G. Dissertori ETH Zürich 9.10.2003 ECAL ESR - DCS 1 ECAL Detector Control System G. Dissertori...

9.10.2003ECAL ESR - DCS

1G. DissertoriETH Zürich

ECAL Detector Control System

G. Dissertori Electronics System Review, Oct 9, 2003

Status report

Trigger/DAQ project DCS

CMS DCS

ECAL DCS

Outline

Overview

Temperature Safety System (TSS)

Precision Temperature Monitoring (PTM)

Humidity Monitoring (HM)

SM internal cabling and patch panel

Outside cabling

Quality assurance

Planning

Overview

ECAL module

crystal

PCBs for VFE and FE

cooling

LV, HV

Laser system

Offline, DAQ

Data Bases

prec. temp. sensor

Monitoring

TSS temp. sensor

Monitoring Safety, PLCinterlock

cooling, faults

humidity sensor

Specification Document

wwweth.cern.ch/dcs Documents ESR

Overview general duties of DCS in ECAL

development, design, prototyping, testing, installation of environmental sensors

Alarms, monitoring, archiving of environmental parameters

ECAL safety system - hardware interlocks (LV/HV)

Interfaces : HV, LV, DAQ, Cooling, Laser, CMS DCS, CMS DSS.

set-up of overall control/monitoring software

Detectors : ECAL EB, EE, Preshower

24h non-stop operation !!

not responsible for set-up and control of front-end electronics readout of sensors/slow control data related to front-end (via DCU)

however: this information should be exchanged via DAQ-DCS interface

Laser control : but there should be communication with DCS

Overview

Now focus on :

EB ( + EE)

Temperature Safety System - TSS Precision Temperature Measurements - PTM Humidity Measurements - HM

PC/PVSS – PTM, HM

---------

PLC – TSS

PC/PVSS – PTM, HM

---------

PLC – TSS

CMS balcony

ReadoutelectronicsReadout

electronics

Cavern UXC55 Counting room USC55

No electronics inside CMS !(all electronics is accessible – at least during CMS shutdowns)

Important :

Temperature Safety System - TSS

Belgrade group

• Full system autonomy in all aspects;

• Independent, continuous temp. monitoring of the ECAL VFE + FE environment in

both ECAL SM + Endcaps; Precision : 0.5 deg C

• Archiving of temp. data and system status information for analysis of system and

detector performance;

• Reliable hardwired interlocks with ECAL HV and LV Power Supply systems;

• External Alarm Interfaces with ECAL Cooling system (and ECAL LV?), as well

as interface with general CMS DSS + TCR (?);

• Prompt reaction on any external alarm or critical change of temperature inside the

ECAL by issuing, in a proper time sequence, Warnings and Alarms to:

1. HV System Crates (hardwired interlocks),

2. LV System Crates (hardwired interlocks),

3. System Operator (soft PVSS Warnings and Alarms);

• Radiation tolerance in accordance with CMS radiation dose specifications;

• Maximum possible level of robustness, reliability, safety and maintainability;

TSS : Requirements

Three interconnected system layers:

• Temperature conversion and channel multiplexing - TSS FE LayerTSS FE Layer,• Data acquisition, data processing and interlock generating - TSS PLC LayerTSS PLC Layer,• System monitoring and system control - TSS Soft LayerTSS Soft Layer;

Several external interfaces to:

• ECAL Low Voltage, ECAL High Voltage and ECAL Cooling systems,• CMS Detector Safety System (DSS),• LHC Technical Control Room (TCR) (?).

Schematic layout

There are in total 288+64 NTC 100 Ohms 288+64 NTC 100 Ohms thermistors (BC components)positioned in pairs at each measurement point ( “Twin” sensors ).

2x twisted pair cableSCEM = 04.21.51.704.4SCEM = 04.21.51.704.4, 2x2x0.05mm2,outside diameter 2.9mm, PETP insulationPETP insulation

TSS : Sensor Location

10-35m long 9xSTP cable sectionsSCEM = 04.21.51.405.2SCEM = 04.21.51.405.2 – 9x2x0.008 mm2outside diameter 7.2 mm, MA 18 P

TSS : Sensor Location

TSS : sensors

FE Electronic components

Rad-tolerant Max4582:

TTL/CMOS compatible Temperature Range 0°C - 70°C On-resistance 150 Ohms at 5V Off-leakage current 1nA at 25°C Low Distortion Low crosstalk

NTC 100 Ohms

Resistant Bridge Front-End ASIC: DMILL 100 + 30% spares ordered (with LHC cryo group)

• Bi-directional three-level programmable Internal Current Source (1μA, 10μA and 100μA),

• Differential Amplifier, gain = 50 (adjustable), input range: -50mV – 50mV, output range: 0 - 5V,

• Analog switches, 8 measurement modes of the chip, controlled by the Ck0, Ck1 and Ck2 bits,

• Removes ASIC voltage offsets, thermocouple effects, power supply and ambient temperature dependencies

RBFE ASIC

TSS FE is modular system made of TSS Units as independent modules. All identical;

Each TSS unit has its own, independent and redundant power supply;

Each TSS unit provides redundant readout for four SM or one Endcap. There are 12 in total (1+5+5+1) units needed for (EE+EHB+EHB+EE) There should be at least 3-5 spare TSS units (about 16-24 spare entries in total);

TSS units can be interconnected in order to be controlled in parallel by the same PLC Control Signals --> possibility for parallel readout of several EB Super Modules and reduces the cabling between the Counting Room and the TSS Racks on the balconies;

Redundant architecture of the TSS readout unit : provide maximum reliabilitymaximum reliability, so that, in the case of malfunction of any internal electronic components, the unit still works properly with minimum possible loss of temperature information from the inside of ECAL

All the electronic components of TSS FE Units should be radiation tolerantradiation tolerant in accordance with the CMS radiation doses specifications for UXC5.

TSS FE Layer – FE Electronics

Functional layout of TSS Unit in control of

four ECAL Super Modules

Reliability analysis (for 4 designs)

This layout with 8 RBFEs/4SM has smallest prob. to loose large number of modules in case of component failure

Fuses - limit the current in primary and two redundant secondary circuits, LED Indicators – the status of redundant internal power supply systems.

analog signals - from four ECAL SM or one Endcap, amplified analog signals - from RBFE ASICs to the TSS PLC AI modules, digital input signals - to control RBFEs and MUXs inside the TSS Unit. Input from the TSS PLC or neighbouring TSS unit; digital output - to transfer digital control signals to neighbouring TSS unit.

Layout of ECAL TSS interconnections

2 x S7 PS307 PLC 24V Power Supply module (External Batteries, UPS ?),

2 x S7 DP315-2 PLC CPU module (256KB, 0.3MIPS, software redundancy),

1 x S7 IT 343-2 Communication module (Ethernet, MPI, DP and Email connection,

firewall).

6 x S7-331 8xAIx15bit modules (44 analog inputs, 0-5V, total a/d conversion time <

? x S7-321 16xDI modules for ? alarms from ECAL LV and Cooling Systems,

? x S7-322 16xDO modules for 10-bit Control Signals for TSS FE Unit control and ?

interlock signals for the ECAL HV and LV

Siemens S7-300 Family PLC System for TSS:

TSS : PLC Specifications

Interfaces

TSS PLC-to-DSS/TCR Interface

TSS PLC-to-HV/LV/Cooling Interface:

form compatible TTL and relay interlock signals for the ECAL HV and ECAL LV crates, based on raw interlock signals from the TSS PLC. accept interlock acknowledgment signals from ECAL HV and LV for the purpose of eventual interlock wire-break detection.

accept, convert and transfer external TTL and relay alarm signals to the TSS PLC

Interface

Tests with SM0

SM0: sensor location

SM0 : PLC

Tests with SM0ECAL TSS (FE + Interface) PCB Calibration curve for one TSS sensor

Noise dependence on RBFE position

(ΔL ~ 40m)Noise distributions for 4 twisted pairs

~0.04°C

~0.025°C

Tests with SM0

Oscillations of temperature of the air inside and outside of the SM0 are correlated!

Cooling problems !Cooling problems !

Cooling water temp. too highCooling water temp. too high-> TSS interlock ! -> LV off !-> TSS interlock ! -> LV off !

Cooling problem solved !Cooling problem solved !

LV On !LV On !

Cooling problems !Cooling problems !

LV On !LV On !

TSS interlock !TSS interlock !

System performance System performance satisfactory !!!satisfactory !!!

Tests with SM0: Example

Precision Temperature Monitoring - PTM

S. Zelepoukine, IHEP Protvino and ETHZ

Requirements:

very high precision temp. monitoring : check stability of water cooling system, to stay within 0.05-0.1 deg C.

no hardwired feedback to cooling, but software link possible

relative precision : 0.01 deg C

one sensor/module on thermal screen and grid main water IN, main water OUT

PTM : Sensors

Thermistors (NTC) from Betatherm, 100k

10 / EB SM 10 / EE quadrant 20 reference sensors

around CMS (accessible for calibration)

Note : We do not use the Betatherm aluminium housing

First order (100 sensors) placed

use our own calibration setup

Patch panel

Thermal screen

Sensor probes location inside SM:

Probes of type 1 (N = 4 + 4) Probes of type 2(N = 2)

Number of probes (per SM): 4 + 4 + 2 = 10Each probe has its own signal cable – twisted pair

M1 M2 M3 M4

PTM : Sensor location

PTM : Sensor location (SM0)

probe M3

cable from M3 probe

cables from M1 and M2 enter M3 via different windows

Patch panellocation

by F.Mossiere

Material: aluminum alloy

St.steel;outer / inner dia = 4 / 3 mm

by F.Mossiere

PTM : immersion probes

Surface probe – SM grid / thermal screen:

Construction: Aluminum piece (17 x 10 x 6 mm); to be fixed with 2x M2.5 screws on the grid or thermal screen surface.

Location: in the center of each module (grid / th.screen sides);

Immersion probe – SM IN/OUT cooling pipes:

Construction: St.steel tube (length = 55 mm; inner/outer dia = 3/4 mm); to be immersed into the cooling water flow.

Location: on the SM’s entry/exit cooling pipes

PTM : sensor probes

Heat gun80C

Heat shrinkagesleeves (1.5 / 0.5)

Stage 1 - isolation of sensor leads

Heat gun80C

~ 1mmHS sleeve

PTM : sensor probe assembly

Gap Filler M4 screw

Stage 2 - mounting sensor into the probe

~ 3mmHS sleeve

Heat gun80C

Insert sensor into the probe; put a drop of Gap Filler.

Close the hole with a screw M4;Put a protective HS sleeve on theoutgoing wires.

Stage 3 - soldering signal cable (tw.pair)

5.1 - Solder sensor lead to the cable wire

5.2 - Protect with HS sleeves

5 Twisted pair (no shield, no jacket);length ~ 5m (4m min)

6 – put 2 markers with the unique sensor ID number: on the probe (top side) and on the cable about 0.5m from the end

100100

PTM : Readout - Layout

ELMBELMB

Cur.srcCur.srcPC / PVSSPC / PVSS

UXC55 balcony:4 + 2 DCS racks

Counting room

20x2 STP cables(44 + 2 sections)

CANbus cables(6x2 sections)

~ 500 sensors(NTC thermistor Betatherm;100K @ 25C; indiv.calibrated;better than 0.01C rel.accuracy)

Readout electronics:ELMB based;ELMB reads voltages andconverts to digital data, thensends data via CANbus.DC-DC converters

DC Power supplies

Monitoring application:PVSS based;data storage/archiving,visualization/trending,warnings/alarms.

Network access

Galvanicisolation

(100K)

I = 10 uA

Rs = (Vs / Vr) / RrefRs = (Vs / Vr) / Rref

Sensor (100K @ 25C)

Current source

T(K) = 1 / (A + B * Log(R) + C * Log3(R)) T(K) = 1 / (A + B * Log(R) + C * Log3(R))

Vr = 1.0 VVs = 1.36 V @ 18C

Vr = I * Rref

Vs = I * Rs

Current sources boardCurrent sources board

ELMB carrier board(2x redundant ELMBs)

MUX boardMUX board

SensorexcitationI = 10 uA

Sensorvoltage drop(V = 0.8 - 1.5V)

Ref.resistorvoltage drop (1V)

CANbus_1 CANbus_2

Eurocrate 6U

Sensor cablingEach 3-board assemblycan support max 32 sensors( = 3x EB SM)

PTM : Readout Based on ATLAS ELMB (Embedded Local Monitor Board)

see http://atlas.web.cern.ch/Atlas/GROUPS/DAQTRIG/DCS/ELMB/elmb.html

PTM : ELMB Plug-on Board

PTM : ELMB

Mother

40 ELMBs+6 MB bought

PTM : Tests with SM0Prototype: Sensor, probes, locations, readout scheme as described before

current sources

ELMB for 100k NTC (Betatherm)

ELMB for 10k NTC

ELMB for humid. sensors

PTM : example measurement

PTM, SM0, weekend of 24.8.03:

water OUT

water IN

on grid, module 4

precision =< 0.01 deg C !!

LV OFF

Humidity

Humidity Monitoring - HM

Humidity

Requirements:

monitor relative humidity level (RH) in a module issue software warning in case of critical reading

precision required : 5 % (on RH)

HM : Sensors

UPS-600 from Ohmic Instruments Co.

1 / Module, 4 / EB SM 4 / EE quadrant

Ceramic resistive humidity sensor

irradiation tests at IRRAD-2 : stable up to barrel doses, EE doses ongoing

market survey and selection together with Tracker DCS

HM : Readout

Same scheme as for PTM, based on ELMB: use ELMB in addition : Transmitter from Ohmic Instruments

signal conditioning circuit, sine wave RC oscillator, 440 Hz

150 mV RMS amplitude stabilizer, logarithmic amplifier, linearizer output voltage directly to ELMB : 1V - 3 V needs 5 V power supply to be checked : radiation tolerance

HM : Readout - Layout

ELMBELMB

transmitterstransmitters

PC / PVSSPC / PVSS

UXC55 balcony:4 + 2 DCS racks

Counting room

4x2 STP cables(44 + 2 sections)

CANbus cables(6x2 sections)

~ 200 sensors(relative humidity,resistive type, 5% RH)

Readout electronics:ELMB based;ELMB reads voltages andconverts to digital data, thensends data via CANbus.DC-DC converters

DC Power supplies

Monitoring application:PVSS based;data storage/archiving,visualization/trending,warnings/alarms.

Network access

Galvanicisolation

Sensor (RH - resistive)

Transmitter ELMB

V = 1.24 - 2.96 V (0% - 90% RH)

~150 mV440 Hz

Logarithmicamplifier

Oscillator;Freq --> DC

+5 VR = 200M - 2K (0% - 90% RH)

Log ADC

Transmitters boardTransmitters board

ELMB carrier board(2x redundant ELMBs)

MUX boardMUX board

Sensorexcitation(150 mV; 440 Hz)

voltage signal(1.24 - 3.96 V)

CANbus_1 CANbus_2

Eurocrate 6U

Sensor cabling

Each 3-board assemblycan support max 64 sensors( = 16x EB SM)

HM : Tests with SM0

first time, testing two sensors (UPS 500 and 600, from Ohmic Instr), rad.hardness tested up to barrel levels

both sensors in M4

readout scheme based on ELMB , together with transmitters on the rack

with SM0 : first tests, reading rel. humidity. Detailed data analysis to be awaited for after Serguei’s return

HM : Tests with SM0

18:0000:0006:0012:0018:0000:0006:0012:0018:0000:0006:0012:0018:0000:00

Degrees C

DATA_LOGGER: SM0 (H4) Humidity -- 25-30 Aug.03

N22 - ext N21 - int

18:0000:0006:0012:0018:0000:0006:0012:0018:0000:0006:0012:0018:0000:00

RH (%)

DATA_LOGGER: SM0 (H4) Humidity -- 25-30 Aug.03

UPS-500 - ch_01UPS-600 - ch_02

Cabling

Cabling inside a SM / Quadrant

A single twisted pair runs from each sensor to the patch panel.(After the patch panel two pairs, 4-wire connection, are foreseen for PTM)

Pairs count / cable length: PTM -- 10 pairs 1.5 – 4 m HM -- 4 pairs 1.5 – 4 m TSS -- 8 pairs 1.5 – 4 m

Cable type – the same for all three applications: Section 0.13 – 0.22 mm2. Rad.resistant insulation : For EB: PE ok; for EE : Kapton --> offer from Habia for more details see talk by S. Zelepoukine, TCG, 17.6.03

Patch panel connectors : the same type for all three applications: Rad.resistant insulation Crimping contacts Burndy Quickmate rectangular plastic connector; insulation/construction

material is nylon (PA)

Cabling Inside

Patch PanelPatch panel – EB SM / EE quadrant

24-pin 18-pin 12-pinBurndy Quickmatefemale

Burndy Quickmatemale

21x2 STPDia= 11mm04.21.51.410.5

4x2 STPDia= 5.8mm04.21.70.104.6

PTM TSS HM

10 sensors (4-w)

8 sensors (2-w)

4 sensors (2-w)

9x2 STPDia= 7.2mm04.21.51.405.2

Connectors

Cabling

Cabling outside a SM / Quadrant

Cable lengths: SM/Dee – balconies in UXC55:

27m for EB 25m for EE (according to W. Funk)

Balconies – counting room in USC55:100 m

Radiation resistance – PE cables can safely be used.

Cable type – STP (shielded twisted pair); 0.09 – 0.13mm2

Grounding – cable shield grounding point ??

Further details : see talk by S. Zelepoukine, TCG, 17.6.03

Cabling

from discussion with CMS integration group

Counting roomCMS

Barrel

Endcap

Barrel

Electronics

Cabling

Rack location

QA / Testing

Quality Assurance / Testing

QA / Testing Sensors/ Installation

simple resistance measurements immediately after installation full PTM , HM , TSS setups in Bld. 867 --> test of the full readout

ELMB rely on extensive work by ATLAS will do standard checks on all ELMBs

RBFE rely on extensive work by LHC cryogenics group delivery early 2004: all chips will be tested by them further checks by us on the TSS FE boards

Planning

rough indicatorsSensor probes, cables, connectors inside SM/Dee are designed 2003 (EB)(ECAL integration). later (EE/SE)

Sensor probes, cables, connectors inside SM/Dee are produced. 2003 (EB) later (EE/SE)

ECAL (EB/EE/SE) module production – installation of sensors. 2004 (EB)later (EE/SE)

Electronics (sensor transducers) is developed and tested (Rad/Mag). 2003-2004

Cabling and electronics location scheme outside EB/EE/SE 2003is designed (CMS integration).

Electronics (sensor transducers) production 2003 - 2004 later (EE/SE)

Cabling and electronics installation (underground cavern). 2004-2005Counting room – computers/electronics installation and testing.

Overall system testing and comissioning. 2005

Milestones (simplified)see also CMS DCS planning file

Conclusions

Hardware already important milestones passed this year several important orders placed already sensor installation in SMs started tests with SM0 encouraging close to readiness for mass production

Software important achievements this summer will adapt to software changes this winter/next spring

PTM : sensor irradation

Together with tracker DCS :

Neutron irradiation at IRRAD-2 facility during summer : Barrel dose reached no change in behaviour observed tests ongoing to go to EE levels

No. racks = 6

Applications: - precision temperature + humidity

EB rack: 9 x 10 = 90 ch. --> 2 ELMBs (prec.temp)9 x 4 = 36 ch. --> 1 ELMB (humidity)

EE rack: 4 x 10 = 40 ch --> 1 ELMB (prec.temp)4 x 4 = 16 ch --> 1 ELMB (humidity)

sub-total: 4 x 3 + 2 x 2 = 16Redundant ELMB config. ==> 16 x 2 = 32Total (incl. spares) = 32 + 8 = 40---------------------------------------------------If prec.temp and humidity can share ELMB:

EB rack: 90 + 36 = 126 ch --> 2 ELMBsEE rack: 40 + 16 = 56 ch --> 1 ELMBsub-total: 4 x 2 + 2 x 1 = 10redundancy: 10 x 2 = 20 Total (incl.spares): 20 + 8 = 28 --> 30

PTM : ELMB ordering

have bought : 40 ELMBs (+6 MB) as client to big order by ATLAS

Backup / Further Info

6.10.03, 9 - 12am

PTM, SM0, weekend of 24.8.03, on thermal screen:

24.8, afternoon

PTM, SM0, weekend of 24.8.03, on grid:

water IN, OUT and M4

M3M1+2

24.8, afternoon

PTM sensors probes

Delta T = 1 K(plate – air)

Delta T = 0.06 mK(sensor location)

Finite Element Model : A.Riabov (IHEP, Protvino)

ETH Zurich

IHEP Protvino

VINCA Belgrade

Project Leader: Guenther Dissertori (ETHZ)Deputy Leader: Serguei Zelepoukine (IHEP)

Project mgt, procurements,software (PVSS),participation in elec.development(in a collab. with IHEP)

Temperature/humidity monitoring,software (in a collab. with ETH)

Safety system interlockssoftware

Teams:

Project Organization

Part 1 – SM production testing/calibration of sensor assemblies (sensor probe + cable) installation of sensor assemblies in the detector (EB SM or EE Dee) testing of all installed sensors

Part 2 – Installation in CMS

laying down cables outside ECAL (a centralized activity)

mounting connectors on the cables outside of the detector

testing/calibration of the off-detector electronics (ELMBs, TSS FE boards)

installation of the off-detector electronics

installation of the electronics and computers in the counting room

connecting everything, powering on and final testing/commissioning

Planning

Strain gauges mostly for monitoring during installation after installation: read out required? What frequency? will be outside a SM

Radiation sensors should be overall CMS task. Exact location? We should have access to these

Hall probes (EE) see radiation sensors

Smoke detectors sniffer tubes inside SM. Sniffers to be installed by DSS group

Other ECAL sensors

G. Dissertori ETH Zürich 9.10.2003 ECAL ESR - DCS 1 ECAL Detector Control System G. Dissertori...

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