P3K Infrastructure – July 19, 2010P3K Infrastructure I&T 9-22-10

P3K Palomar Infrastructure

Balance AdaptationsLarger Cass weight load from instrument & electronics

Electrical Service UpgradesHigher electric service requirements at Cass, Computer

Room and AO Lab

Cooling of Cass Electronic RacksRemoval of ~6 kW of heat from below primary mirror

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P3K Infrastructure – July 19, 2010P3K Infrastructure I&T 9-22-10

Cass Mounted System Weights

Current AO Cass System Weights

AO Bench3820 lbs

AO Rack 1 415 lbs

AO Rack 2 345 lbs

Cables 85 lbs

AO System Total 4665 lbs

With Heaviest AO Instrument

P1640 340 lbs P1640 elec.

400 lbs

Total w/ Instrument 5405 lbs

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P3K AO Cass System Weights P3K Bench 3900 lb P3K DM rack 1 525 lb P3K DM rack 2 525 lb P3K Ctrl rack 1 258 lb P3K Ctrl rack 2 348 lb Cables 475 lb Glycol system 260 lb

AO System Total 6291 lb

With Heaviest AO Instrument P1640 / Cal 380 lbs (est) P1640/ Cal elec. 450 lbs (est)

Total w/ Instrument 7120 lbs

~1700 lbs more than current maximum

P3K Infrastructure – July 19, 2010P3K Infrastructure I&T 9-22-10

P3K Cass mounted component weights exceed current balance adjustments via moving counterweights

New balance adaptations required:

1. Additional ~700 lbs of lead added to weight boxes on Tube upper ring

2. Implementation of up to three ‘dummy’ electronic cabinets: 2 cabinets loaded with 475 lbs of weight, the third with ~200-300lbs To be applied with lower weight Cass instrument / electronic

configurations

Status: Design concept complete.

Risks: Additional load on tube may effect telescope pointing model.

No structural concerns have been identified.

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Balance Adaptations

P3K Infrastructure – July 19, 2010P3K Infrastructure I&T 9-22-10

Electrical Service Upgrades

Power Requirements Computer Room Electronics (2 Racks)

Total Rated Power : 11,870 W Total measured continuous measured: 3500 W Continuous + Intermittent measured: 5400 W

Cass Cage mounted Electronics (4 Racks)

Total Rated Power: 8900 W Total continuous measured: 6250 W Continuous + Intermittent measured: 7210 W Current AO system measured: 1035 W

• Highest power AO instrument P1640 ~ 500W• P1640 Cal power TBD

Chiller in Coude 220 V / 3 Phase / 42 amp service ~ 10,000 W

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P3K Infrastructure – July 19, 2010P3K Infrastructure I&T 9-22-10

Required Electrical Upgrades Computer Room Electronics

Add 3x 120V / 30 Amp Receptacles (ready for connection)

Cass Cage Add 3x 120V / 30 Amp Receptacles Add Load Center in Cass Cage Insufficient paired conductors available in exiting wrap-up to provide

required power (electromagnetic field cancellation concerns)» A new, auxiliary wrap-up will be used to bring required power to Cass» This auxiliary wrap-up will also be used to & from transport glycol to Cass

AO Lab Add 3x 120V / 30 Amp Receptacles, Contactors (ready for connection)

Coude (Chiller location)

Add Breakers, Disc. contactors, and Junction Box

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Electrical Service Upgrades

P3K Infrastructure – July 19, 2010P3K Infrastructure I&T 9-22-10

Power Dissipation / Mirror Temperature

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13M

irro

r Tem

pera

ture

(ºC)

Month/Day: UT Time

200" Mirror Temperature

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E

SE

S

SW

W

NW

AO power on AO power off

CO2 cleaningcaused rapid cooling

24 hour data gap

Sensor Location

Current AO power ~ 1000 W

P3K Infrastructure – July 19, 2010P3K Infrastructure I&T 9-22-10

Cass Rack Power Allocation

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RACK ID

MEASURED CONTINUOUS

POWER (W)

MEASURED Intermittent

POWER(W)

DM 1 2,420 2,420DM 2 2,420 2,420

Cass 1 1,270 1,270Cass 2 140 1,080

Total 6,250 7,210

These racks to be cooled~6100 W

P3K Infrastructure – July 19, 2010P3K Infrastructure I&T 9-22-10

Cooling System Functional Parameters

Basic Functional Requirement Provide system for cooling of Cass mounted electronics in order to

minimize the heat dissipated to environment below the primary mirror and dome air.

Operating parameters: Ambient temperature range: -10ºC to +30ºC Target Coolant temperature: 3ºC below ambient Cooling fan air flow: Constant speed Coolant Mix: 35% Propylene Glycol Coolant Temperature Range: -13ºC to +27ºC Facility Chilled water temp: 5ºC to 10ºC (seasonal range)

Thermal modeling of electronic rack heat exchangers by Thermatron to confirm heat exchanger design within proposed operating parameters and define performance requirement of chiller

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P3K Infrastructure – July 19, 2010P3K Infrastructure I&T 9-22-10

Chiller Specification

Requirements for Cass Electronics Cooling Total heat load: 6100 W Max. coolant flow rate: 16 GPM

» DM Racks: 3x 2 gpm x 2 Racks = 12 gpm» Cass 1 Rack: 2x 2 gpm x 1 Rack = 4 gpm

Coldest required supply coolant temp: -13ºC (3º below lowest ambient) Warmest required supply coolant temp: +27ºC (3º below highest ambient)

Chiller Construction / Installation for Cass instrument cooling Water cooled chiller: exhaust chiller heat through facility chilled water 7.5 ton capacity chiller from Opti-temp to be installed in Coude lab

» Delivery scheduled for Oct 4, 2010

Chiller Construction / Installation for AO Lab: Acquired Neslab System III Liquid to Liquid Heat Exchangers (no cost to project)

» Ready for installation after clean-up and testing

Cooling requirements are less stringent when operating in AO lab, so refrig of process coolant not req’d

No need to move chiller from dome floor to AO lab or long plumbing runs

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P3K Infrastructure – July 19, 2010P3K Infrastructure I&T 9-22-10

DM Rack Cooling System Layout

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Cage inside Cage outboard

P3K Infrastructure – July 19, 2010P3K Infrastructure I&T 9-22-10

Electronic Rack Heat Exchanger

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Delivery of 10 pcs Week of Sept. 20, 2010

P3K Infrastructure – July 19, 2010P3K Infrastructure I&T 9-22-10

Cooling Fan Speed Control

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Proposed solution from Degree C

•Accepts up to nine fans•·Synchronizes rotational speeds of 4-wire fans to eliminate “beat” noise and vibration•· Monitors speed of 3-wire fans•· Simultaneously controls up to two types of fans•· I2C and RS232 communication interfaces•· Field configurable through serial interface•· Programmable alarm thresholds & fan curve•· Open collector alarm output•· One onboard/ two external temperature sensors•· Non-volatile memory to store configuration•· Power & Alarm LEDs with external connections•· Software selectable 3.3/5V logic operation•· Isolated Fan and Logic power domains•· Single/Dual power input•· Inrush current limiter for “hot swap”•· Fan failure detection and prediction

Delivery of 10 pcs Week of Oct 18, 2010

P3K Infrastructure – July 19, 2010P3K Infrastructure I&T 9-22-10

Electronic Rack Cooling

Work completed Spec and order Heat Exchangers Spec and order Fan Trays & Speed Controller Packaging of DM racks Design & and pre-sourcing of rack plumbing, hose ass’y, manifold &

attachment hardware

Work Remaining Packaging of Cass 1 control rack Installation of HX, fan trays, plumbing into racks Testing of in-rack cooling system prior to electronic integration

Risks More than 72 fans @ >100 cfm flow; Coolant flow @ 16 gpm

» Will instrument be sensitive to vibration from fans or coolant flow?

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P3K Infrastructure – July 19, 2010P3K Infrastructure I&T 9-22-10

System Supervisor Requirements Document: http://www.oir.caltech.edu/twiki_oir/bin/viewfile/Palomar/Palm3000/P3KInfrastructure?rev=1;filename=P3K_Cooling_Supe

rvisor_Concept_9-17-10.doc

Campbell Scientific 3000 data logger/controller The Campbell data logger and control system has a versatile set of analog and digital

inputs and outputs that are programmed with a simple interface and is in use at 4 location already at Palomar Observatory.

Parameters to be monitored: Ambient air temperature and dew point at cabinet location. Cabinet internal air temperature Cabinet wetness Fan Speed Emergency stop status Sensor Bypass configuration (overrides) Chiller coolant temperature (at chiller) Chiller coolant flow rate (at chiller) Chiller enable state Cabinet skin temperature Cabinet coolant flow rates (TBD)

Cooling System Control

P3K Infrastructure – July 19, 2010P3K Infrastructure I&T 9-22-10

Modes of operation:

Constant temperature set point (AO Lab operational mode) Controller maintains a constant internal air temperature

Ambient Temperature Tracking (Telescope operating mode) Controller maintains a temperature relative to the ambient temperature

Dew point avoidance (Telescope operating mode) Controller maintains a temperature relative to dew point for improved

safety during high dew point conditions.

Cooling System Control

P3K Infrastructure – July 19, 2010P3K Infrastructure I&T 9-22-10

Work completed Hardware spec & ordered Initial design complete Initial software design complete

Work Remaining Bench testing to begin after receipt of hardware (Oct 1) Complete System integration and test

Cooling System Control

P3K Infrastructure – July 19, 2010P3K Infrastructure I&T 9-22-10

Auxiliary Wrap-up Routing

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Turning GuideAttached at yoke bottom center

South Polar Axis Routing

To Coude

P3K Infrastructure – July 19, 2010P3K Infrastructure I&T 9-22-10J.Zolkower 31

Auxiliary Wrap-up Routing

Dec AxisEast ArmTube

P3K Infrastructure – July 19, 2010

East Arm

Spool Attached To Tube (Tube not shown)

Guide trough (cutaway) Attached to East Arm

Dec Axis Wrap-up Concept

Dec axis

Igus Cable Carrier

P3K Infrastructure – July 19, 2010P3K Infrastructure I&T 9-22-10

Cass Plumbing & Electric Routing

Cooling distribution manifold

Electric Load Center

South side

Duct for hose routing

P3K Infrastructure – July 19, 2010P3K Infrastructure I&T 9-22-10

Cooling Distribution Manifold

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2 Required•Cass Cage•AO lab

B&G Balance Valve

Parker Quick Coupling

Stainless Steel Manifold

P3K Infrastructure – July 19, 2010P3K Infrastructure I&T 9-22-10

Cooling / Electrical System Distribution Work completed

Distribution Manifold design Spec and pre-source of distribution manifolds, controls, valves, and pre-

fabricated hose ass’y

Work Remaining Design of Auxiliary Wrap-up Spec & procurement of Aux Wrap-up components Installation of Chiller in Coude (electric & plumbing) Installation of Neslab at AO Lab Procurement of manifolds, controls, valves, and pre-fab. hose ass’y Installation of Distribution Manifold in AO Lab and Cass Cage Installation of Auxiliary Wrap-up Complete System integration and test

Risks Aux Wrap-up varying effect on balance. Need to analyze.

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