Safety Review Document for the ADF Crates in the D-Zero Run IIB Level 1 Calorimeter Trigger --------------------------------------------------- Rev. Date 3-AUG-2005 This documentation covers the 4 ADF Crates in the new Run IIB Level 1 Calorimeter Trigger System. The contact person for the ADF Crates is: Dan Edmunds Fermi Phone: x2832 MSU Phone: 517-355-9200 x2521 Email: edmunds@pa.msu.edu The 4 ADF Crates in the Run IIB Level 1 Calorimeter Trigger System are located in the 1st floor of the D-Zero Moving Counting House. There is one ADF Crate in each of the following racks: M104, M106, M109, M111. This document is primarily written to provide information about the ADF Crates as they are used in the fully assembled Run IIB Level 1 Calorimeter Trigger System in the Moving Counting House. In addition, 2 ADF Crates will be used during the summer and fall of 2005 in the commissioning area for this system on the "sidewalk" next to the Moving Counting House. As used in this commissioning area the ADF Crates will be setup in the same way as they will be installed in the finished system. Specifically, both on the sidewalk and as installed in the finished system in the Moving Counting House, the AC input power to the ADF Crate is controlled by a standard Fermi D-Zero Rack Monitor. The ADF Crate itself is a commercial unit made by Wiener. It is their type UEV 6023 crate with their type UEL 6020 LX fan tray and type UEP 6021 power supply chassis. This equipment has the TUV and IEC regulatory certificates. This crate holds electronics cards that are 6U tall and it has a VME64-X type backplane. The 4 racks that hold the ADF crates are protected by standard Fermi D-Zero Rack Monitors. These monitors include smoke and water leak protection. Detection of a fault condition in a given rack drops the AC input power to the ADF Crate in that rack. Cooling in each rack is provided by an air to water heat exchanger. This heat exchanger is located below all of the active electronics in the rack. Air is pushed through this heat exchanger by a fan tray which is mounted under it and holds 9 fans. The ADF Crate holds all of the active electronics in each of these racks. The air flow through the ADF Crate itself is provided by a fan tray that is part of the Wiener crate assembly. The operation of the 3 fans in the crate's fan tray and the air temperature in the crate are monitored by the built in monitoring system in the crate. Information from this built in monitoring system is sent, via CAN Bus, to the D-Zero Significant Event System (Alarm System). The monitor system built into the crate will shut it down if the air temperature is over the set limit or if a fan fails. The total heat dissipated by the electronics in each of the ADF Crates is less than 700 Watts. In the ADF Crates no DC power is brought out external to the ADF Crates themselves. Each ADF Crate has the following set of connections: CAN Bus connection for monitoring (1x) Vertical Interconnect connection for control & download (1x) SCLD connection (LVDS) for timing signals (1x) ADF to TAB connection (LVDS) for sending Et data to TABs (60x) BLS analog input signals to the ADF-2 cards (640x) All of these connections are "signal level" connections and none of them can provide a substantial amount of current. With the ATC cards (described below) installed in the back of the ADF Crate backplane all of the high current DC buses are effectively covered up. No one could reach in and accidently touch a ring or something across a DC bus. There are only 3 types of cards used in the ADF Crates. These 3 types of cards are: ATC, Vertical Interconnect, ADF-2. ATC In each ADF Crate there are 20 ATC cards used on the back side of the backplane. ATC stands for "ADF Transition Card". The ATC does not make any connections to the crate's power buses. No power is brought onto the ATC card. The ATC card only makes input and output connections to signal cables. Vertical Interconnect In each ADF Crate there is one Vertical Interconnect card in slot number 1. The Vertical Interconnect card was designed and manufactured by Fermilab and will not be described in detail in this note. There is a description of the Vertical Interconnect on the web at: www-linac.fnal.gov/LINAC/hardware/vmesys/boards/vi/viInfo.html ADF-2 In each ADF Crate there are 20 ADF-2 cards used in slots 2 through 21. ADF-2 stands for "ADC and Digital Filter version 2". Each ADF-2 card makes power supply connections to the: +3.3V, +5V, +12V, and -12V VME backplane busses. The number of pins used by the ADF-2 card to make connection to each of these busses is shown in the following table along with the size of of the fuse used on that bus. Backplane Number of Pins Used Bus Connection for this Connection Fuse Rating -------------- ------------------- ----------- +3.3 V 10 pins 3 Amps +5.0 V 6 pins 3 Amps +12.0 V 1 pin 2 Amps -12.0 V 1 pin 2 Amps GROUND 47 pins As they are brought onto the ADF-2 card, each power supply bus passes through a fuse before it reaches any other components. All pins used to bring a given power supply bus onto the ADF-2 card are connected to a small isolated section of a circuit board power plane. The only other connection to that isolated section of power plane is the input to that supply's fuse. After its fuse, each power supply bus has a transit voltage suppressor and a bulk filter capacitor before entering the electronics area of the card. The fuses used are Littelfuse Part No. R154003T. Copies of the actual films used to manufacture the ADF-2 circuit can be seen on the web in the following directory: www.pa.msu.edu/hep/d0/ftp/run2b/l1cal/hardware/adf_2/manufacturing/ Filename Shows the Power Bus Connection for ------------------- ---------------------------------------------- adf2_film13_l3.gif shows one of the two equivalent Ground planes. adf2_film12_l4.gif +5V is collected from 6 pins and routed to its fuse by the strip along the right hand edge of the card. adf2_film07_l9.gif +3.3V is collected from 10 pins and routed to its fuse by the strip along the right hand edge of the card. adf2_film04_bot.gif The +12V and -12V VME Buses are routed adf2_film05_l11.gif directly to their fuses by thick traces at the right hand side of these layers. Each bus is carried by a thick trace on each of these two layers. These films can be studied to verify that each power supply bus passes through a fuse before connecting to any other components on the ADF-2 card. A photograph of the ADF-2 card can be see on the web at: www.pa.msu.edu/hep/d0/ftp/run2b/l1cal/hardware/adf_2/pictures/ in the file: adf2_front.jpg The 4 power input fuses on the ADF-2 card can be seen along the right hand edge in this photograph.