Hybrid & Module Electrical Testing Outline Overview of Current Testing At UCSB Estimates of time/manpower/equipment needed How we can shorten times Reductions of tests Improvements in automation

Hybrid Testing Cycle 28 hybrids per day expected rate per site Wirebond PA (28) Mount/Inspect Hybrids (28) Quick Test Hybrids (28) Thermal Cycle Hybrid (28) Assemble into Modules (15) 28 hybrids per day expected rate per site Ship to TEC/FNAL(13)

Module Testing Cycle Repair (If necessary) Repair (If necessary) Gantry makes modules (15) Quick test unbonded modules (15) Wirebond (15) Repair (If necessary) Bonded module tests (15) Thermal cycle modules (15) Repair (If necessary) Final pinhole tests (15) Storage/Mount on Rods

Mount/Inspect Hybrid Upon receiving hybrid, must attach test tail and mount onto hybrid plate After mounting, hybrid wire bonds inspected quickly for damage ~ 5 minutes need in total per hybrid ~2 ½ man hours

Quick Test Hybrid Hybrids are tested on ARCS stand prior to PA wire bonding Ensure no damage has occurred during shipment No/little faults found No repair Test takes 10-15 minutes per hybrid 4 ½ - 7 hours ARCS stand time Takes ~5 minutes manpower per hybrid ~ 2 ½ man-hours Includes mounting/unmounting, determining test result and local database entry During production, we should drop this test. We would find all these problem in 4-hybrid test or visual inspection If problem is found in 4-hybrid test, then we quick test rest of shipment

Hybrid Thermal Cycler-Pulser 4 hybrids are taken to operating temperature (-20 C) and charge injecting into chip through capacitive coupling of pulser to PA Checks wirebond quality and first “long” test of hybrid ~45 minutes to thermal cycle 4 hybrids ~9 cycles per day possible ~20 minutes of manpower needed per cycle Includes data analysis, mounting/unmounting and database ~3 man hours No opens or shorts caused by bonding so far

ARCS Module Test Before Bonding Checks if assembly damaged sensors/hybrid Quick hybrid Test + IV test Test takes ~20-25 minutes per module ~5-6 hours of ARCS stand needed About ~20-25 minutes of man-power per module needed ~5-6 man-hours needed per day Includes data analysis, loading/unloading, and local database entry Test only for first few modules of each type (will NOT be performed during full production)

ARCS Module Test After Bonding Main tests to find faults introduced during assembly Full set of test run Test takes ~20-25 minutes per module TIB/TEC also report 20-25 minute test time ~5-6 hours of ARCS stand needed Includes tests performed at multiple bias voltages About ~10 minutes of man-power per module needed ~2 ½ man-hours needed per day Includes data analysis, loading/unloading, and database entry

Wien Cold Box/Burn-in Wien cold box cycles modules from –20 C to 20 C while reading out up to 10 modules Module burn-in/tests modules at operating temperature Modules cycled ½ day with ~2 thermal cycles per load 2 loads/unloads needed About 1 hour to unload/load box Assume another 1 hour per load for data analysis, database, etc. ~ 4 man-hours per day This time could be shrunk considerably if we make two set of cold plates per site Load one as we test bonded modules, unload other set as post-cycle LED test proceeds

ARCS Pinhole Test After thermal-cycling, module retested on ARCS with noise and LED pinhole test Ensures no new faults from thermal cycle/burn-in Test takes about ~10 minutes per module ~2 ½ hours of ARCS stand time ~2 ½ man-hours per day

Man-Hours/ARCS Stand Time Man-hours Needed ARCS Stand Time Needed Mount/inspect hybrids ~2 ½ hours N/A Quick Test Hybrids ~4 ½ -7 hours Thermal Cycle Hybrids ~3 hours Mount Module Cables ~ ½ hours Unbonded Module Test ~5-6 hours Bonded Module Test Wien Box Test ~4 hours Pinhole Test TOTAL ~22 ½ - 23 ½ hours (3 techs) ~17-21 ½ hours (3 stands)

How we shorten times necessary Reduction of tests taken Removal of hybrid quick test and unbonded module tests Test bonded modules at only one voltage Improved automation of testing “One button” testing (for ARC hybrid/module tests and Vienna box) Man-hours per test dominated from starting/stopping test, changing test settings, etc. Clear progress is being made with both ARCS and LT software Improve creation of local/global database entry Database group and Derek providing more/faster tools Multi-tasking Mount/inspect hybrids while hybrid quick test and 4 hybrid test are running Mount modules onto cold plates during bonded modules test Unmount modules onto cold plates as post-thermal cycle testing Database entry during tests Construction of second set of cold plates

Man-Hours/ARCS Stand Time (Shortened) Assumes only reduction of time due to removed tests Man-hours Needed ARCS Stand Time Needed Mount/inspect hybrids ~2 ½ hours N/A Quick Test Hybrids ~4 ½ -7 hours Thermal Cycle Hybrids ~3 hours Mount Module Cables ~ ½ hours Bonded Module Test ~5-6 hours Wien Box Test ~4 hours Pinhole Test TOTAL ~14 - 15 hours (2 1/2 techs) ~7 ½ -8 ½ hours (2 stands) Would prefer 1 additional tech and ARCS stand for stand down time, vacations, etc. So I guess 3 ½ techs and 3 ARCS stands necessary for testing

Conclusions With reduction of testing and some multi-tasking, current ARCS equipment should satisfy needs With the reduction of testing and some more automation of testing, I believe 4 techs/grad students/post-docs could perform module test At least 1 experienced physicists should be in room at all times If necessary, other tests could be removed if no additional problems found with tests Post-thermal cycling module testing