06/03/2002Ivan Hruska EP/ATE1 LV brick for TILECAL  Overview Design summary Results from 2nd radiation tests in PSI Villingen Bulk supply Plans for future

06/03/2002Ivan Hruska EP/ATE2 LV brick for TILECAL  New brick design - LT sample extension

06/03/2002Ivan Hruska EP/ATE3 LV brick for TILECAL

06/03/2002Ivan Hruska EP/ATE4 LV brick for TILECAL  New design - based on PSI results from June ‘02 PCB design ready - 8 pieces produced Still in debugging procedure - check of all possible effects New custom made flat transformer New rectifying MOSFET Efficiency 90% till 30A !

06/03/2002Ivan Hruska EP/ATE5 LV brick for TILECAL  Experience from debugging Debugging of prototype With first type of transformer & IRF MOSFET we reached only 75% of efficiency Problems with EMI in surrounding of LT1681  original schematics changed to improve situation  redesign of PCB needed-shielding/grounding Tested water cooling via alumina bars  works well but  wrong thermal contact for some components - co- planarity of bars  soldering of alumina bars to the semiconductors High side driver power circuit added  additional winding on transformer

06/03/2002Ivan Hruska EP/ATE6 LV brick for TILECAL  Power dissipation from MOSFET drivers need of external boost of secondary driver  25% overload for primary no-change  survived TID & SEE in PSI in the same conditions  possible to cool in final setup  New components exchanged & checked New flat PCB transformer - custom made by Payton - SMD New MOSFET from VISHAY - low Rdson < 3.5mohm

06/03/2002Ivan Hruska EP/ATE7 LV brick for TILECAL  Temperatures of components measured all ~ 30degC excluding MOSFET drivers  primary 55degC  secondary 50 degC MOSFETs  45degC when full power Transformer - PAYTON  75 degC Some of hot chips can be cooled

06/03/2002Ivan Hruska EP/ATE8 LV brick for TILECAL Efficiency measured with IRF -> 86 % (only to 20A - cooling problems) with VISHAY SUM110 -> 90% - 30A (power components ~45 degC)

06/03/2002Ivan Hruska EP/ATE9 LV brick for TILECAL  Not yet completely solved High side driver power when low PW ratio - very low output power Resonance of transformer in some regimes of operation

06/03/2002Ivan Hruska EP/ATE10 LV brick for TILECAL  Design of small cooling system Impossibility to test the brick only with air cooling Used heatsink from ‘01 design Tank with water & pump - no heat exchanger Need of additional & cheap cooling systems for radiation tests in: PSI TCC2

06/03/2002Ivan Hruska EP/ATE11 LV brick for TILECAL  Radiation tests Planned test in PSI delayed by 3 months Not sufficient flux in PSI during Nov’02 Test performed see special presentation Lateral SEE Test of MOSFETs (comments to my TMB presentation ) SEE test of new rectifying MOSFET SEE Test of high side driver chip IR 2213 Optocoupler for synchronous rectifying New linear regulators ( LM117 - reduction of costs ~ 40CHF/brick ) Crowbar ( transil ) Bipolar latches for remote control

06/03/2002Ivan Hruska EP/ATE12 LV brick for TILECAL  Results and plans We have verified and selected most of components for the design To get missing information we are preparing additional component test + NIEL test + board test Design changes according to results from SEE,TID & electrical tests (EMI) new PCB design should be very close to the prototype

06/03/2002Ivan Hruska EP/ATE13 LV brick for TILECAL  Remote control Design of remote control PCB based on 2001 design and new ideas how to use ELMB for power supply ELMB is not reliable component in radiation - SEEs Idea of “electronic shielding” by using bipolar latch verified Good results from SEE test of latches Discrete DAC for voltage trim

06/03/2002Ivan Hruska EP/ATE14 LV brick for TILECAL  Power & cable measurements Selected cable (USA15->UX15) ~ 2.20CHF/m Tests of real resistivity of whole circuit in preparation complete connector & cable setup  Bulk supply Detailed specification prepared Because of changes of voltage drop -> sense wires or negative resistance required Cooling and deployment preliminary solved 9 crates is possible to place to one 52U high rack Need of only ~2.5 rack for all 64 channels Cooling is sufficient

06/03/2002Ivan Hruska EP/ATE15 LV brick for TILECAL Example of rack with 9 crates of bulk power supply in USA15 3 boxes can have maximum power dissipation ~ 3kW 1.5kW dissipation from 3 crates Power coming from top bus bars - 75A/ phase Not yet solved power distribution inside racks Consultations with Paul Maley & J. Inigo - Golfin 52U RACK 27 outputs/rac k total input power 45kW Current 75A/phase 4U empty space 15kW section input/ 1.5kW power dissipati on Turbine & rack control 4U 3 x AC/DC 1700W output converter in 4U Air deflector Heat exchanger Fan tray Heat exchanger Fan tray Heat exchanger Fan tray

06/03/2002Ivan Hruska EP/ATE16 LV brick for TILECAL  Conclusion Design of new PCB component placement electrical test radiation test Additional radiation test of some components SEE test for MOSFETs & chipset statistics NIEL test Cooling unit for radiation tests needed Ordering of prototype of bulk supply Test of cabling system ( USA15-> brick)