01 Mar 2020
Project .zip sent by Jakub
- Removal of all the "OlderVersions" folders?
- Removal of spaces from the file/folder names; replace with "_" if possible
- Renaming of the "CAD Files\Custom Elements\Other" -> "CAD_Files\Custom_Elements\Fully_Custom" to be compatible with the BOM categories
- BOM: it is not clear to me if the "6HP Rear Panel for RTM modules" is Scroff-custom; also there is no relevant dwg for that, right?
- addition of Mikolaj's cabling drawing in the "DIOT_Crate_Prototype\Manuals\Cabling"
Open issues:
- clarify in the users guide how/when to use the extra cpci-s backplane GND and the GNDed mounting holes
- in the KiCad 3D views, all cpci-s mounting holes appear to be plated, when only 4 of them are actually
30 Mar 2020
General
- Correction of Power Backplane PE,N,L cabling
- Provide cabling drawings (incl. cabling types), as they might be difficult to trace in the 3D models
- Grouping of power supply cables by power supply not by polarity -> mark as: to be fixed in nxt release
- AUX IDC cable to have 4-pins instead of 16
- Two versions of the 3D models: one as the one sent today with the crate fully populated and one with only the mechanics and the 3xPCBs, no power supplies/system board/peripherals and no optional parts like roof/feet
Comments on BOM
- Rename "Standalone Version Components" -> "Optional Components"
- In "Other components" should the "3D Printed Cable Holder" be with "Cabling Components"
- In "Other components" there are some empty lines
- "Fully-Custom - Custom part to be manufactured by Creotech" -> "Fully-Custom - Custom part to be manufactured using the provided designs"
- Links for PCBs:
Front Panel Wiring
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I just realised that the current version is using single-pole switches; we would need DPST switches. There should be 4-poles wired like this:
- L/Nin come from the sockets
- L/Nout go to the screw terminals.
- We will need 2 x DPST switches, one per PSU.
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BNC cable diameter: Ø0.5mm
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How does something like this look to you for the front panel? The letters, black or colored, will be cut by the components but since they are clear letters it seems to me it could work, but please let us know what you think, before moving to implementation!
Otherwise, we could go for something like this:
- Jakub to specify where to focus the review
Items to discuss 27 Mar 2020
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Integration of latest crate front panel and cabling (discuss missing silkscreen from 3d models)
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Cabling and connectors safe materials
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In the silkscreen of the crate-front-panel, please write:
- Switches: PSU1, PSU2
- BNC: RST-IN
- IDC top: AUX
- IDC bottom: FAN-TRAY
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ACTION A18 ask Schroff for divider plate 100mm -> manufacture 100mm custom part and order schroff divider to test both
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ACTION A16: Provide coherent version of:
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3D model
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assembly manual
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technical drawings; key views
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BOM
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drawings of Schroff customised parts
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drawings of fully-customised (CTI) customised parts
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ACTION A7: Autodesk model browser descriptive names
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ACTION A9: Anna for the BOM purchase for the first prototype
Crate-front-panel final design
Please use this step file: https://ohwr.org/project/diot-crate-hw/blob/review_changes/pcb/crate_front_panel/Crate-Front-Panel.step
For cabling, please check silkscreen:
Materials clarification
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Cables should be halogen-free, in principle LSZH
Here is an example of common cabling for underground use: SPECIFICATION : LO-GE Nº493
CONDUCTOR : tinned copper
CONSTRUCTION : 30 x 0.25 mm dia.
Dia. 1.50 mm
INSULATION : SILTEM
Max. o.d. 2.30 mm
SPECIFICATIONS : RATED VOLTAGE 250 V r.m.s.
MAX. OPERATING TEMP. -40 to 130°C
ACCORDING TO SAFETY INSTRUCTION IS 23
Data sheet: EDMS 1965218/ 1965217 (for cern-internal-stores) -
According to [1] to be considered “halogen-free”, the pH and conductivity values outlined in the standard should be met for the material:
- The pH value should not be less than 4.3 when related to one liter of water
- The conductivity value should not exceed 10 μS/mm when related to one liter of water.
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For connectors, as other equipment groups, we could consider: This Instruction [2] applies to all equipment or installations consisting of or containing substantial amounts of plastics. It is of particular importance in experimental areas and all underground areas. It does not apply to small parts (such as knobs, handles, rollers, gaskets, fasteners, clips, grommets, rub strips, pulleys or small electrical parts) which would not contribute significantly to smoke, toxic, or corrosive gas emissions.
ConfCall 23 Mar 2020
Main Backplane
Here is the back side of the main backplane, where you can see the silkscreen on the power bags. It's a pity that in the 3D models there is no silkscreen, but for the moment let's continue like this. Please use this picture also for the documentation, if needed.
Power Backplane
Crate Front Panel
There are 4 screw terminals; below you may see the connections to each one of them, so as to arrange best placement:
Materials
We move forward with PVC cables; Eva to clarify --> PVC is not halogen free and cannot be used /!\
WhatsApp exchange of 19 Mar 2020
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Both Schroff and Elma PSUs fit well
--> Great! ACTION A11d: DONE! -
In next message I will send you design of front panel to accept. IDC connectors are both 16 pin there. As we talked 6-pin panel mount IDC connectors are no available, so maybe we can just use two 16 pin.
--> OK for 2x16pin IDC! In the silkscreen of the crate-front-panel, please write:
- Switches: PSU1, PSU2
- BNC: RST-IN
- IDC top: AUX
- IDC bottom: FAN-TRAY
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We have an idea about front panel PCB. Is it possible to make it 100mm in one of its dimensions? Then we can mount rails and just insert PCB behind the front panel. Additionally, we can use Schroff front handles on PCB to screw it to that panel (i. e. For transport purposes). With that solution we will be also able to use standard Schroff dividers
--> Good idea! This requires a small change from Michal; currently the pcb is ~133x51mm; I will write to Michal to confirm the change wont compromise our current scheduling (delivery nxt Friday); following our last discussion on Tuesday, it would also help if you were also in contact during the redesign for the best implementation (easily accessible cabling and any other issue that may popup):) -
Materials. Do you have some new information about prohibited materials? Especially small amount of PVC in i. e. Connectors.
--> We have confirmed PVC in cable insulation.
Do we know if the concentration of PVC in connectors is similar to the concentration on cable insulation? Which connectors are concerned?
As you suggested I will now anyway ask about the allowed concentration of PVC; I'm sorry had not followed this up since our last mail.
I'm also seeing now on your last mail, Jakub, you asked whether the mechanical design is focused on CERN internal use or easy-access crate; here I would say we first need to comply to all the safety rules (no option on that;) and then go for the most easy-access crate!
18 Mar 2020
Crate Front Panel
- Even if the fact of having the crate-front-panel makes the mechanics more difficult and introduces a non-standard part (thicker separator to be able to screw the pcb) it was decided to move forward with this option and once a physical prototype is available check for possible modifications and moving it to the front.
Upcoming schedule
- Friday 20/3 pm call to confirm models
- Monday 23/3 call to confirm deliverables
- Friday 27/3 project to be delivered
- Anna and the logistics team will then take over for the quotation and ordering the parts
13 Mar 2020
ACTIONS to be followed up by Creotech:
Note: after pcb validation Creotech will need ~1.5 weeks to deliver crate designs/bom
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ACTION A20 Confirm the rail for the Power Backplane is the correct one for power supplies (there is a shift on the rail to accommodate the case) ->DONE
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ACTION A18 ask Schroff for divider plate 100mm -> manufacture 100mm custom part and order schroff divider to test both
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ACTION A19 Have two executions: basic crate/ roof+feet set -> OK
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ACTION A11d: Use updated model of Schroff/ ELMA Power Supply -> to resend models; talk on Friday to confirm models --> DONE
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ACTION A13: Ensure no collisions with the POWER Backplane and the ELMA model! Here we have tested with a power-backplane-mechanical-prototype on the Schroff supply.
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ACTION A16: Provide coherent version of:
- 3D model
- assembly manual
- technical drawings; key views
- BOM
- drawings of Schroff customised parts
- drawings of fully-customised (CTI) customised parts -> talk on Monday 23/3 to finalise the design; next Friday final documentation; settle final price and data for the order -> end of next week final product -> quote will be available later
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ACTION A7: Autodesk model browser descriptive names: this is very time consuming and does not make sense to do it now that some parts are uncertain; for now we leave them like that and Kuba/Michal confirmed that in the end of the project they will be ok -> yes for nxt Friday 27/3
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ACTION A8: Ask Schroff if the following colors or similar are available in metallic paint:
RAL5051, RAL4003, RAL9010 -> forget for the moment; on a big order, at the moment of ordering schroff may find the color;) -
ACTION A9: Mikolaj has contacted Anna for the BOM purchase for the first prototype; he will follow up -> from nxt Friday, 27/3 on
PCBs validated:
- CPCIS-Backplane.step: https://ohwr.org/project/diot-crate-hw/blob/master/pcb/cpcis_backplane/CPCIS-Backplane.step
- PowerBackplane.step: https://ohwr.org/project/diot-crate-hw/blob/master/pcb/power_backplane/Power%20Backplane.step
- Crate-Front-Panel.step: https://ohwr.org/project/diot-crate-hw/blob/master/pcb/crate_front_panel/Crate-Front-Panel.step
06 Mar 2020
- CPCIs and Power backplane mechanical proto validated! Michal to put guide elemts as "not mount
04 Feb 2020
- ACTION A18 ask Schroff for divider plate 100mm
- ACTION A19 Have two executions: basic crate/ roof set
- ACTION B6 safe materials; send mail and put Creotech in copy
- ACTION B7 Creotech in contact with mechanical reviewers
- Note: after pcb validation Creotech will need ~1.5 weeks to deliver crate designs/bom
25 Feb 2020
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ACTION B5: CERN to check first all the boards before asking for 3D models modifications
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ACTION A17: Mikolaj/Kuba to provide Schroff confirmation that none of the materials-to-avoid are present in the BOM; to check also if the 3D printed parts are conformant
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ACTION A11d: Use updated model of Schroff/ ELMA Power Supply Check if the Power Backplane fits properly both these power supplies.
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ACTION A14: Ensure all items of the 3D model are in the BOM (ex: backplanes)
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ACTION A15: Clarify what are the hidden items in the BOM and what is represented by MH
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ACTION A16: Provide coherent version of:
- 3D model
- BOM
- drawings of Schroff customised parts
- drawings of CTI customised parts
- small explanation of all the TBS items
17 Feb 2020
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ACTION B4: Done; CERN to check which materials should not be installed in the tunnel and confirm that plastics: PLA/ ABS/ photopolymeric raisins are ok.
For cables, see Table 1: https://edms.cern.ch/ui/file/335745/LAST_RELEASED/E_IS23.pdf
For plastic/non-metallic materials, see Table 1: https://edms.cern.ch/ui/file/335806/LAST_RELEASED/IS41_E.pdf
04 Feb 2020
ACTIONS to be completed before the CERN review:
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ACTION A11a: New model of Power backplane from Michal
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ACTION A11b: New model of Main backplane from Michal
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ACTION A11c: New model of Crate Front Panel from Michal
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ACTION A11d: Updated model of Schroff/ ELMA Power Supply
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ACTION A13: Ensure there are no collisions between any items; provide relevant report The collission report is not useful; there are collisions anyway with screws/gaskets etc; with the first prototype we will check this
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ACTION A14: Ensure all items of the 3D model are in the BOM (ex: backplanes)
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ACTION A15: Clarify what are the hidden items in the BOM and what is represented by MH
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ACTION A16: Provide coherent version of:
- 3D model
- BOM
- drawings of Schroff customised parts
- drawings of CTI customised parts
- small explanation of all the TBS items
15 Jan 2020
New ACTIONS
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ACTION A11: To proceed with the CERN review, we would need the following:
- new models of both backplanes and of the front panel from Michal
- models of off-the-shelf power supplies
- models of system and peripheral boards including new provided models/front panels
- roof/feet consolidation (see ACTION A4)
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ACTION A12: BOM spreadsheet hidden items are the screws; it s not clear yet which ones are provided with the Schroff parts; will confirm after the first prototype is built.
- ACTION B5: Ask Michal to move IDC connectors in main backplane more to the edge for the RTM separator; 1mm more would be great
ACTIONS to be followed up
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ACTION A4: Roof and feet design:
- Feet: should we add more feet at the center of the crate for better weight distribution?
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Roof: we would need to see the model with the roof risen to confirm that it would not interfere with connectors on the front panels and that it would also protect the back from water drops. Please also have a look at this better picture of another crate installed in the LHC (ignore the red circles, they came with this picture I found); here the space above and below the crate is used to pass cabling, which is also probable is our case.
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ACTION A6: 3-D printed cable holders have been added; there are also these spring-type ones, but they do not appear correctly in the 3D model, they seem like tubes. Could this be corrected in the 3D model?
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ACTION A7: Autodesk model browser descriptive names is very time consuming and does not make sense to do it now that some parts are uncertain; for now we leave them like that and Kuba/Michal confirmed that in the end of the project they will be ok
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ACTION A8: Ask Schroff if the following colors or similar are available in metallic paint:
RAL5051, RAL4003, RAL9010
Note that Schroff has confirmed the availability of 6HP RTM front panels; min order 25 and price 10eur/pc, which is expensive, but there is availability; the front panels for the front modules are more available and cheaper.
- ACTION A9: Mikolaj has contacted Anna for the BOM purchase for the first prototype; he will follow up
- ACTION B4: CERN to check which materials should not be installed in the tunnel and confirm that plastics: PLA/ ABS/ photopolymeric raisins are ok
ACTIONS completed
- ACTION A2: Metal plate under design; to be delivered next week
- ACTION A10: Tentative BOM to be provided (for Schroff, CERN-stores)
Provided material
- BOM: Tentative_BOM_DIOT_Crate-20200116.xlsx
- BOM: BOM-20200115.xlsx
- 3D model: https://autode.sk/2Tp750A
10 Jan 2020:
New ACTIONS
- ACTION A10: Tentative BOM to be provided (for Schroff, CERN-stores) ----> Done
- ACTION B4: CERN to check which materials should not be installed in the tunnel and confirm that plastics: PLA/ ABS/ photopolymeric raisins are ok ----> Ongoing
ACTIONS to be followed up
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ACTION A2: Metal plate under design; to be delivered next week ----> Done; to ask Michal to move IDCs
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ACTION A4: Roof design ongoing; feet added on the perforated bottom panel; cheap solution; 6 to 10 feet added to hold all the weight. Note that the perforated panels are anyway customized (not off-the-shelf) for the cutouts at 160 and 220mm ----> Ongoing
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ACTION A6: Please have a look at the WR-switch cable holder ----> These cable holders are actually being used; the model is not clear
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ACTION A7: Ongoing Autodesk model browser descriptive names ----> Will be done at the end of the project once the list is finalised
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ACTION A8: Waiting for Schroff input on colors and 6HP RTM front panels ----> RTM front panels available; CERN to provide colors
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ACTION A9: Anna is back from holidays on Monday and will follow-up with Erik ----> On going
Next steps:
- Creotech corrects the aforementioned issues (A8 and A9 may not be completed)
- CERN reviews 3D model
- In parallel Creotech purchases all the BOM; Anna and Erik will be in contact
- After the 3D approval, Creotech writes the technical doc
- Finally CERN reviews all the work-package output with the mechanical office
ACTIONS completed:
- ACTION A1: Done; elements added
- ACTION A3: Done; butterfly screw added
- ACTION A5: Done; rails do have ESD protection (the metalic part is added as an extra); green rails for the 160mm power suppl; RTM rails available only in red
- ACTION B1: Done; AWG-10 for 600W (12V, 50A) -- 6mm2 cross section area of copper, 5.1mm outer diameter including insulation
- ACTION B2: Done; https://cernbox.cern.ch/index.php/s/0hkfPstk6pJq3lK
7 Jan 2020:
ACTIONS to be followed up
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ACTION A1: What about the addition of the elements shown below, that are present in the off-the-shelf crates, on the front and the back? ----> Done
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ACTION A2: Addition of a metal plate protection of 230V cables for the RTMs; check if it would disturb the External Power Supply cassette ----> To be delivered next week
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ACTION A3: Replace GND connection screw with butterfly type ----> Done
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ACTION A4: Add to the crate design optional roof and feet; an example shown here:
----> Feet added on the perforated bottom panel; cheap solution; 6 to 10 feet added to hold all the weight. The perforated panels are customized for the cutouts at 160 and 220mm
- ACTION A5: Rails to confirm they have the ESD protection; For power cards rails could be green, as in off-the-shelf crates; It seems there are only red rails for RTMs, to be confirmed; ideally they should all be grey but the one of the AUX power supply, which should be green
----> Done. rails do have ESD protection (the metalic part is added as an extra); green rails for the 160mm power suppl; RTM rails available only in red
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ACTION A6: Parts to keep cables together will be added, either off-the-shelf or 3D printed ----> to follow up
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ACTION A7: Autodesk model browser to have descriptive names, not just part numbers, if possible ----> on going
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ACTION A8.1: Creotech waiting for Schroff answer on painting options
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ACTION A8.2: Creotech waiting for Schroff answer on 6HP RTM front-panel availability ----> no updates yet
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ACTION A9: Creotech to purchase all the BOM parts for the first sample crate; Anna would contact Erik ----> starts on Monday
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ACTION B1: CERN will provide a number on the allowed cable voltage drop on 12V cables, 50A ----> ok
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ACTION B2: CERN will provide STEP models of the front panels of the system and peripheral boards and model of the FMC-nanoFIP ----> ok
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ACTION B3: CERN to organise internal review with Christos, Lalit, Matteusz, Kamil, Pieter, Paul, William, Greg, Eva
Discussion points:
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Next steps:
- Creotech corrects the aforementioned issues
- CERN reviews 3D model
- In parallel Creotech purchases all the BOM; Anna and Erik will be in contact
- After the 3D approval, Creotech writes the technical doc
- Finally CERN reviews all the work-package output with the mechanical office
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Technical doc to be provided will include:
- BOM
- technical drawings for all custom made parts
- assembly manual
- technical drawings; key views
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It is probable to be compatible with other manufacturers, but it would be a different analysis for Creotech to check for that; CERN could ask directly ELMA/ATOS for their equivalent BOMs and 3D models
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CPCI-serial backplane power bags touching the rail -> confirmed with Michal that he will move the power bags higher to ensure that with different crate manufactures there wont be a risk
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Checked with Michal that the font panel will be a pcb screwed on the metal plate
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Files delivered 7/1/20 by Creotech:
- With RTM: https://autode.sk/39MD3JS
- Without RTM:https://autode.sk/2QSAM7i
- STEP files: https://www.dropbox.com/s/efn6d8k36e34zd8/DIOT_Crate.rar?dl=0
17 Dec 2019:
- We need to protect user from being electrocuted by accidentally touching 230V cables going to the front panel. You will evaluate 2 solutions: 1) enclosing front panel in a "metal box" where 230V cables enter through a hole in the back and other than this, it is covered from all sides; 2) 2 metal plates separating slot 9 and PSU slot from the front panel area.
---> Finally 2 custom-made metal plates will be used, as they are easier to attach to the crate
- We have a freedom of placing the IEC power entry sockets in the back panel, you will evaluate the most ergonomic way to ease routing of 230V cables inside the crate. Removing a power cable with Schurter V-Lock mechanism requires some space, you will add the model of the power plug to evaluate how IEC power entry sockets should be placed.
---> Done; above 35 mm between the two V-locks
- We can flip the way RTMs are mounted to have the **locking/ejecting handles on the bottom ** (like the front cards), but this will require swapping also the L-shaped metal parts at the sides of the crate to have all EMC gaskets in place. NOTE: I checked the CompactPCI Serial standard. In section 3 (Mechanical Requirements) it defines how the rear boards should be placed. Please have a look at Figure 4 which shows that IEEE handle is placed at the bottom and both rear and front boards are in the same plane (there is no offset of the guiding rails).
---> mirror version of the front panels available at Schroff but not 6HP.. to follow up with Schroff; the 3D drawing is not a component from Scroff
- You got a reply from Schroff that they can provide painted crate components in both variants: conductive paint OR normal powder coating with some parts exposed (not painted). The plan is to finalize the design of the crate and then submit it to Schroff for price estimations for both variants.
---> no answer from Schroff yet
- After placing step models of the backplane and cards, the whole crate fits into the standard components of 355mm depth.
- For the assembly of the crate, there is a possibility of ordering subrack components, or pre-assembled crate from Schroff. In the latter case, one still needs to mount the backplanes and cabling. To be seen later, which option is cheaper.
---> what about elma/atos? it is probable; will check into other manufacturers gut feeling: pretty simple project, would be easy to find tricky points: power bags touching the rail; with different manufactures it might not fit 16-pin IDC connector on front panel -> could be different analysis to check if another vendor could
- To increase the chances of receiving the final 3D model with cabling beginning of January, we agreed that you will prepare this full 3D model which we will review internally. The paper documentation will follow once we approve the 3D model. You will provide the final 3D model on 7-Jan, which is also when we'll have our next call. The 3D model should come in 2 variants: crate populated with all possible modules (PSUs, front and rear boards) AND crate not populated with cards/PSUs.
13 Dec 2019:
- CERN provided STEP models of System and Peripheral Boards
12 Dec 2019:
Below you can find online drawing of the crate as well as a link to the archive with technical drawings. Especially important is Drawings/DIOTCrate_Dim/DIOTCrate_Dim.pdf, as that's what we'd like to have accepted.
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DIOTCrate_Dim (view for board dimentions): https://autode.sk/2YCRpqM
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DIOTCrate_RTM_Mounted: https://autode.sk/2qBGsJA
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DIOTCrate_wo_RTM: https://autode.sk/2PanQtI
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Archive with STEPs and technical drawings: https://www.dropbox.com/s/1dga5i3htyyog38/DIOTCrate.rar?dl=0
11 Dec 2019:
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We will be expecting sometime in the beginning of next week the first version of the crate design, 3D drawing and document. We will then review internally at CERN and iterate with you if needed; finally you will proceed with BOM corrections and reevaluation of the price
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Kuba is currently working on COTS modifications and could join our call next week
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The back enclosure of the crate will have to be custom-made, as there aren’t standard size parts you could find; this is ok as it includes the 230V gaskets which have to be custom anyway
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Michal is working on the front panel BOM/specification
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Crate dimensions are not clear in our specification document; the document specifies only board dimensions; the exact crate dimensions to be defined by Creotech
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Currently you are working with Schroff’s kits for 355mm-long crates
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You are in contact with Schroff regarding the paint; the options here are either conductive paint everywhere, or normal (non-conductive paint) selectively on areas without connections. You have a tool to check conductivity between painted parts
19 Nov 2019:
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Do you want to have rear cover EMC sealed? Should there be EMC gasket between two parts of the cover? Yes, we want to have the rear cover EMC sealed. As you mentioned the rear cover is composed of two modules, one covering the PSUs and one covering the RTMs and we want EMC gasket between the two parts. Ok
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In the specs document board dimensions (e.g. 6.1.1) are PCB dimensions RTM pcb dimensions are 100 x 100 mm
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Point 4.1.18 states that some mechanical mounting for monitoring components should be provided. What components are expected and in what locations? Is monitoring module to be mounted on a backplane? Is backplane == motherboard? Indeed this point is not clear in our specs. The monitoring component is mounted on the PSU and then it is accessed through the Utility connectors of the PSUs. There is no monitoring mounted on the backplane. For you, for the crate design, there is no extra cabling regarding the monitoring module; all the cabling of the crate is shown in Figure 11. Ok
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Conductive coloring