11 SSD Power and Cooling on the Cone STAR Integration Workshop Howard Matis May 16, 2008 STAR Integration Workshop Howard Matis May 16, 2008

2 The SSD

3 The SSD is a working detector

4 Background  Important for the HFT physics program  It is being upgraded to be fully compliant with DAQ1000  The SSD NIM paper had 41 people  We are trying to do the upgrade with  Experienced but unattached SSD engineers  A few young scientists (software)  Several “highly experienced” physicists (hardware)  Manpower and resources limited  Have designed an upgrade path with very finite resources and to fit existing STAR upgrade funds  Important for the HFT physics program  It is being upgraded to be fully compliant with DAQ1000  The SSD NIM paper had 41 people  We are trying to do the upgrade with  Experienced but unattached SSD engineers  A few young scientists (software)  Several “highly experienced” physicists (hardware)  Manpower and resources limited  Have designed an upgrade path with very finite resources and to fit existing STAR upgrade funds

5 Outline  Overview  Electrical past  Electrical future  Cooling past  Summary  Overview  Electrical past  Electrical future  Cooling past  Summary

6 Existing Cables on the Cone  20 groups of cables feeding ladder on each end  Readout on each end  Only need to bias detector on one end  Each group contains either  3 round cables going to a rectangular connector (sense, LV, HV)  2 round cables (sense, LV)  20 groups of cables feeding ladder on each end  Readout on each end  Only need to bias detector on one end  Each group contains either  3 round cables going to a rectangular connector (sense, LV, HV)  2 round cables (sense, LV)

7 Cable Bundles along the Cone Bundle (picture taken during Removal of SVT from STAR)

8 Readout chain 30 MHz BLVDS bus Ribbon cable (1m) shielded cable (2m) Readout board 3 MHz on a ladder 10 ADC boards Two Shielded Cables per side

9 Existing Space on the Cone (one side) (Rectangular Area  Area assuming cable is a square with the diameter of the cable) Low voltage cable may be smaller

10 Previous Cooling doc_2.pdf  Cooling at a ladder level  Air is taken from inner STAR  10 outputs go to East  10 outputs go to West  16 watt/ladder  1/2” tubes with outer layer protection at exit of the cone (~3/4”)  Kinked hoses big problem  Cooling at a ladder level  Air is taken from inner STAR  10 outputs go to East  10 outputs go to West  16 watt/ladder  1/2” tubes with outer layer protection at exit of the cone (~3/4”)  Kinked hoses big problem

11 Existing Cooling Diagram

12 Air from inner field cage Output to Vortex

13 Features of Existing Cooling System  Input air temperature defined by IFC TPC air temperature  Noticed more temperature failures on SSD as hall temperature increased  Design provides symmetric heat load on east and west TPC  Large cooler, very loud - Vortex  Hoses easily crimped  20 tubes on each side in the vicinity of the SSD end  10 tubes go under the cone  Input air temperature defined by IFC TPC air temperature  Noticed more temperature failures on SSD as hall temperature increased  Design provides symmetric heat load on east and west TPC  Large cooler, very loud - Vortex  Hoses easily crimped  20 tubes on each side in the vicinity of the SSD end  10 tubes go under the cone

14 Problems with existing cooling  Input air temperature  Is inner field cage controlled to 20 C as per original specifications?  Need a source of cool air  Hoses kink easily  Find stiffer hose that meets safety requirements  Vortex very noisy (acoustical)  Find new blower  Input air temperature  Is inner field cage controlled to 20 C as per original specifications?  Need a source of cool air  Hoses kink easily  Find stiffer hose that meets safety requirements  Vortex very noisy (acoustical)  Find new blower

15 Cooling in new design  Need cooled incoming air  Symmetric cooling from east and west side  Cool evenly  Similar heat load on both sides of the TPC  10 inputs and 10 outputs on each end  Total of 20 at each end  New electronics might take more power  Complete design so can calculate heat load  Assume can find BNL approved hoses which don’t kink at 0.5”  Need cooled incoming air  Symmetric cooling from east and west side  Cool evenly  Similar heat load on both sides of the TPC  10 inputs and 10 outputs on each end  Total of 20 at each end  New electronics might take more power  Complete design so can calculate heat load  Assume can find BNL approved hoses which don’t kink at 0.5”

16 Cables for Old/New Design

17 SSD Upgrade  Power  Need to finish design to determine how much power  Reducing gauge of power wires requires a new power supply  Data  Two optical cables for each ladder (one per side)  Slow Control  28 wire copper cable or  Two optical links per ladder (one per side)  need person to design (not budgeted for in SSD proposal)  Air Cooling  One tube on each end - sized to 1/2” aperture of SSD  Must have a source of cool air  Need a person to do a system design  Coordinate with HFT  Power  Need to finish design to determine how much power  Reducing gauge of power wires requires a new power supply  Data  Two optical cables for each ladder (one per side)  Slow Control  28 wire copper cable or  Two optical links per ladder (one per side)  need person to design (not budgeted for in SSD proposal)  Air Cooling  One tube on each end - sized to 1/2” aperture of SSD  Must have a source of cool air  Need a person to do a system design  Coordinate with HFT

18 Proposed Designs on one end of the Cone*  * Warnings:  Need more resources to implement optical for slow control  Need to study if smaller cable diameter can be tolerated  Cooling design necessary to fix hose requirements  * Warnings:  Need more resources to implement optical for slow control  Need to study if smaller cable diameter can be tolerated  Cooling design necessary to fix hose requirements  Howard Matis:  Jim Proposes remove unshielded option.  Fix left adjustment  Howard Matis:  Jim Proposes remove unshielded option.  Fix left adjustment

19 Mechanical Mounts  Must maintain original attachment to the cone

20 Integration Questions  What is new design of the cone?  What is the bend radius of pipes and cables allowed by the IST or FGT?  What is the path of the cables on the cone to the SSD?  Who is assigning space on the cone and drawing the design?  Air manifolds - location  Bend radii of cooling hoses  How to route cables and pipes on the cone?  How to cables and pipes from cone to ladders?  Where to get cold air?  Can SSD be cooled from one end?  Who will do this?  What is new design of the cone?  What is the bend radius of pipes and cables allowed by the IST or FGT?  What is the path of the cables on the cone to the SSD?  Who is assigning space on the cone and drawing the design?  Air manifolds - location  Bend radii of cooling hoses  How to route cables and pipes on the cone?  How to cables and pipes from cone to ladders?  Where to get cold air?  Can SSD be cooled from one end?  Who will do this?

21 Integration Questions (cont.)  Need space for the RDO boxes on the magnet end  Use existing SSD rack on South Platform  Need space for new air cooler (North Platform?) and hose  Cables in trays and festoon not significant change from before  Plenty of space in DAQ room  Must keep SSD mechanical mounts on cone  Need space for the RDO boxes on the magnet end  Use existing SSD rack on South Platform  Need space for new air cooler (North Platform?) and hose  Cables in trays and festoon not significant change from before  Plenty of space in DAQ room  Must keep SSD mechanical mounts on cone

22 Summary of SSD Upgrade  Ladders refurbished - same silicon  New ladder ADC and transmission to RDO Board  New RDO and connection to DAQ Room  Using standard STAR DAQ1000 electronics  New cooling system  Keep existing power cables  Ladders refurbished - same silicon  New ladder ADC and transmission to RDO Board  New RDO and connection to DAQ Room  Using standard STAR DAQ1000 electronics  New cooling system  Keep existing power cables  Howard Matis:  Wrong place  Howard Matis:  Wrong place

23 Summary  Rectangular size of previous cables on the cone  97.3 cm 2 (counting both air hoses)  Rectangular size of current design (with contingency)  180 cm 2 – copper slow controls  90.1 cm 2 – optical slow controls (Needs engineering)  To do items  Approve SSD proposal and provide funds  Complete technical design to determine heat load  Coordination with HFT for cooling  Support for design of slow controls and cable design  Numerous integration issues  Rectangular size of previous cables on the cone  97.3 cm 2 (counting both air hoses)  Rectangular size of current design (with contingency)  180 cm 2 – copper slow controls  90.1 cm 2 – optical slow controls (Needs engineering)  To do items  Approve SSD proposal and provide funds  Complete technical design to determine heat load  Coordination with HFT for cooling  Support for design of slow controls and cable design  Numerous integration issues  Howard Matis:  Jim proposes remove 55.4 cm2  Howard Matis:  Jim proposes remove 55.4 cm2

24 Repair Status May 2008

25 Current Situation  SSD in Nantes  All Ladders tested  No dead ladders  Ladder 7 fixed by replacing ADC and connection board  SSD in Nantes  All Ladders tested  No dead ladders  Ladder 7 fixed by replacing ADC and connection board

26 Current Testing - Need 20 ladders Six very good ladders Seven Ladders with one bad hybrid (half module) Those ladders may be fully “good” if the bias of the module is forced. Nine Ladders with several bad modules Some need to have the bias forced Because of problem with JTAG chain, configuration can be determined with present software Some improvement can be done Four of these Ladders with a real high voltage trip. Can be good if capacitors replaced Will result in 10 very good ladders ladders Six very good ladders Seven Ladders with one bad hybrid (half module) Those ladders may be fully “good” if the bias of the module is forced. Nine Ladders with several bad modules Some need to have the bias forced Because of problem with JTAG chain, configuration can be determined with present software Some improvement can be done Four of these Ladders with a real high voltage trip. Can be good if capacitors replaced Will result in 10 very good ladders ladders  Howard Matis:  Fix slide  Howard Matis:  Fix slide

27 Summary with NO repair

28 Comments  Currently STAR software requires both n side and p side for a track  Efficiency different if can allow only one side  6 chips (ALICE128) are programmed by a JTAG chain  When there is a break, then chips cannot be programmed correctly  Current test software cannot bypass  Can be bypassed using STAR Slow Controls  Problem can be improved Can bypass and then lose 128 strips  Currently STAR software requires both n side and p side for a track  Efficiency different if can allow only one side  6 chips (ALICE128) are programmed by a JTAG chain  When there is a break, then chips cannot be programmed correctly  Current test software cannot bypass  Can be bypassed using STAR Slow Controls  Problem can be improved Can bypass and then lose 128 strips

29 High Current  Capacitors are added to isolate power lines  Probably due to bad capacitor  Should be repairable  How to locate bad capacitors  Use infrared imagery  Capacitors are added to isolate power lines  Probably due to bad capacitor  Should be repairable  How to locate bad capacitors  Use infrared imagery

30 Picture of Module Capacitors

31 Infrared scan Power off Power on Power off Power on Bad Capacitor

32 Summary  Efficiency good now  Better than 90%  Will improve  Efficiency good now  Better than 90%  Will improve