Safety Review Document for the Control Crate in the D-Zero Run IIB Level 1 Calorimeter Trigger --------------------------------------------------- Rev Date 10-AUG-2005 This documentation covers the Control Crate in the new Run IIB Level 1 Calorimeter Trigger System. The contact person for the Control Crate is: Dan Edmunds Fermi Phone: x2832 MSU Phone: 517-355-9200 x2521 Email: edmunds@pa.msu.edu Notes: - Some earlier documentation on this web site may refer to this crate as the Communications Crate. All recent documentation uses the name Control Crate for this object. - There are two implementations of the Control Crate: an initial implementation is used for commissioning in the Sidewalk Commissioning Area, and a final implementation is used in the permanent new Run IIB L1 Cal Trig system that will be installed in the Moving Counting House. To avoid any confusion, this document will discuss these two implementations of the Control Crate separately. Control Crate Sidewalk Commissioning Area Implementation ------------------------------------------ There is one Control Crate in the commissioning area for the new Run IIB L1 Cal Trig. This crate is on the Sidewalk next to the MCH. This Control Crate is located near the top of rack number S108 at the North end of the Sidewalk commissioning area. This Control Crate holds the following cards: one Bit-3 VME Interface card, two Vertical Interconnect Master cards, one SCLD card. This crate itself and the three types of cards that it holds are discussed in the following sections. Crate The crate used for the Sidewalk commissioning area Control Crate is a surplus crate from a D-Zero Run I system. This crate has a section of 6U slots and a section of 9U slots. The 9U section is not used in this Control Crate application. This crate is made from the following components: - Schroff mechanical card file components A full list of these mechanical parts and their Schroff part numbers is available if needed. - Dawn VME Products, the backplanes: 9 Slot J1 Backplane Model # VMEBP09J1R Order # 06-400139 12 Slot J1 Backplane Model # VMEBP12J1R Order # 06-400142 9 Slot J2 Backplane Model # VMEBP09J2R Order # 06-400159 12 Slot J2 Backplane Model # VMEBP12J2R Order # 06-400162 There is no J3 backplane at any of the slots. - Molex connectors, the power connectors to the backplanes: 2 Circuit Housings Molex # 09-50-3021-P 10 Circuit Housings Molex # 09-50-3101-P Contacts Molex # 08-50-0106 These connectors mate with the DC power connectors on the backplanes. They are 0.045" square pins spaced 0.156". Molex rates this connectors at 7 Amps per pin when used with #16 wire. - Power Supply Power-One Model SPM2A6M6 Which has outputs: 5 Volt 60 Amp (used for VME +5V) 5 Volt 10 Amp (not used in this application) 12 Volt 10 Amp (used for VME +12V) 12 Volt 10 Amp (used for VME -12V) - DC power wire is all: Belden #8522 18 AWG wire - The DC power wiring is the following: +5 Volt 60 Amp Power: 8 of the #18 conductors in parallel to each of the 4 backplanes. Each conductor connects to its own Molex contact-pin. 32 of the #18 conductors total. Return: 10 of the #18 conductors in parallel to each of the 4 backplanes. Each conductor connects to its own Molex contact-pin. 40 of the #18 conductors total. +12 Volt 10 Amp Power: 1 of the #18 conductors to each of the J1 backplanes. Each conductor connects to its own Molex contact-pin. 2 of the #18 conductors total. Return: 1 of the #18 conductors to each of the backplanes. Each conductor connects to its own Molex contact-pin. 4 of the #18 conductors total. -12 Volt 10 Amp this is the same as the +12 Volt DC power wiring. Remote Sense - Not used in this application. There is no remote sense wiring. - Cooling Fan Tray 9 fans Dawn VME Products Model # VMEFAN-9/RM Order # 54-1002424 Bit-3 VME Card The BIT-3 VME interface card is a SBC Bit-3 model 618. I believe that this card uses only +5V from the VME bus. Only one of these commercially manufactured 6U cards is used in the Control Crate. Vertical Interconnect Master Cards The Vertical Interconnect is a Fermilab designed and manufactured card and will not be described in detail in this note. There is a description of the Vertical Interconnect on the web at: www-linac.fnal.gov/LINAC/hardware/vmesys/boards/vi/viInfo.html Two Vertical Interconnects are used in the Control Crate. The Vertical Interconnect is a 6U tall +5 Volt only card. SCLD Card The SCLD card was designed and manufactured by Denis Calvet at Saclay. The card's name stands for "Serial Command Link Distributor". Just one SCLD card is used in the Communications Crate. The SCLD is a 6U card. The SCLD receives only +5V from the VME backplane. This power bus is received via 6 backplane pins and it passes through a 3 Amp fuse on the SCLD card before reaching any other components on the card. The SCLD card uses 12 ground pins to connect it to the backplane. A picture of the SCLD card can be seen on the web at: www.pa.msu.edu/hep/d0/ftp/run2b/l1cal/hardware/scld/ in the file: denis_photo_front_of_scld.jpg Along the right edge of the SCLD card in this photo you can see the power input fuse and the wide trace that connects together the 6 power input pins and the fuse. In the same directory on the web one can view the schematic of the SCLD card in the file: denis_scld_sch.pdf On the first page of this schematic is the power entry section of the SCLD card. This page shows the power and ground pins, the power input fuse, and the transit voltage protection device. Control Crate Permanent Moving Counting House Implementation ---------------------------------------------- There is one Control Crate in the permanent Moving Counting House installation of the new Run IIB L1 Cal Trig. This crate is located in MCH rack M108. This Control Crate holds the following cards: one Bit-3 VME Interface card, two Vertical Interconnect Master cards, one SCLD card, and one VME/SCL card. This crate itself and the four types of cards that it holds are discussed in the following sections. Crate The Control Crate itself is a commercial unit made by Wiener. It is their type UEV 6023 crate with their type UEL 6020 LX fan tray and type UEP 6021 power supply chassis. This equipment has the TUV and IEC regulatory certificates. This crate is setup with Wiener mechanics to hold a mix of 6U and 9U tall cards. This crate has a VIPA type J1-J2 backplane and no J3 backplane. The rack that holds the Control crate are protected by a standard Fermi D-Zero Rack Monitor. This monitor includes smoke and water leak protection. Detection of a fault condition drops the AC input power to the Control Crate. Cooling in the rack that holds the Control Crate is provided by an air to water heat exchanger. This heat exchanger is located below all of the active electronics in the rack. Air is pushed through this heat exchanger by a fan tray which is mounted under it and holds 9 fans. The Control Crate holds all of the active electronics this rack. The air flow through the Control Crate itself is provided by a fan tray that is part of the Wiener crate assembly. The operation of the 3 fans in the crate's fan tray and the air temperature in the crate are monitored by the built in monitoring system in the Wiener crate. Information from this built in monitoring system is sent, via CAN Bus, to the D-Zero Significant Event System (Alarm System). The monitor system built into the crate will shut it down if the air temperature is over the set limit or if a fan fails. The total heat dissipated by the electronics in the Control Crate is less than 200 Watts. In the Control Crate no DC power is brought out external to the crate. The Control Crate has the following external connections: CAN Bus connection for monitoring (1x) VME interface connection to the Bit-3 card optical fiber (1x) Vertical Interconnect connection to the 4 ADF Crates (4x) Vertical Interconnect connection to the Readout Crate (1x) SCL connection to the SCLD card (1x) SCLD connection to each of the 4 ADF Crates via LVDS Cable (4x) SCL connection to the VME/SCL card (1x) Cable from the VME/SCL card to: each of the 8 TAB cards (8x) and to the one GAB card (1x) All of these connections are "signal level" connections and none of them can provide a substantial amount of current. To control the flow of cooling air, the Control Crate will have blank front panels installed over the slots that are not used. To restrict accidental access to the power buses on the back of the backplane, the Control Crate will have a G10 cover installed over the back of its backplane. Bit-3 VME Card The BIT-3 VME interface card is a SBC Bit-3 model 618. I believe that this card uses only +5V from the VME bus. Only one of these commercially manufactured 6U cards is used in the Control Crate. Vertical Interconnect Master Cards The Vertical Interconnect is a Fermilab designed and manufactured card and will not be described in detail in this note. There is a description of the Vertical Interconnect on the web at: www-linac.fnal.gov/LINAC/hardware/vmesys/boards/vi/viInfo.html Two Vertical Interconnects are used in the Control Crate. The Vertical Interconnect is a 6U tall +5 Volt only card. SCLD Card The SCLD card was designed and manufactured by Denis Calvet at Saclay. The card's name stands for "Serial Command Link Distributor". Just one SCLD card is used in the Communications Crate. The SCLD is a 6U card. The SCLD receives only +5V from the VME backplane. This power bus is received via 6 backplane pins and it passes through a 3 Amp fuse on the SCLD card before reaching any other components on the card. The SCLD card uses 12 ground pins to connect it to the backplane. A picture of the SCLD card can be seen on the web at: www.pa.msu.edu/hep/d0/ftp/run2b/l1cal/hardware/scld/ in the file: denis_photo_front_of_scld.jpg Along the right edge of the SCLD card in this photo you can see the power input fuse and the wide trace that connects together the 6 power input pins and the fuse. In the same directory on the web one can view the schematic of the SCLD card in the file: denis_scld_sch.pdf On the first page of this schematic is the power entry section of the SCLD card. This page shows the power and ground pins, the power input fuse, and the transit voltage protection device. VME/SCL Card The VME/SCL card was designed and manufactured by Columbia Nevis Laboratory. One VME/SCL card is used in the Communications Crate. The VME/SCL is a 9U tall card that uses only the +3.3 Volt supply from the VIPA backplane. A schematic of the power entry part of the VME/SCL card is shown in the pdf drawing on the web at: www.nevis.columbia.edu/~evans/l1cal/hardware/safety/vme-scl_power.pdf The J1 backplane connection that receives the +3.3 Volt bus from the backplane is shown on the right hand side in this drawing. The input fuse and the transit voltage protection device are also shown. A picture of the VME/SCL card can be seen on page 3 of the following pdf file: www.nevis.columbia.edu/~evans/l1cal/meetings/031211/VME_SCL.pdf The +3.3 Volt input power protection fuse can be seen at the right hand edge of the circuit board .