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BI Seminar 22 February 2013 Beam Loss Monitoring Section William Vigano’

Redundant Power Supply structure and Single Failure Tolerant power connection for Crate applications. BI Seminar 22 February 2013 Beam Loss Monitoring Section William Vigano’. Presentation Objectives. 1) Introduction of a “single failure tolerant” power supply structure.

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BI Seminar 22 February 2013 Beam Loss Monitoring Section William Vigano’

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  1. Redundant Power Supply structure and Single Failure Tolerant power connection for Crate applications. BI Seminar 22 February 2013 Beam Loss Monitoring Section William Vigano’ william.vigano@cern.ch

  2. Presentation Objectives 1) Introduction of a “single failure tolerant” power supply structure. 2) Manage the diagnosis for cable connections and Power Supply statuses. 3) Replace Resettable Fuses with Circuit Breakers: a) To improve the current threshold tolerance. b) To improve the current cut timing. 4) Maintain the possibility for optional use of the Redundant Power Supply. william.vigano@cern.ch

  3. Block Diagram 19’ CRATE Backplane Main Power Supply Unit Power Interface Circuit Breaker #1 Card #1 Available Power Supply Circuit Breaker Circuit Breaker #2 Card #2 Redundant Power Supply Unit Cable Connection Diagnostic Current Consumption Main PSU Current Consumption Redundant PSU Card #n Circuit Breaker #n Multiple Cable Connection Control Unit william.vigano@cern.ch

  4. Failure Mode Analysis Concepts • Failure mode and effect analysis (FMEA) is the first step of a system reliability study. • An FMEA is an inductive failure analysis. • An FMEA activity helps to identify potential failure modes based on experience with similar products. • A FMEA is also used to structure Mitigation for Risk reduction. • Failure probability can be reduced by understanding the failure mechanism and reducing or eliminating the (root) causes. william.vigano@cern.ch

  5. Power Interface Block Diagram Power Interface Diagnostic Interface Diagnostic Interface Connector 1 Connector 2 Main Power Supply Unit Fast-On A Fast-On A Current Consumption Measurement Current Consumption Measurement Available Power Supply Fast-On B Fast-On B Fast-On C Fast-On C Jumper Redundant Power Supply Unit william.vigano@cern.ch

  6. Power Interface Failure Modes Power Interface Diagnostic Interface Diagnostic Interface Main Power Supply Unit FAILURE Connector 1 Connector 2 Fast-On A Fast-On A Current Consumption Measurement Current Consumption Measurement Available Power Supply Fast-On B Fast-On B Fast-On C Fast-On C Jumper Redundant Power Supply Unit The structure above allows to guarantee the availability of the Power Supply, also with a diode in short circuit condition AND a Power Supply in failure. william.vigano@cern.ch

  7. Power Interface Failure Modes Power Interface Diagnostic Interface Diagnostic Interface Main Power Supply Unit Connector 1 Connector 2 Fast-On A Fast-On A Current Consumption Measurement Current Consumption Measurement Available Power Supply Fast-On B Fast-On B Fast-On C Fast-On C Jumper Redundant Power Supply Unit Nothing happen if a diode is broken. Possible failures are diagnosed. william.vigano@cern.ch

  8. Maintenance Plan Example Power Interface Diagnostic Interface Diagnostic Interface Connector 1 Connector 2 Main Power Supply Unit Fast-On A Fast-On A Current Consumption Measurement Current Consumption Measurement Available Power Supply Fast-On B Fast-On B Fast-On C Fast-On C Jumper Redundant Power Supply Unit It is not possible to make automatic diagnostic of these diodes, so their check is part of the Maintenance Plan (otherwise we are in the «Sleeping Failure Case>>). william.vigano@cern.ch

  9. 48VDC Power Interface Electrical Circuits Input Connectors Current Monitors Gnd Connectors Jumper MTBF = 2 × 10 7 @ 40°C (MIL-HDBK-217 Calculation) MTBF = 4.8 × 10 10@ 40°C (Supplier Calculation) Diagnosis Interface The T5 Collector is connected to a pull-up on the FPGA (or µC) I/O, so if the power line fails, the T5 driving is released and the failure is detected. Note: 20 years correspond to 1,752 × 10 5 william.vigano@cern.ch

  10. Circuit Breaker Block Diagram 50mohm (to limit the Drop Out voltage) Available Power Supply (e.g.48VDC) Circuit Breaker Over Voltage Protection Shunt Switch Output To the Cards in the Crate Enable Auto-Retry Circuit Breaker 60V max • The Current flowing from the Input to the Output creates a Voltage Drop on the Shunt. The Voltage Drop is compared inside the Circuit Breaker against an Interal Voltage Comparator. If the threshold is excedeed, the Circuit Breaker disables the Switch • The Circuit Breaker controls the Load In-Rush current, regulating the power-up ramp. william.vigano@cern.ch

  11. +9V to 60V Circuit Breaker @ 1Amp MTBF = 3.45 × 10 8 @ 55°C (Supplier Calculation) MTBF = 2.15 × 10 8 @ 55°C (MIL-HDBK-217 Calculation) 1 MTBF = 1.55 × 10 7 @ 40°C (MIL-HDBK-217 Calculation) TPS2491DGS has Automatic Retry: as soon the over current is removed, the output power supply is available. william.vigano@cern.ch

  12. Circuit Breaker Failure Modes The Shunt short circuit condition is the 3% of the global calculated MTBF, so it is really rare (>1010 working hours). If the Shunt is open, the output voltage is not available. The N-Mosfet is driven by means of a Charge-Pump, so if the Ciruit Breakers Fails, the Load is Disabled (safe failure). 1 If components dedicated to settings fail, the Circuit Breaker is not anymore compatble with the In-Rush current, but the Trip Current does not change because it depends to the Shunt + Inner Comparator. william.vigano@cern.ch

  13. PCB Implementation Diode connections for redundant power supply connections Circuit Breakers 2,5 cm 5 cm 4 cm Current Monitors 2 cm william.vigano@cern.ch

  14. Crate Implementation Circuit Breaker Feedbacks Power Supplies Connection Feedback william.vigano@cern.ch

  15. Additional Notes 1) The schematic has been optimized for 48VDC @ 200Watt. 2) To prevent Common Mode Failures it is better select different types and / or suppliers for the Power Supplies. 3) The current supply measurement resolution with a 12 Bit ADC and VREF = 2,048VDC is => 2,5mA / Bit. (I max = 10,24 Amp) 4) When the Jumper is connected, the current path depends on the Diode’s VF (forward voltage). 5) The Jumper is used to maintain the “single failure tolerance” capability of the circuit when only one Power Supply is connected. 6) The current is always taken from the Power Supply with higher value. william.vigano@cern.ch

  16. Thank you for your attention! william.vigano@cern.ch

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