P3K Palomar Infrastructure

Balance Adaptations
Larger Cass weight load from instrument & electronics

Electrical Service Upgrades
Higher electric service requirements at Cass, Computer
Room and AO Lab

Cooling of Cass Electronic Racks
Removal of ~6 kW of heat from below primary mirror
J.Zolkower
P3K
9-22-10
P3KInfrastructure
InfrastructureI&T
– July
19, 2010
1
Cass Mounted System Weights

Current AO Cass System Weights
 AO Bench
 AO Rack 1
 AO Rack 2
 Cables
AO System Total

3820 lbs
415 lbs
345 lbs
85 lbs
4665 lbs
With Heaviest AO Instrument
 P1640
 P1640 elec.
340 lbs
400 lbs
Total w/ Instrument
5405 lbs

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
J.Zolkower
P3K
9-22-10
P3KInfrastructure
InfrastructureI&T
– July
19, 2010
2
Balance Adaptations

P3K Cass mounted component weights exceed current balance
adjustments via moving counterweights

New balance adaptations required:
Additional ~700 lbs of lead added to weight boxes on Tube upper
ring
Implementation of up to three ‘dummy’ electronic cabinets:
1.
2.
 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.
J.Zolkower
P3K
9-22-10
P3KInfrastructure
InfrastructureI&T
– July
19, 2010
3
Electrical Service Upgrades
Power Requirements
 Computer Room Electronics (2 Racks)
 Total Rated Power :
 Total measured continuous measured:
 Continuous + Intermittent measured:

Cass Cage mounted Electronics (4 Racks)
 Total Rated Power:
 Total continuous measured:
 Continuous + Intermittent measured:
 Current AO system measured:
• Highest power AO instrument P1640
• P1640 Cal power TBD

11,870 W
3500 W
5400 W
8900 W
6250 W
7210 W
1035 W
~ 500W
Chiller in Coude
 220 V / 3 Phase / 42 amp service
J.Zolkower
P3K
9-22-10
P3KInfrastructure
InfrastructureI&T
– July
19, 2010
~ 10,000 W
4
Electrical Service Upgrades
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
J.Zolkower
P3K
9-22-10
P3KInfrastructure
InfrastructureI&T
– July
19, 2010
5
Power Dissipation / Mirror Temperature
13
200" Mirror Temperature
12
AO power off
AO power on
11
Mirror Temperature (ºC)
10
Sensor
Location
9
N
CO2 cleaning
caused
rapid cooling
8
7
Current AO power ~ 1000 W
6
E
SE
S
SW
W
NW
5
4
NE
24 hour data gap
3
Month/Day: UT Time
J.Zolkower
P3K
9-22-10
P3KInfrastructure
InfrastructureI&T
– July
19, 2010
6
Cass Rack Power Allocation
These
racks to
be cooled
~6100 W
J.Zolkower
RACK ID
MEASURED
CONTINUOUS
POWER
(W)
MEASURED
Intermittent
POWER
(W)
DM 1
DM 2
Cass 1
Cass 2
2,420
2,420
1,270
140
2,420
2,420
1,270
1,080
Total
6,250
7,210
P3K
9-22-10
P3KInfrastructure
InfrastructureI&T
– July
19, 2010
8
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:
 Target Coolant temperature:
 Cooling fan air flow:
 Coolant Mix:
 Coolant Temperature Range:
 Facility Chilled water temp:

-10ºC to +30ºC
3ºC below ambient
Constant speed
35% Propylene Glycol
-13ºC to +27ºC
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
J.Zolkower
P3K
9-22-10
P3KInfrastructure
InfrastructureI&T
– July
19, 2010
9
Chiller Specification

Requirements for Cass Electronics Cooling
 Total heat load:
 Max. coolant flow rate:
6100 W
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:
 Warmest required supply coolant temp:

-13ºC (3º below lowest ambient)
+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
J.Zolkower
P3K
9-22-10
P3KInfrastructure
InfrastructureI&T
– July
19, 2010
14
DM Rack Cooling System Layout
Cage inside
J.Zolkower
Cage outboard
P3K
9-22-10
P3KInfrastructure
InfrastructureI&T
– July
19, 2010
18
Electronic Rack Heat Exchanger
Delivery of 10 pcs
Week of Sept. 20, 2010
J.Zolkower
P3K
9-22-10
P3KInfrastructure
InfrastructureI&T
– July
19, 2010
19
Cooling Fan Speed Control
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
J.Zolkower
P3K
9-22-10
P3KInfrastructure
InfrastructureI&T
– July
19, 2010
21
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?
J.Zolkower
P3K
9-22-10
P3KInfrastructure
InfrastructureI&T
– July
19, 2010
22
Cooling System Control

System Supervisor Requirements Document:
 http://www.oir.caltech.edu/twiki_oir/bin/viewfile/Palomar/Palm3000/P3KInfrastructure?rev=1;filename=P3K_Cooling_Super
visor_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)
P3K
9-22-10
P3KInfrastructure
InfrastructureI&T
– July
19, 2010
Cooling System Control
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.
P3K
9-22-10
P3KInfrastructure
InfrastructureI&T
– July
19, 2010
Cooling System Control

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
P3K
9-22-10
P3KInfrastructure
InfrastructureI&T
– July
19, 2010
Auxiliary Wrap-up Routing
South Polar Axis Routing
Turning Guide
Attached at
yoke bottom
center
J.Zolkower
To Coude
P3K
9-22-10
P3KInfrastructure
InfrastructureI&T
– July
19, 2010
30
Auxiliary Wrap-up Routing
Dec Axis
Tube
J.Zolkower
P3K
9-22-10
P3KInfrastructure
InfrastructureI&T
– July
19, 2010
East Arm
31
Dec Axis Wrap-up Concept
East Arm
Spool
Attached To Tube
(Tube not shown)
Dec axis
Igus Cable Carrier
Guide trough
(cutaway)
Attached to East Arm
P3K Infrastructure – July 19, 2010
Cass Plumbing & Electric Routing
Duct for hose
routing
Cooling
distribution
manifold
Electric
Load
Center
South side
P3K
9-22-10
P3KInfrastructure
InfrastructureI&T
– July
19, 2010
Cooling Distribution Manifold
B&G Balance Valve
2 Required
•Cass Cage
•AO lab
Parker Quick Coupling
Stainless Steel Manifold
J.Zolkower
P3K
9-22-10
P3KInfrastructure
InfrastructureI&T
– July
19, 2010
34
Cooling / Electrical System Distribution

Work completed
 Distribution Manifold design
 Spec and pre-source of distribution manifolds, controls, valves, and prefabricated 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.
J.Zolkower
P3K
9-22-10
P3KInfrastructure
InfrastructureI&T
– July
19, 2010
40