1 S. Lusin, LV Cabling, CERN 06 Apr 06 LV Cabling 06 Apr 06 S. Lusin Fermilab / CERN Cabling from...

1S. Lusin, LV Cabling, CERN 06 Apr 06

LV Cabling 06 Apr 06 LV Cabling 06 Apr 06

S. Lusin

Fermilab / CERN

Cabling from USC to UXC,Power Distribution


LV Cabling Issues …LV Cabling Issues …LV Project is responsible for supplying AC power to input of AC/DC

converters• For CAEN-based systems this means supplying power cabling to detector• For Weiner-based systems power is supplied to USC• Power cable chosen is 7x6mm^2, shielded, 23mm dia.

• Used for CAEN systems, Weiner systems & service power• Will be CERN stores item• 8 km on order

• Primary purpose is for installation in YE1, HF cable chain• Some cable will be available for magnet test

DCS cabling was subdetector responsibility• In the interest of system coherence & installation schedule, ESSC has

recently agreed to make DCS cabling design & procurement in cable chains for CAEN-bus systems an LV project responsibility

• Financial responsibilities still to be worked out with subsystems• Cable is 50-conductor twisted pair• Ends at detector patch panel

• “Standard” CERN stores cable for this purpose is not available in lengths that we need

• Alternate cable has been identified, at some cost savings, but needs termination by hand

• This should not be a problem. Cable counts are not large.


Cable SelectionCable Selection


Connectors US- UXConnectors US- UX

Simple, robust design• Can be used by all subsystems

Service power uses similar connector

• Smaller insert, prevents cross-plugging

Primary power, service power use same kind of cable

• Can be terminated in place


Patch panel connections Patch panel connections Matches 7x6mm^2 cable to 2 or 3 Harting connector outputs

Breakout box design has now been superseded by simple panel

Grounding braid termination not shown


On- Detector (UX-UX) Dist.

On- Detector (UX-UX) Dist.


Connectors at LVPS end …Connectors at LVPS end …Original motivation for quick-

connect system was modeled on LV distribution boxes used on standard rack power distribution units

• First deliveries of A3486 to B904 had standard three-phase plug (right)

• Needed modification to use 16A Harting connector (below)

• CMS environment will use 380 and 230V three-phase power

• Would like to introduce keying mechanism to prevent cross-plugging of AC-DC converters

• Working with POOL to have vendor implement keying


LV breakout boxesLV breakout boxes

Favored solutions are currently H & J• Needs to be coordinated with CERN POOL & CAEN


Service Power OptionsService Power Options

QuickTime™ and aTIFF (LZW) decompressor

are needed to see this picture.

QuickTime™ and aTIFF (LZW) decompressor


Local Cascade

EASY power supplies in hostile area have internal controls that are powered from external sourceThe external source is located in USC

• Original motivation was to provide battery backup for the control circuit in the hostile area• Each EASY module has a control board• Current requirements are:

• A3009- 650 mA• All others- 400 mA

• Adds up to a substantial current in a long cable


Service power budgetService power budgetIf all service

power provided from USC …

Service Power for Subsystems- CAEN EASY System only

service_voltage = 48.00service_current_module = 0.40service_current_a3009 = 0.65service_current_a4602 = 0.65service_current_a3486 = 0.40service_current_c10 = 0.65 cable cost 55.8mm^2 (CHF/m)= 3.58

cable cost 10mm^2 x 4= 7.20Baseline configuration: Service power supplies in USC

Detector

Model Quant. V I / module I total Power # 48V units # Pairs length size resistivity voltage power loss total cable total cable cableReq. drop (A/R) in cables length cross-section cost

V A A W m mm^2 Ohms/km V W m cm^2 CHF

Pixel-near FE A4603 28 48 0.40 11.2 538AC-DC A3486 2 48 0.40 0.8 38Total 12.0 576 0.2 1 50 55.8 0.505 0.6 7.3 100 2.3 358

Pixel-far FE A4603 28 48 0.40 11.2 538AC-DC A3486 2 48 0.40 0.8 38Total 12.0 576 0.2 1 150 55.8 0.505 1.8 21.8 300 2.3 1074

Tracker-near APV A4601 486 48 0.40 194.4 9331Control A4602 44 48 0.60 26.4 1267AC-DC A3486 20 48 0.40 8.0 384Total 228.8 10982 2.9 4 50 55.8 0.505 2.9 660.9 400 9.3 1432

Tracker-far APV A4601 486 48 0.40 194.4 9331Control A4602 44 48 0.60 26.4 1267AC-DC A3486 20 48 0.40 8.0 384Total 228.8 10982 2.9 10 150 55.8 0.505 3.5 793.1 3000 23.4 10740

ECAL N/A

ES Total A3025 50 48 0.40 20.0 960AC-DC A3486 12 48 0.40 4.8 230Total 24.8 1190 0.3 2 150 55.8 0.505 1.9 46.6 600 4.7 2148

HCAL RBX A3016 44 48 0.40 17.6 845AC-DC A3486 10 48 0.40 4.0 192Total 21.6 1037 0.3 2 150 55.8 0.505 1.6 35.3 600 4.7 2148

MB Power A3009 63 48 0.65 40.6 1950A3050 125 48 0.40 50.0 2400

S.C. A3100 10 48 0.40 4.0 192AC-DC A3486 60 48 0.40 24.0 1152Total 118.6 5694 1.5 6 150 55.8 0.505 3.0 355.3 1800 14.0 6444

RB RPC A3009 60 48 0.65 39.0 1872LBB A3016 40 48 0.40 16.0 768AC-DC A3486 40 48 0.40 16.0 768Total 71.0 3408 0.9 4 150 55.8 0.505 2.7 190.9 1200 9.3 4296

RE RPC A3009 108 48 0.65 70.2 3370LBB A3016 28 48 0.40 11.2 538AC-DC A3486 24 48 0.40 9.6 461Total 91.0 4368 1.1 4 150 55.8 0.505 3.4 313.6 1200 9.3 4296

ME Total A3486/c10 30 48 2.00 60.0 2880 0.8 4 150 55.8 0.505 2.3 136.4 1200 9.3 4296

Total 868.6 41694 10.9 38 1746.4 7100.0 63.1 25418.0

Modules Service Req. System Total Cabling

QuickTime™ and a decompressor


not including cable power dissipation



using ECAL cable as

reference (WF

16aug05)



quote from Champlain cable for 8 AWG x 4, shielded



assuming 80A loading on each unit



no packing factors applied


Service power budget - Remote

Service power budget - Remote

Service power supplies are on-detector …

Remote service power configuration: Service power supplies on-detector

Detector

Model Quant. V I / module I total Power # 48V units # Pairs length size resistivity voltage power loss total cable total cable cableReq. drop (A/R) in cables length cross-section cost

V A A W m mm^2 Ohms/km V W m cm^2 CHF

Pixel-near FE A4603 28 48 0.40 11.2 538AC-DC A3486 2 48 0.40 0.8 38Total 12.0 576 0.2 1 10 55.8 0.505 0.1 1.5 20 2.3 71.6

Pixel-far FE A4603 28 48 0.40 11.2 538AC-DC A3486 2 48 0.40 0.8 38Total 12.0 576 0.2 1 10 55.8 0.505 0.1 1.5 20 2.3 71.6

Tracker-near APV A4601 486 48 0.40 194.4 9331Control A4602 44 48 0.60 26.4 1267AC-DC A3486 20 48 0.40 8.0 384Total 228.8 10982 2.9 2 10 55.8 0.505 1.2 264.4 40 4.7 143.2

Tracker-far APV A4601 486 48 0.40 194.4 9331Control A4602 44 48 0.60 26.4 1267AC-DC A3486 20 48 0.40 8.0 384Total 228.8 10982 2.9 2 10 55.8 0.505 1.2 264.4 40 4.7 143.2

ECAL N/A

ES Total A3025 50 48 0.40 20.0 960AC-DC A3486 12 48 0.40 4.8 230Total 24.8 1190 0.3 1 15 55.8 0.505 0.4 9.3 30 2.3 107.4

HCAL RBX A3016 44 48 0.40 17.6 845AC-DC A3486 10 48 0.40 4.0 192Total 21.6 1037 0.3 1 15 55.8 0.505 0.3 7.1 30 2.3 107.4

MB Power A3009 63 48 0.65 40.6 1950A3050 125 48 0.40 50.0 2400

S.C. A3100 10 48 0.40 4.0 192AC-DC A3486 60 48 0.40 24.0 1152Total 118.6 5694 1.5 1 15 55.8 0.505 1.8 213.2 30 2.3 107.4

RB RPC A3009 60 48 0.65 39.0 1872LBB A3016 40 48 0.40 16.0 768AC-DC A3486 40 48 0.40 16.0 768Total 71.0 3408 0.9 1 15 55.8 0.505 1.1 76.4 30 2.3 107.4

RE RPC A3009 108 48 0.65 70.2 3370LBB A3016 28 48 0.40 11.2 538AC-DC A3486 24 48 0.40 9.6 461Total 91.0 4368 1.1 1 15 55.8 0.505 1.4 125.5 30 2.3 107.4

ME Total A3486/c10 30 48 2.00 60.0 2880 0.8 1 15 55.8 0.505 0.9 54.5 30 2.3 107.4

Total 868.6 41694 10.9 12 751.8 240.0 21.0 859.2




assuming 80A loading on each unit



not including cable power dissipation



no packing factors applied


Cascade Service PowerCascade Service Power

Total power dissipation in USC is 4.7 KW

Total power dissipation in cables is 308 W

• Assumes 10 mm^2 cable pair for ea. Subsystem (for approx. only)

Motivation for cascade power configuration is to minimize impact on shared services

Service Power for Subsystems- CAEN EASY System onlyProviding power to AC-DC converters only

Detector

Model Quant. V I / module I total Power # 48V units # Pairs length size resistivity voltageReq. drop (A/R)

V A A W m mm^2 Ohms/km V

Pixel FE A4603 32 48 0.00 0.0 0AC-DC A3486 4 48 0.40 1.6 77Total 1.6 77 0.0 2 50 10.8 2.551 0.2

Tracker APV A4601 972 48 0.00 0.0 0Control A4602 88 48 0.00 0.0 0AC-DC A3486 40 48 0.40 16.0 768Total 16.0 768 0.2 2 50 10.8 2.551 2.0

ECAL N/A

ES Total A3025 50 48 0.00 0.0 0AC-DC A3486 12 48 0.40 4.8 230Total 4.8 230 0.1 1 150 10.8 2.551 3.7

HCAL RBX A3016 44 48 0.00 0.0 0AC-DC A3486 10 48 0.40 4.0 192Total 4.0 192 0.1 1 150 10.8 2.551 3.1

MB Power A3009 63 48 0.00 0.0 0A3050 125 48 0.00 0.0 0

S.C. A3100 10 48 0.00 0.0 0AC-DC A3486 60 48 0.40 24.0 1152Total 24.0 1152 0.3 5 150 10.8 2.551 3.7

RB RPC A3009 60 48 0.00 0.0 0LBB A3016 40 48 0.00 0.0 0AC-DC A3486 40 48 0.40 16.0 768Total 16.0 768 0.2 4 150 10.8 2.551 3.1

RE RPC A3009 108 48 0.00 0.0 0LBB A3016 28 48 0.00 0.0 0AC-DC A3486 24 48 0.40 9.6 461Total 9.6 461 0.1 2 150 10.8 2.551 3.7

ME Total A3486/c10 30 48 0.65 19.5 936 0.2 4 150 10.8 2.551 3.7

Total 95.5 4776 1.2 21



Global LV PartitioningGlobal LV PartitioningMain UPS capacity is 1.5 MVA

• Contract is finalized, vendor is MGE• Installation design is under way

Six isolation transformers in USC• 300 KVA each, 380V or 230V three-

phase, no neutral• Dual electrostatic shields• Have to be partitioned out between

subsystems

Cabling imposes additional constraints

• No cable can be fed by more than one circuit breaker

• One circuit breaker can feed two triplets or three pairs

• One distribution cabinet can hold up to 35 circuit breakers

• Room for six cabinets available• May need more than that


Proposal for Coordination …Proposal for

Coordination …

1 S. Lusin, LV Cabling, CERN 06 Apr 06 LV Cabling 06 Apr 06 S. Lusin Fermilab / CERN Cabling from...

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