 Phys | Install rack doors. ORC approval. Cabling, mapping. |
| Commissioning | >15 May 2006 | 6+ wks | Multi-Physicists |  |

## Installation Comments

**Some work can overlap.**
**Staggered work over the full set of racks.**
**Items with common color code on Slide 10.**
**Schedules for various cabling is based on experience from performing mock-ups.**
**Procedures documented, and pre-installation training is assumed.**
**All durations assume one shift per day of either physicists or engineers.**
**May have two crews for some tasks working in parallel**
**Constraints: Space, power interruptions, noise**
**May have multiple shifts per day to accelerate well-defined tasks**
**Constraints: Limited expertise**
**L1 CAL upgrade has priority for MCH activities during installation.**

**Duration for stripping racks and installing services provided by John Anderson.**
**L1 CAL trigger upgrade will have to draw from the same pool of resources for mechanical and electrical support.**
**No engineer or technician is working 100% on L1 CAL.**
**We are assuming that overtime will not be an option.**
**A lot of advanced work is already done in building, ordering, and preparing all rack infrastructure.**
**The next order of business is to assign names to each task.**
**We already have a good idea of how much person power is needed.**
**Complicated by shutdown delay.**
**Premature to assign post-doc & grad student names to tasks planned for 6-8 months from now.**

## Installation Person Power

**Decable & Label BLS Cables**
**Two persons work as a team**
**2 racks per day**
**Two teams can work in MCH1 at a time (physicists)**
**Remove Run IIa **
**Remove boards, power supplies, heat exchangers, ribbon cables, airflow ductwork**
**Removal is faster as the components do not need to be recovered**
**Two persons work as a team**
**Technicians, but will need engineering supervision**
**1 rack per day**
**Two teams may work at opposite ends of MCH1 at a time**
**But, may only have support for one team per day**
**May require welder to cut apart sub-crates**

**Install Rack Infrastructure**
**Technicians, following engineering designs and rack specifications**
**Estimate 1 rack per 2-3 days**
**6 racks with services**
**Patch panels can be installed by physicists (<1 week) **
**Reconnect BLS Cables**
**Services are done from rear of rack, BLS cables from front, possibility for overlap**
**Same plan as “Decabling”**
**Crate Installation**
**Transport from Sidewalk to MCH1**
**Connect to power**
**Strong backs**
**Could take only a day**
**Other Cabling**
**Pleated Foil & LVDS Cabling similar to BLS Cabling**
**Rest of system uses <100 cables which can be routed & connected  < 1 day**
**TFW, TAB-to-GAB, L2/L3, L1CalTrk **

## Summary

**Electronics in hand & tested**
** ****All Crates & Boards**
**Transition System in hand**
**Waiting for the final batch of production boards from vendors**
**< 2 weeks for remainder**
**Testing will take about 2 weeks**
**Infrastructure ready**
**All Power & Safety Services**
**Cabling:  Routing & Support Structures, Labels**
**Safety**
**Sidewalk:  pORC received Sep 2**
**MCH1:  need approval about 8 weeks into shutdown**
**Docs nearly ready, submit in advance for consideration**
**Documentation**
**Labelling complete**
**Tested mechanically & with software**
**Cable installation pending**
**BLS decabling & recabling**
**PFC, LVDS routing & strain relief**

**Present Installation Schedule**
**Conservative with broad strokes **
**Installation Features**
**Technician & engineering support **
**Would benefit from someone  working >30% on L1CAL **
**Could accelerate decommissioning of current racks & installation of Run IIb services with overtime and/or extra person power (front-loaded)**
**MCH1 decommissioning uncertainty**
**Not feasible to do a full mock-up**
**Original racks were built at MSU & rolled as complete in early Run I**
**Detailed plan for BLS trigger cabling**
**Careful training for anyone handling these cables**
**List of dead & noisy channels **
**Final Installation Schedule**
**Assign individual names to all tasks**
**Factor in university schedules**
**Need daily breakdowns with Plan A & B**
**And multiple shifts, weekends **
**Integrate with other systems**
**Run Coordinator, Calorimeter, DAQ, Mechanical & Electrical Ops**