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

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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

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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)

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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)

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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

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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

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Cable plant details

1

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).

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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.

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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

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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)

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“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.