CB-Fan Card Cost Estimate ----------------------------- Rev. 4-NOV-2011 This is a draft sketch for doing the CB-Fan card. This is not based on a real design or on studying the best way to accomplish the required functions. This is based on just looking up the prices of parts that I know could accomplish the required functions. My current understanding of the CB-Fan Card is: - From an H-Clk card receive one copy of: CRST, TRG, CLR, CLK, L2A, and L2R. Fan out these 6 signals as LVDS to 16 CBs. - Receive from 16 CBs the BUSY-1 and BUSY-2 signals as LVDS signal levels and send them to two 16 bit wide GPIO ports on the H-Clk card. - The 8 signals in each of the 16 CBs are organized on the CB-Fan card's connectors in the same order as on the CAEN TDC card. - Provide for translation of all 16 CBs from LVDS level to the ECL level that is used on the CAEN TDC CB. - From an H-Clk card receive one copy of the "DAQ Computers Please Readout Now" signal and fan this out 16 ways at LVDS level with all 16 copies on one 34 pin header. - Between a pair of standard 34 pin headers provide for either ECL-->LVDS conversion or LVDS-->ECL conversion. CB-Fan card: Semiconductors: Clk/Ctrl Fanout to 16 LVDS CBs 12 parts $ 93 per card Convert 16 LVDS CBs to ECL 192 parts $ 1117 " Fanout 16 DAQ Computers Readout 2 parts $ 16 Convert 16 signals ECL-->LVDS 24 parts $ 147 " or Convert 16 signals LVDS-->ECL 24 parts $ 138 " LEDs, TVSs, Diodes 5 parts $ 5 " ------------------ $ 1358 per card Connectors: VME Backplane 2 parts $ 41 per card 16 pin 2x8 0.1" 0.1" header 1 part $ 3 " 34 pin 2x17 0.1" 0.1" header 6 parts $ 16 " 50 pin 2x25 0.1" 0.1" header 5 parts $ 16 " ------------------ $ 73 per card Passives: Tantalum Caps 12 parts $ 28 per card Aluminum Caps 4 parts $ 4 " SMD Chip Resistors 256 parts $ 26 " SMD Chip Capacitors 500 parts $ 50 " Fuses and Blocks 2 parts $ 4 " ----------------- $ 112 per card On Card Power Supplies: -3.3V >5A 1 parts $ 25 per card -2V >5A 1 parts $ 25 " ------------------ $ 50 per card Hardware: VME front panel kit 1 part $ 21 per card Machine Shop Work 1 part $ 25 " Silkscreen Work 1 part $ 5 " ------------------ $ 51 per card Circuit Board: Raw PCB 6 layer 160x233mm 1 part $ 123 per card PBC Mfg Setup Costs 1 part $ 275 one time cost ------------------ $ 123 per card plus $ 275 one time cost Assembly Services: 1011 Comps mixed SMD THD 1 part $ 250 per card Paste Stencils 1 part $ 650 one time cost ------------------ $ 190 per card plus $ 650 one time cost ---> CB-Fan card total: $ 2036 per card plus $ 925 one time costs Draft Sketch of Power Consumption in the LVDS <--> ECL conversion Per Signal: ECL receivers take about 10 mA Vcc and 12 mA Vee ECL drivers take about 2 mA Vcc and 30 mA Vee ECL terminator takes about 25 mA Vtt A Control Bus is: Receive 2 signals, Drive 6 signals 16 ECL Control Buses --> 0.51 A Vcc 2.4 A Vtt 3.3 A Vee 16 ECL Control Buses will require about 17.5 Watts for the conversion to/from LVDS. This just covers the 16 CBs - there is a little more for the 16 generic ECL-->LVDS or LVDS-->ECL signals Alternate ECL Parts 5-NOV-2011 --------------------------------- The above draft cost estimate sketch was based on using current active production Motorola (On-Semi) ECL parts. About 80% of the cost of making the ECL version of the Control Bus is in these ECL parts. Characteristics of these current production parts: 1 channel per chip about 18 sq mm per chip in the TSOP package about 73 mW per receiver channel about 106 mW per driver channel An alternative would be to use no longer in production 300K series Fairchild ECL parts that we have in stock. Characteristics of these no longer in production parts: 6 channels per chip about 33 sq mm per channel in the PCC-28 package about 58 mW per receiver channel about 85 mW per driver channel We used these Fairchild 300K parts in equipment that we built for D-Zero Run II. Differential ECL was used for signalling between cards in that equipment because LVDS was not yet actually available (or not yet fast enough). We ran about 6,345 of these hex ECL chips in that equipment for 12 years with zero failures. The 300K Fairchild parts are slower than the above current production Motorola parts but they are clearly fast enough for the HAWC application, i.e. about 1 nsec typical propagation delay and about 0.6 nsec maximum skew. The generic twist and flat cable has very significant attenuation at the 1 nsec level and more skew than this - even is short lengths. In any case the CAEN TDC card is using an even older and slower chip to receive the ECL Control Bus (a Motorola 10H part). In Stock I have about 1,000 of both the hex receiver chips and of the hex driver chips. I have a full un-touched reel of both receivers and drivers (750 parts per reel) and a partial reel of each. Making 16 ECL Control Busses requires about 16 of these hex ECL driver chips and about 6 of these hex ECL receiver chips. Converting 16 generic signals to/from ECL requires either 3 driver or 3 receiver chips. There are alternative current production ECL parts available from Motorola to those that I used in the 4-NOV-2001 version of the cost estimate. These are older slower parts in a less compact package and they use more power but they are only about 1/4 the cost per channel. It's not possible to make an accurate cost estimate until there is a serious design of the CB-Fan card.