Status of the Tracker Outer Barrel Joe Incandela University of California Santa Barbara for the US and CERN Tracker Groups Annual Review June 15, 2004

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 2 Covered in this talk Past year: We had to overcome problems with hybrids and sensors Also had to adapt to a shorter production schedule US production lines reworked to be as robust as possible Upgraded US production capacity by factor of 3 Recent Milestones Good module components are flowing Frames and sensors are well off critical path Hybrids still pace production but rates will rise US module production has ramped to ~65% of peak Quality is close to what we anticipated and improving. Mechanics and integration preparations proceeding well at CERN Current issue: Rods Rod component procurements and assembly nearing completion Seeing potentially serious problems with rods (as we expected) that must be dealt with now despite potential schedule disruptions. I will cover activities in the US followed by CERN

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 3 US Tracker Group Brown University R. Hooper, G. Landsberg, H.D. Nguyen, C. Pehlevan, T. Hartman, H.Y. Jung University of California, Riverside (UCR) G. Hanson, H. Liu, G.Y. Jeng, G. Pasztor, A. Satpathy, R. Stringer University of California, Santa Barbara (UCSB) A. Affolder, S. Burke, C. Campagnari, F. Garberson, D. Hale, J. Incandela, S. Jaditz, P. Kalavase, S. Kyre, J. Lamb, D. Stuart, D. White + technicians University of Illinois, Chicago (UIC) E. Chabalina, C. Gerber, L. Nigra, T. Ten Fermilab (FNAL) S. Cihangir, M. Demarteau, D. Glenzinski, H. Jensen, A. Ronzhin, J. Spalding, L. Spiegel, S. Tkaczyk + technicians University of Kansas (KU) P. Baringer, A. Bean, L. Christofek, D. Coppage Mexican Consortium: Cinvestav: H. Castilla, R. Perez, A. Sanchez Puebla: E. Medel, H. Salazar San Luis Potosi: A. Morelos University of Rochester (UR) R.Demina, R. Eusebi, Yu. Gotra, E. Halkiadakis, S. Korjenevski, S. Lockwood D. Miner, P. Tipton + technicians

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 4 US Module Assembly Plates Now in useproposedTotals Plate TypesUCSBFNALUCSBFNALActual If add R7 at FNAL TOB R-phi7815 TOB Stereo3477 TEC R5 R-phi333 R5 Stereo333 TEC R6555 TEC R73538 Totals Currently we are setup to process at most 20 plates (60 modules) per day. A much larger number of plates was prepared to allow us to adapt to whatever variations may occur in component deliveries and tracker needs.

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 5 US Production Cycle Quick test hybrids on ARCGantry makes modules. Modules test on ARC Assemble rods from modules Rod burn-in Rods shipped to CERN Thermal cycled module Wire bond Final pinhole test on ARC Wire bond Thermal cycle hybrids

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 6 US Production Steps/Status TaskCapacityManpower issuesSoftware Issues? Hardware Issues? Hybrid Bonding & Thermal Cycle 84/dNoneNo Module Assembly50/dNoneNo Module Bonding>50/dNoneNo ARC Testing>50/dNoneNo LT Testing200/wkNoneNo ARC LED>50/dNoneNo Reinforcing>50/dNoneNo Rod Assembly8/dNoneNo Single rod test>8/dNoneNo Multi rod test>32/wkNoneYes DAQ Component shortages and/or failures can limit production testing capacity in future

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 7 Module types built in the US

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 8 UCSB TEC Production Module Production R5N, R5S, R6 and R7 Designed built commissioned: Assembly plates, wirebond fixtures, carrier plates, shipping boxes All are in use and appear to work fine The last of the TEC commissioning phase (R7) ends this week General capacity issues Could saturate our production capacity with TEC production (30/d) Actual rate depends on need and availability of parts as well as TOB production parts availability and schedule Bonding and Testing capacity adequate LT testing capacity limit is ~100 per week but could eventually be mostly TEC if necessary (since TOB burn-in will be shifted to rods) or it will have to be sampled

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 9 US Components Inventory HybridsSensorsFrames FNALUCSBFNALUCSBFNALUCSB STHPITSTHPITSTHPITSTHPIT 4 chip ~852 L56pu ~852 R5p R5s R R Plenty of sensors and frames Hybrids are the critical path components

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 10 Quality assurance program at University of Rochester  Total number of sensors received 2351 since October 2004 (only OB1 and OB2 HPK silicon microstrip detectors)  Corresponds to 89 production batches  All batches are qualified for production 254 sensors(*) have been fully tested 4 Rejected – damaged during shipment * Last shipment of 532 sensors is being tested.

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 11 (All quantities are up to June 10th 2005) US Module Assembly Weekly Cumulative ABFABF% Passing L12pu % L12pd % L12su % L12sd % L34p % L56p % R5N % R5S % R % R % Total %

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 12 Sensor-to-sensor-alignment  =6.5  m  =8.5  mUCSB 1009 modules FNAL 670 modules Metrology Specification is  30  m (i.e. range shown on x axis)

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 13 US Hybrid Testing Set - - up in Clean Room  - - Chiller Cold Box PC for Monitoring + Controlling Electronics Gas/Water Flow Control

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 14 ARCS Testing Results UCSB 945 Tested 936 Grade A 3 Grade B 6 Grade F This week: 10 of channels bad (0.023%) Total Production: of channels bad (0.047%)

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 15 US ARCS Testing Status

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 16 US LT Testing Status

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 17 US module production (to June 10) US will build a total of >8,000 modules

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 18 Further Planning US groups have agreed to help accelerate TEC schedule R7 production at FNAL in Autumn at modules per day. Plate design were transferred from UCSB for FNAL modifications. FNAL will fabricate and commission the plates. UCSB making additional wirebond fixtures, shipping boxes UCSB will also transfer all programs related to testing. FNAL will manufacture carrier plates, Wien box plates etc. Second hybrid line UCSB overseeing hybrid assembly at Amtech (GS substrates) Initial results are as good as HSA. New tooling has been ordered. Expect to be ready for 200/wk production in July Riverside repair and diagnostics center nearly online

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 19 Diagnostic Facility at UC Riverside ARC Test Test stand is operational Able to reproduce problems found at production sites Long Term Test All hardware components (except TPO) are in hand Debugging test stand Will be operational shortly Other capabilities Optical inspection and probe station

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 20 Rods Overview Basic components procured Assembly of frames is nearing completion Integration of modules on rods is understood Rate of ≳ 8/d in the US should not be a problem … Testing has been problematic US rod production was halted Persistent and widespread I2C communication errors Recent and very substantial effort to understand and remedy Communication is marginal Simple solutions exist but we are not sure how robust Better solutions probably require some redesign Secondary issues of header errors and failures in LT tests are also under study

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 21 Tests of I2C errors Guido Magazzu & Wim Beaumont Visited FNAL then UCSB May 30 to June 7 Many studies performed. Most, but not all, mysteries resolved. Full Report is available Problem: different RC time constants on the I2C clock lines (to hybrid and optohybrid) Causes transitions to occur at non-ideal relative times Margin we have to play with is less than ~7 ns !!! See:

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 22 Tests at UCSB RodModErrors 192jumper no i2c errors (warm, cold cycle) (some header errors) 361R=820 ohm no errors (warm, cold cycle) 498R=0 no errors (warm, cold cycle) 498R=0 single PS no errors (warm, cold cycle) noise OK 20R=3 kOhm error "23" in Wim's i2ctest.sh Most of the proposed solutions worked in Tests at UCSB Situation at FNAL is less clear – under investigation

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 23 Other Issues Fighting coolant leaks at UCSB Isolated to flowmeters inside fridge Catalog says: flowmeters have vitan o-rings Vitan is "bad" with C6F14 Took it apart, observed damaged o-rings UCSB will now focus on restart of rod production Fighting software (?) problems at FNAL FNAL is working with Wim and Guido to understand the source of residual errors that are appearing. FNAL will then also focus all attention on rod production Expect an I2C solution to be chosen this week! Hope to restart rod production next week.

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 24 Frame production in Helsinki Rod frame production in Helsinki complete. 753 good frame produced compared to 760 possible and 688 needed in TOB (target was > 723, i.e. > 5% spares) Geometry of each frame is checked The positions and orientations of the 12 module positioning pins relative to the frame, as defined by the rod support spheres, are the most critical dimensions. Data goes into the production database

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 25 Rod cabling at CERN Discovered end of March: Microscopic solder residues on 2 (out of 3) types of PCBs Potential source of corrosion in the presence of humidity Restarted assembly after re-cleaning ~60% of rods are now cabled Continuing smoothly 100% yield with experienced technicians Rate > 5 rods per day Example of a dirty board Before After

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 26 TOB wheel construction: complete Mechanics complete and rotated into final position Precision elements of disks and cylinders glued on single gluing jig yielding typically 30  m relative precision Relative positioning of disks and cylinders limited only by measurement system precision (  m)

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 27 Thermal screen operational Wheel (above) is ready for insertion in the tracker support tube. The tube with thermal screen are ready in the assembly clean room (right) Wheel on assembly chariot Wheel ready

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 28 There is sufficient storage facilities available to house production rods before/after acceptance test Rod CERN Box: 3-rod capacity, dry air line T/RH probes interlocked to PS Mobile source + scintillator DAQ (XDAQ + RCMS) ready migrating to new OS Scenario with automatic scan of all sensors finalized 1/2 room temperature includes control of HV power supply Scan of rod label  DAQ configured from DB Up-loading results to DB still to be defined “XY table” test setup Located in “rod clean tent”  source on moving arms Scintillator moving with source

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 29 TOB integration TOB integration is done by cooling segments One cooling segment = 8 to 22 rods fed by the same manifold, that serves as common ground (the TOB cooling system has soldered joints) Several preparation tasks - on auxiliary workbenches clean rod cooling pipe and leak test prepare and register optical ribbons pre-cable rod with optical ribbons select, test and register power cable In addition: Production and testing of the 88 cooling manifolds Production and validation of all Digital Optohybrid Modules (92 in the TOB)

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 30 Preparation work - status DOHM production 5 prototypes successfully produced Assembly and testing procedure defined Cleaning and leak-checking of pipes Fixtures ready Sophisticated He leak detection system commissioned TK assembly room plumbing is now being finalized Rod pre-cabling with optical ribbons Fixtures ready Labeling scheme defined, software tools being finalized

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 31 Preparation work - status Cable production Acceptance test defined Now finalizing of lengths (nearly done) Manifold production Procedure defined and tested Need to finalize radial pick-off points (nearly done) Optical ribbon preparation 1/3 of the ribbons of layers 5-6 split to two connectors 1/2 of ribbons for layers 1-2 implement a modified connector Work is underway Overall procedure for integration of a cooling loop has been carefully defined: May need to be modified depending on the choice of solution to the I2C problem

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 32 Special case: layer TOB6- Due to small clearance to support tube Layer 6- integrated with wheel outside support tube Test with incomplete plumbing and temporary power cables Then, finally can Insert TOB in support tube Next we want to run at operating temperature Complete and leak check all plumbing Complete cabling and test functionality

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 33 Summary and Conclusions US production lines have completed 25% of TOB >99% yield and >99.5% good channels Nevertheless, we believe that production rates of modules/day and ≳ 8 rods/day can be achieved, provided adequate parts flow and stable multi-rod qualification testing Rod frames production in Helsinki is nearly complete CERN rod assembly is well off critical path I2C communication problem is under control (we think) TOB Wheel is basically ready Integration should start soon Large capable team at CERN US to send large team as soon as all production is stabilized Every day is a challenge… but we’re winning…

Additional Slides

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 35 Modules Enter Bonded, Untested Modules Shelf ARCS Testing If Failed If Passed Can We Fix It? Yes Repairs Repaired Modules Shelf Needs Repair Shelf in Bonding Room Failed Modules Shelf No Good ARCS Tested Modules Shelf LT Testing Bad Thermal Cycle, Needs Retest Shelf Chosen for LT Test? TEC or TOB? TEC or TOB? TEC Thermal Cycled Ready For Shipping Shelf TOB Thermal Cycled Ready For Rod Assembly TEC Not Thermal Cycled Ready For Shipping Shelf TOB Not Thermal Cycled Ready For Rod Assembly No Yes If Passed If Failed TEC TOB Is the Problem Understood? Undiagnosed Modules Shelf YesNo TECTOB Module Testing Flowchart

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 36 FNAL ARCS Testing Status

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 37 AOH FE-Hybrid SCL SDA 82  Parasitic on FE Hybrid C H Parasitic on AOH C A C H > C A Present Electrical circuit

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 38 (Main) Solutions under investigation R=82 Ohms  R=0 Ohms As implication for power-on sequence. Would need to power-on control and F.E. at the same time Most robust from I2C stand point Tune one of the R to equalize RC R to AOH ~ 820 ohm Jumper across resistance Forces same RC

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 39 AOH FE-Hybrid SCL SDA 82  Parasitic on FE Hybrid C H Parasitic on AOH C A PSU Control PSU FE before Solution 6

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 40 Integration of a Cooling segment Insert rods for a CTRL ring Test ring with temporary DOHM When all rings are populated: Solder joints (uses a dedicated vacuum cleaning system) Test cooling tightness Dress optical ribbons Integrate and dress power cables (register in DB) Connect cooling, FE power, readout and temporary DOHMs Perform full test of the cooling segment All connections to be registered in db Testing protocol defined and documented last November Commissioning of test system (hardware and software) on the Cosmic Rack as soon as possible After completing one TOB half Integrate all DOHMs, dress their ribbons Integrate and dress DOHM power cables Re-test functionalities of all CTRL rings (at least)

Tracker Outer Barrel, J. Incandela, UCSB - June 15, 2005 – CMS Annual Review slide 41 Summary of steps towards the start of TOB integration 1.Commission vacuum system for pipe soldering 2.Finalize power cable lengths and manifold geometry 3.Start manifold production (in house - technology well in hand) 4.(final power cables needed only after insertion in Support Tube) 5. Commission test setup (still waiting for powering and readout hardware) 6.Receive and validate production rods from US sites Steps 1-4 are expected to happen within 1-2 weeks Rod integration appears now to be the critical activity