Summary:

1
Status of Control Module integration

• Summary
• LCM integration PRR
• (in particular integration rehearsal of last
  week)
• Preparation for xCM production

2
Control Module production

• It consists of the following processes

Reception
(transportation)
Storage
Component level
Integration
Module level
Test
Packing (storage)
(transportation)
3
Control Module production scenario

• All activities under definition based on the
  following considerations
• Time constraints (schedule request one working
  LCM produced in two days)
• Manpower needs (one person?)
• Safety requirements power grounding during
  functional tests, ESD protection, fibre handling
• Quality Control approach detailed procedure for
  each operation, development of tools
• Traceability test needs

Target Full system defined and working in time
for the construction of the MILOM modules
(according to the current schedule by end of
June 2004)
LCM integration test for LCM PRR necessary step
to check the overall design of the module from
the integration point of view and in particular
to spot out all possible (minor) modifications to
the module components before the mass productions
start
4
LCM integration tests for PRR

• First test performed in week 12 (March) report
  available at
• http//www.ba.infn.it/circella/LCM/LCM_int_first
  _report.pdf
• Complete rehearsal of the integration performed
  in week 16 (last week) procedure and report
  available at
• http//www.ba.infn.it/circella/LCM/LCM_integrati
  on_test_prr_10.pdf
• http//www.ba.infn.it/circella/LCM/LCM_int_secon
  d_report.pdf

Conclusion after both tests NOT READY
(but not so far away from readiness)
5
LCM PRR integration test report

• Difficulties concerned
• Missing or wrong specifications on screw sizes,
  screwing torque, thread locker decisions made
  on the site
• Not all components available the nylon ring and
  the 1 M? resistor for connection to the flange, a
  few screws, the plastic tubes and their brackets
  were missing
• spare parts (most from the PSL) recycled or
  adapted
• 3. Not all boards in final configuration
• - glue problem on the backplane
• - LCM_CLOCK without fibre tray
• - cooling plates of the crate out of
  specifications?
• not possible to test the final LCM
  configuration
• 4. Integration supports not available
• not possible to test the final procedure
• Most serious problem electrical contact between
  crate and titanium (flange tube)

6
Module integration (summary)
0. (Get all components and tools at hand) 1.
Assemble a complete module before making any
tests 2. Power and optical margin test check
that the voltage and current values are
acceptable when powering up the module with a
test board (SUMO) inserted between the power box
and the crate and that the optical transmission
work with proper attenuators inserted along on
the optical fibres. Then remove the SUMO and
mount the power box on the module 3. Functional
test
7
LCM integration procedure (rehearsal of)
(0. Get all proper components and tools at hand)
Result step 0 not all components available ( a
few specification errors)

• assemble the crate (backplane included), and fix
  the gas venting tube to it

Option fix the fibre spiral tube as well!

• Comments
• no supports needed for this step
• it is not convenient (or possible?) to mount the
  spiral tube at this step

8

• Result step 1
• backplane excess of glue on coaxial cables,
  coaxial cables not labelled
• ground cables from backplane what is the ideal
  position?
• insertion of the coaxial cables in the trays of
  the backplane holders difficult
• brackets for the plastic tubes can not be
  mounted without modifying the crate

LCM integration test (details)
possible modifications to the crate and backplane
9
LCM integration procedure (rehearsal of)

• Fix the crate to the titanium flange

flange

• Comments
• preferred orientation is horizontal (supports
  needed)
• no (more) alignment holes in the flange and
  couronne 1

10

• Result step 2
• difficult alignment of flange and crate
  (rehearsal made with crate vertical due to
  missing supports)
• difficult insertion of the kapton ring
• missing 1 M? resistor
• wrong screws used for the resistor (due to
  missing specifications)
• difficult to get crate and flange isolated (due
  to flanges washers? plastic inserts of the
  screws?)

• improve documentation
• develop integration supports
• fix the nylon rings to the crate?
• check again all screws with torque
  specifications
• modifications to flange or crate?

11
LCM integration procedure (rehearsal of)
(old version support)
3. then the (flangecrate) block is fixed on its
support
Comment support not available during this test
12
LCM integration procedure (rehearsal of)
Power box
SUMO test board
4. the crate is connected to the power box
through a power supply test board (SUMO Supply
Monitor)
Comment SUMO board not used during the test
5. ...then we insert the boards one at a time
13

• Result step 5
• fibre spiral tube not initially fixed to crate.
  It needs to be fixed to the table and elongated
  up to 70-80 cm
• wrong screws used for DAQ and CLOCK cooling
  bases (due to missing
• specifications)

• improve documentation
• develop integration supports

14
LCM integration procedure (rehearsal of)
Power box
SUMO test board
6. when all boards are inserted we fix the fibre
spiral tube to the crate, then we make all
connections to the test bench (power, fibres,
flange connectors) and make the power and optical
power margin tests
Option we mount at least one of the cooling
plates before the poweroptical power margin
and/or the functional tests
Comment step 6 not made during the rehearsal
15
LCM integration procedure (rehearsal of)
7. remove the SUMO board and fix the power box
to the crate 8. functional tests!!
Comment steps 7-8 not made during the rehearsal
16
LCM integration procedure (rehearsal of)
9. (assuming the test is ok) prepare for shipping
(old version LCM)
17
What to do at the line integration site
10. If necessary, remove the protection from the
bottom flange 11. Install/replace the o-rings of
the bottom flange 12. Install the titanium
cylinder and mount the container on the line
Comment only step 12 relevant for this rehearsal
Result step 12 contact between crate and
titanium container! Solved by putting kapton tape
on the short edges of the cooling plates
18
PBS and bar-code

• General formula for traceability
• PBSNumber/VersionNumber.SerialNumber
• (rule one individual PBS number used to identify
  only components which are always completely
  interchangeable)

Is this THE rule? Are there exceptions?

• Notes added after the meeting
• the rule above is no longer endorsed by the
  Steering Committee (therefore the discussion of
  page 22 needs to be updated)
• the traceability format remains valid, with the
  SerialNumber to be a unique number for ONE object
  of a given PBS (i.e., the SerialNumber increases
  independently of the VersionNumber)

19
LCM configurations

• There are 3 kinds of LCMs (leaving aside the
  MILOM and IL needs)
• (a) LCM connected to 3 OMs
• (b) LCM connected to 3 OMs and a LED beacon
• (c) LCM connected to 3 OMs and an acoustic
  receiver
• (d) LCM connected to sound velocimeter/CTD

Proposal - let us define a version number to
discriminate among them 1 for LCM (a) 2 for LCM
(b) 3 for LCM (c) 4 for LCM (d) (5, 6, ... for
future needs 0 for the no-version option)
Note there is indeed one PBS number for all
LCMs and MLCMs
20
MLCM configurations

• There are 2 kinds of MLCMs (leaving aside the
  MILOM and IL needs)
• (a) MLCM connected to 3 OMs
• (b) MLCM connected to 3 OMs and a LED beacon

Proposal - let us define a version number to
discriminate among them 1 for MLCM (a) 2 for
MLCM (b) (3, 4, 5, ... for future needs 0 for
the no-version option)
Note there is indeed one PBS number for all
LCMs and MLCMs (so the LCM and MLCM versions
should be enumerated together)
21
SCM configurations

• There are 2 kinds of SCMs (leaving aside the
  MILOM and IL needs)
• (a) SCM connected to acoustic TX/RX, pressure
  sensor and sound velocimeter
• (b) SCM connected to the instruments in (a) a
  laser beacon

Proposal - let us define a version number to
discriminate among them 1 for SCM (a) 2 for SCM
(b) (3, 4, 5, ... for future needs 0 for the
no-version option)
22
PBS updates

• Suggested changes
• crates the current PBS has only 2.1.01 LCM_CRATE
  gt we would need two PBS numbers for LCM_CRATE
  and MLCM_CRATE
• backplanes the current PBS has only 2.1.02
  LCM_BACK and 2.2.02 SCM_BACK gt we would need
  three numbers for LCM_BACK-1 (for LCM-V1 and
  LCM-V3), LCM_BACK-2 (for LCM-V2), and LCM_BACK-3
  (for LCM-V4) 2 numbers for MLCM_BACK-1 (for
  MLCM-V1) and MLCM_BACK-2 (for MLCM-V2) and 2 for
  SCM_BACK-1 (for SCM-V1) and SCM_BACK-2 (for
  SCM-V2). Then, we will add more numbers if/when
  needed
• LCM flange the current PBS has only 1.3.2
  LCM_CONTAINER gt we would need three different
  numbers for the different flanges (for the three
  LCM configurations). Should we also introduce
  different PBS numbers for the flanges and the
  other parts of the containers, as for the SCM
  case?
• LCM_DAQ/SC the current PBS has only 2.1.17
  LCM_DAQ/SC gt we would need three different
  numbers for MLCM_DAQ/SC, LCM_DAQ/SC and
  SCM_DAQ/SC
• MLCM_DWDM the current PBS has only 2.1.16
  MLCM_DWDM gt we would need EITHER 5 different PBS
  numbers OR the version number used to specify the
  different wavelengths (or are there other
  options?)
• SCM_REP the current PBS has only 2.2.04 SC_REP
  gt we would need two different numbers for
  SCM_REP1 (serving 3 sectors) and SCM_REP2
  (serving 2 sectors)
• LPB the current PBS has only 2.2.11 POWER_BOX.
  It is indeed the same object used inside the
  LCM/MLCM/SCM, but in case of the xLCM it will be
  powered at 380 V, in the SCM it needs to be
  powered at 48V the difference is made by the
  connector gt shall we give a PBS number to the
  connector and its cable?
• h) should we also worry about the different SCM
  flanges?

See notes on pages 18, 19, 20
Further suggestion double-check all labels and
avoid using numbers in labels when not strictly
needed (so LCM_BIDICON gt MLCM_BIDICON
SCM_WDM1 gt SCM_WDM SCM_BACK1 gt
SCM_BACK-1/SCM_BACK-2 )
23
LCM main components

• LCM-V1 (configuration with just 3 OMs) is
  composed of
• - 1 LCM_CRATE PBS-2.1.1 ()
• - 1 LCM_BACK-1 PBS-2.1.2 ()
• - 1 POWER_BOX PBS-2.1.11 ()
• - 1 titanium flange PBS-1.3.2 () the rest of
  the container will be installed at the level of
  line integration
• - 1 COMPASS_MB PBS-2.1.3
• - 3 ARS_MB PBS-2.1.4
• - 1 LCM_DAQ/SC PBS-2.1.17 ()
• - 1 LCM_CLOCK PBS-2.1.7

Note PBS-related issues exist for items marked
()

• Then,
• LCM-V3 (configuration with 3 OMs and an acoustic
  receiver) comprises in addition
• - 1 ACOUST_RX_PREAMP PBS-2.1.8
• - 1 ACOUST_RX_DSP PBS-2.1.9
• - 1 ACOUST_RX_CPU PBS-2.1.10
• LCM-V2 (configuration with 3 OMs and a LED
  beacon) comprises in addition
• - a fourth ARS_MB PBS-2.1.4 (but we have to
  replace LCM_BACK-1 with LCM_BACK-2)
• for LCM-V4 LCM_BACK-1 should be replaced with
  LCM_BACK-3)
• Beware the flange is different for each
  configuration

24
MLCM main components

• MLCM-V1 (configuration with just 3 OMs) is
  composed of
• - 1 MLCM_CRATE PBS-2.1.1 ()
• - 1 MLCM_BACK-1 PBS-2.1.2 ()
• - 1 POWER_BOX PBS-2.1.11 ()
• - 1 titanium flange PBS-1.3.2 () the rest of
  the container will be installed at the level of
  line integration
• - 1 COMPASS_MB PBS-2.1.3
• - 3 ARS_MB PBS-2.1.4
• - 1 MLCM_DAQ/SC PBS-2.1.17 ()
• - 1 LCM_CLOCK PBS-2.1.7
• - 1 MLCM_DWDM PBS-2.1.16 ()
• - 1 MLCM_SWITCH PBS-2.1.18
• - 1 (M)LCM_BIDICON PBS-2.1.05

• Then,
• MLCM-V2 (configuration with 3 OMs and a LED
  beacon) comprises in addition
• - a fourth ARS_MB PBS-2.1.4 (but we have to
  replace MLCM_BACK-1 with MLCM_BACK-2)
• Beware the flange is different for the two
  configurations

Note PBS-related issues exist for items marked
()
25
SCM main components

• SCM-V1 (configuration without a laser beacon) is
  composed of
• - 1 SCM_CRATE PBS-2.2.01
• - 1 SCM_BACK-1 PBS-2.2.02 ()
• - 1 POWER_BOX PBS-2.1.11 ()
• - 1 titanium flange PBS-1.2.6.2 ()
• - 1 COMPASS_MB PBS-2.1.3
• - 1 SCM_DAQ/SC PBS-2.1.17 ()
• - 1 SCM_CLOCK PBS-2.2.05
• - 1 SCM_WDM PBS-2.2.03 ()
• - 1 SCM_REP1 1 SCM_REP2 PBS-2.2.04 ()
• - 1 SCM_DWDM PBS-2.2.16
• - 1 ACOUST_RXTX_EM PBS-2.2.07
• - 1 ACOUST_RXTX_PREAMP PBS-2.2.08
• - 1 ACOUST_RXTX_DSP2 PBS-2.2.09
• - 1 ACOUST_RXTX_DSP1 PBS-2.2.10
• - 1 ACOUST_RXTX_CPU PBS-2.2.11
• - 1 ACOUST_RXTX_POW PBS-2.2.12

Note PBS-related issues exist for items marked
()

• Then,
• SCM-V2 (configuration with a laser beacon)
  comprises in addition
• - 1 ARS_MB PBS-2.1.4 (but we have to replace
  SCM_BACK-1 with SCM_BACK-2)
• Beware the flange is different for the two
  configurations

26
Control Module minor components (1)

• For integration of each xCM the following
  components are also needed
• 1. small parts for the crate assembly, namely
• 1.1 the screws to fix couronne 1 to the titanium
  flange
• 1.2 the plastic inserts for these screws
• 1.3 the nylon rings to be put between couronne 1
  and the flange for LCM/MLCM
• 1.4 the screws to fix the LPB to couronne 2
• 1.5 the mini-screws to mount the backplane into
  its support bars
• 1.6 the bolts to fix the ground connections from
  the backplane to the crate
• 1.7 the screws to fix the backplane to couronne 2
• 1.8 the brackets to install the two plastic tubes
  (with screwswashers)
• 1.9 the screws for the cooling bases of
  LCM_DAQ/SC and LCM_CLOCK (LCM/MLCM/SCM),
  MLCM_DWDM and MLCM_SWITCH (MLCM), SCM_DWDM and
  SCM_WDM (SCM)

27
Control Module minor components (2)

• Then we need also
• 2. the 1 MO resistor to be installed between the
  crate and the flange for LCM/MLCM (with its
  screws)
• 3. the LPB connector terminated by the wires to
  be soldered to the backplane (with its screws)
• 4. the HV cable for the LPB (with the screws for
  the connector)
• 5. the gas venting tube and the fibre spiral tube
  
• 6. the thread locker(s)
• 7. the thermal gel for the cooling plates

28
Component reception assumptions

• Very strong recommendation
• Every single board should arrive to the xCM
  integration site ready to be integrated in a
  Control Module
• It implies that at the xCM integration sites
  there will be
• - no modifications to any board
• - no wire or component soldering
• - no check of board configuration

29
Implications for component delivery to the xCM
integration sites

• We expect that
• the titanium flange arrives with all cables
  terminated with the connectors to plug to the
  backplane it should have no o-ring (or, at
  least, no final o-ring) and possibly it should
  be provided with proper protections for the
  connectors and the inner surface
• the backplanes arrive equipped with all
  components properly installed (as needed!),
  including the power wires and the connector to
  plug to the LPB, the coaxials and any other cable
• the LPB arrives equipped with its HV connector
  and wires
• each board arrives exactly in the configuration
  it should be (i.e., as identified by its
  traceability label PBSNumber/VersionNumber.Serial
  Number)
• for all components we expect to receive an
  accompanying test report and to be able to trace
  the product history through the bar code label
  (we will use it as well to update the history of
  the integrated modules)
• - ... (this list will be updated according to
  the integration test results)

30
Component reception at the xCM integration site

• Therefore we need that
• - each component is accompanied by a proper test
  report ( a PBS compliance certificate)
• - traceability is possible through the bar code
  label

• Actions upon reception
• visually inspect the components
• check the accompanying documentation
• interact with the database to update the product
  history

31
Component storage at the xCM integration site

• - Standard laboratory conditions needed for
  storage and integration
• ESD protection required for all sensitive
  components (i.e., electronics boards and LPB) at
  all times
• storage room needs under evaluation (most
  serious requirement from mechanical pieces)

32
Packing (and delivery)

• Transportation logistics provided by IN2P3
  Cellule Logistique
• Flange transportation box will be used for module
  delivery

33
Work in progress...

• In progress (due for xCM PRR)
• PBS list
• component configuration (namely, define possible
  changes)
• integration procedure
• integration supports and tools (all or just what
  is essential?)
• documentation

Target complete rehearsal has to be made in time
for LCM PRR
34
Work to be done...

• To be done (due for end June for LCM)
• definition of intermediate (power, optical power
  margin) tests
• transportation boxes for components and modules
• storage containers/conditions
• bar code traceability (requires reader and
  software)
• complete integration table
• define and implement test benches!
• define test scenario (including failure modes,
  module repair line)
• documentation

35
Critical items...

• Whats critical
• Quality Control directives needed (in time for
  PRR?)
• Test bench status unsatisfactory (needed for
  production)
• the Pisa group can contribute more
• no MLCM training currently possible
• possible conflict in Bari for finalization of the
  SCM and MLCM test benches

36
Implications

• Should the LCM PRR wait to have the full Quality
  Control system implemented?
• Is the integration of the MILOM LCMs really
  needed in July? (SCM and MLCM due in September)
• Can we enable the Pisa group to work on the
  module integration and on the development of the
  test bench at Pisa? (needed onshore clock
  system, ethernet fibre connection, a complete LCM)

37
SCM test bench development (ongoing work at Bari)

• General definition essentially done
• Implementation delay due to unexpected problem
  with the ethernet link
• Implementation essentially stopped because
• - acoustics system control is not possible with
  the DAQ/SC software
• - lack of detailed documentation on other tests
• Current status of the test bench
• - it manages SC and clock communications with
  the SCM
• - it can drive the SCHarness through the state
  machine
• - it can query and decode SC data
• all in an integrated Labview software

38
LCM test bench development (ongoing work at
Catania and Pisa)

• General definition started
• Getting the LCM to acquire data was a tough job,
  due to poor documentation
• Current status of the test bench
• - it manages DAQ/SC and clock communications
  with the LCM
• - it can drive the DAQ/SCHarnesses through their
  state machines
• - it can query and decode SC data
• - it can drive data acquisitions with emulated
  signals from a pulser
• all in an integrated Labview software

39
MLCM test bench development

• Definition essentially linked to the LCM case
  (except for the MLCM-LCM communications and
  ethernet switching)
• Implementation should inherit both from the SCM
  and LCM test benches (not yet defined what to
  inherit from which test bench...)
• Hardware for the MLCM-LCM ethernet connections
  purchased but not yet integrated