Post on 11-Jan-2016
TF Joint Voltage DropInstrumentation
Robert Marsala (609) 243-2507Hans Schneider(609) 243-2017
Engineering OperationsAugust 7, 2003TF_JOINT_Final_Design_Review.ppt
Bob Marsala, Hans SchneiderEngineering Operations
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Voltage Drop Measurement Plan
• Instrumentation Must be Capable of the Following– Maintenance Testing
• Inject up to +/-220A into TF Coil and Measure the Voltage Drop at Every Joint
– Operational Testing• Measure the Voltage Drop at Every TF Joint During an Actual Shot
at Up to 72KA
– Common• Computation or Resistance, Trending, Alarms, Warnings
Bob Marsala, Hans SchneiderEngineering Operations
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System Block Diagram
EPICSR=V/I (at 72kA or 200A)
Agilent 6671A220A @ 8V
1N4047275A200V
PolaritySwitching
Relay
Transorbs450J 50kA
340V200A
1 Ohm275W
Shunt40mV
@ 200A
CAMACCRATE
96Channels
ADC
#24AWG Two Twisted PairTeflon (1500V Between Conductors)Tefzel Outer Insulation(Spark Test to 10kV)
Voltage Dropx 72
Strainx TBD
Instrumentation Rack
Manual Control
Gain 72kA or 200A
Two Twisted Pair Per Flag
Shunt Voltage
TF Power SupplyHalmar Current
DisconnectSwitch
Bob Marsala, Hans SchneiderEngineering Operations
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TF Joint Voltage Measurement Components
• 2 Voltage Probes on Each TF Joint
• Cables from all Probes (144) to Racks
• Instrumentation Consisting of– Quick Disconnect Panel– Isolated Programmable Gain Amplifier– CAMAC Transient Digitizer
• 200 A Source Hardware and Switch
Bob Marsala, Hans SchneiderEngineering Operations
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TF Flag Joint Voltage Probes
Two Probes per Joint 144 Potential Data Points
Two Coax ProbesTo Measure
Voltage Drop
Bob Marsala, Hans SchneiderEngineering Operations
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Probe Detail
Probe Terminated in a SMB Connector
Near Flag
Bob Marsala, Hans SchneiderEngineering Operations
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Cable
• Janor Wire & Cable Corp• 2 Twisted Pairs per Cable with Overall Jacket
– One TP for Each of the Two Probes on a Joint
• #24 Conductors• ETFE Insulation• 10KV Isolation from Conductor to Outer Jacket• Terminations
– Flag End: SMB Mating Cable Spliced to Cable– Rack End: 4 Pin Locking Tripeg Molex Connector
Bob Marsala, Hans SchneiderEngineering Operations
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Instrumentation
• Located in Two Racks on Midplane Level• Consists of
– Mother Boards (6)
– Quick Disconnect (12)
– Programmable Gain Isolation Amplifier (72)
– CAMAC Crate with Transient Digitizers
– Power Supplies
– 200A Source and Control
Bob Marsala, Hans SchneiderEngineering Operations
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Quick Disconnect Modules
• Channels Can be Quickly Disconnected from the Amplifiers
• 6 Channels (12 Probes) Serviced by each of 12 Disconnects
• Uses Properly Spaced Banana Jacks on Mother Board and Banana Plugs on Disconnect Module
Bob Marsala, Hans SchneiderEngineering Operations
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Quick Disconnect
BananaPlugs
MotherBoard
DisconnectBoard
BananaJacks
Bob Marsala, Hans SchneiderEngineering Operations
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Programmable Gain Isolation Amplifier
• Amplifies and Isolates Voltage Across Joint• 12 Boards per Mother Board, 6 Mother Boards = 72 Boards• 5000V Isolation between Input and Output• Two Gain Stages (Each having a Gain of 1, 10, 100 or 1k)
followed by Unity Gain Isolation Amplifier • Overall Gain from 1 to 1 Million Controlled by Two Rotary
Switches on Control Panel– Nominal Gain: 100 for 72kA, 10,000 or 100,000 for 200A
• Board Designed to Measure Voltages from Both Probes of a Joint, but only Parts for One Probe are Installed (Cost)
Bob Marsala, Hans SchneiderEngineering Operations
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Summary• 2 Voltage Probes on Each TF Joint
• Cables from all Probes (144) to Instrumentation Racks
• Quick Disconnects Provided to Open Probe to Amplifier Connections
• Capable of 72kA Operation or 200A Maintenance Operation
• One Probe from Each Joint is Monitored
• Isolation to 5000V
• CAMAC Data Acquisition
• EPICS Used for Calculations, Trending, Alarms and Warnings
Bob Marsala, Hans SchneiderEngineering Operations
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Resistance Measurement System Benefits
• All 72 Joints Monitored at 200A and 72kA– Manual 200A & Automated 72kA Measurements
• Expandable & Upgradeable– Measure All 144 Probes & Automate 200A Measurements
• CAMAC Digitizer Upgraded to PCI Digitizer
– Addition of Strain Measurements• Design Signal Conditioning/Amp/Iso Board
• Least Cost (M&S) and Effort (Manweeks) System– Combo Amp/Iso Board Designed and Being Tested
– CAMAC Crate and 908 Digitizers Available
Bob Marsala, Hans SchneiderEngineering Operations
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Mother Board• Each Mother Board Services 12 Joints (24 Probes)• 6 Mother Boards Mounted in Rack
– 3 Accessible from Front of Rack and 3 from Rear– Expansion to 8 Mother Boards is Provided (Strain or
Displacement)
• Only One Probe from a Joint is Actively Monitored– Capable of Expansion to Actively Monitor Both Probes
• Active Probe can be Selected by Plugging Cable Connector into a Second Connector on the Mother Board
Bob Marsala, Hans SchneiderEngineering Operations
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Mother BoardSamtec SSW-120-01-G-D)mate TSS-120-04-G-D-RA
1
1.062
1.062
.531
1.250
2.000
2.000
70555-0073mate: 50-57-9404Molexref Pg 505/6Mouser 613
Amp 1-380999-0 mate: 1-480270-0
1.250
1.250
1.250
1.250
1.250
2.250 17.000
1.250
1.250
1.250
1.250
1.250
5.000
0.328 diameter
Samtec SSW-105-01-G-mate: TSS-105-04-G-D-RA
16.000
1
D9S
Bob Marsala, Hans SchneiderEngineering Operations
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Iso-Amplifier Schematic
+15V2
U4BUF634/SO
3 6
7
4 1
-15V1
+24V
U2PGA204/SO
4
5
11
12
15
16
13
8
10
1
9
6 7
14
VIN-
VIN+
VO
SENSE
A0
A1
+VCC
-VCC
REF
VO1
VO2
VOSADJ
VOSADJ
Dig Gnd
J3
JUMPER
1
2
TP7
1
need 5ma
TP1
1
R12250k
Ret 2
R7249
+24V Return
+15V1
U1A0
+
C22
1uF@25V
Offset
+
C2322uF@35V
X1 Isolation AmpTP3
1
C90.01
R162k
C30.01
C160.01
U1PGA204/SO
4
5
11
12
1516
13
8
10
1
9
6 7
14
VIN-
VIN+
VO
SENSE
A0A1
+VCC
-VCC
REF
VO1
VO2
VOSADJ
VOSADJ
Dig Gnd
R8
10k
-15V2
R1510k
R1110k
U5T2-2D2415EH
15
1011
13
12
2324
+Vout
Out ComOut Com
-Vout
+Vin+Vin
-Vin-Vin
TP4
1+
C151uF@25V
U2A1
-15V1
+V1/-V1 Com
R5250k
5KV IsolationBarrier
C110.01
C100.01
J4
JUMPER
1
2 Dc/DC Conv
C10.001
U1A1
C50.01
+
C7
1uF@25V
U6
OPI1264C
2
1
4
3
U3ISO121BG
39
4020
38
19
18
2
1
22
21
3 23
4 24
37
17
VIN
GND2GND1
EXTOSC
SENSE
VOUT
C1-
C1+
C2-
C2+
+VS1
+VS2
-VS1
-VS2
COM1
COM2
R9
10k
J1
HEADER 5X2
246810
13579
+V2/-V2 Com
U8
OPI1264C
2
1
4
3
C60.01
C170.01
J6
JUMPER
1
2
U7
OPI1264C
2
1
4
3
R31M
+15V2
+C4
1uF@25V
R1010k
+V1/-V1 Com
+ C1922uF@35V
-15V2
X1,10,100,1000Amplifier
C140.01
U9
OPI1264C
2
1
4
3
C12.001
C210.01
R6
249
TP6
1
J5
JUMPER
1
2
R1
10k 1% 10,00VDC 5W (M750)
R13
10k
U2A0
-15V1
C80.01
R1410k
X1 Buffer
+ C2422uF@35V
C20.001
Input 2+
R41M
C20.0022
Input 2-
J2
HEADER 20X2
246810121416182022242628303234363840
13579111315171921232527293133353739
+15V1
Input 2-
R1751
Input 2+
R210k 1% 10,00VDC 5W (M750)
Out 2
+V2/-V2 Com
TP2
1
TP5
1
+C18
1uF@25V
+C13
1uF@25V
800 Hz Filter
Bob Marsala, Hans SchneiderEngineering Operations
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CAMAC Crate
• CAMAC Crate with 3-908 Transient Digitizers Used to Store Voltage and Current Data
• EPICS Used to Calculate Resistance and for Trending/Status/Alarms
• Memory/Sample Rate TBD
Bob Marsala, Hans SchneiderEngineering Operations
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Programmable Gain IsolationAmplifier Layout
Input Connector
Input Resistors
PG Amps
Isolation AmpBuffer
Opto Couplers
DC/DC Conv
Output and Control Connector
5000
V B
arri
er
Bob Marsala, Hans SchneiderEngineering Operations
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Power Supplies
• All Programmable Gain Isolation Amplifiers Powered by +/- 15V Linear Supplies (2) for Ground Referenced Output and +24V Linear Supplies (2) for DC/DC Converters
Bob Marsala, Hans SchneiderEngineering Operations
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200A Supply and Control
• Supply– Agilent 6671A– 220A @ 8V
• Control and Protection– Current Programmed via Pot on Control Panel– Polarity Switching Relays Controlled from Control Panel– Interlock to Prevent Switching of Polarity while Current
is Flowing in TF Coil– Protection Incase of Open Circuit
• Interlocked Switch to Apply 200A to TF Bus