TRD Electronics Flight Production Wim de Boer, Kai Gassmann, Florian Hauler, Andreas Sabellek, Mike Schmanau IEKP - Universität Karlsruhe (TH)

09/01/2007TIM Jan07, JSCAndreas Sabellek, IEKP 2Outline TRD Electronics Overview Status of FM/FS TRD Electronics production at CSIST Results of Board-level acceptance testing Dec 06 Report on replacement procedure of Actel FPGAs Updated Time Schedule for FM U-Crates assembly and testing

09/01/2007TIM Jan07, JSCAndreas Sabellek, IEKP 3 TRD(U)-Electronics Overview UCrate =TRD electronics crate UBP =TRD backplane UPD=TRD power distribution box UPSFE=TRD power supply for front end UDR=TRD data reduction board JINF=data concentrator and link to higher DAQ UHVG=TRD high voltage generator UFE=TRD front end UTE= TRD tube end UHVD=TRD high voltage distributor V2 U = Uebergangsstrahlung

09/01/2007TIM Jan07, JSCAndreas Sabellek, IEKP 4 QM2 UPD and U-Crate One set of fully qualified QM2 TRD Electronics Crates (two set of FM Crates needed for complete TRD readout) Slow control connection to U-Crate Power supply connectors for U-Crate and 28V 6 UHVGJINF3 UPSFE6 UDR2

09/01/2007TIM Jan07, JSCAndreas Sabellek, IEKP 5 Status of FM/FS Production at CSIST, Taiwan DCDC Converter (S9056,S9048,S9053): FM/FS board production and test completed (May.06, presented on TIM Jul.06) S9011AU Controller: FM/FS board production and acceptance test completed (Dec.06) UBP: FM/FS production finished; Board assembly ongoing UDR2: FM/FS board production and acceptance test completed (Sep/Dec.06, presented on TIM Oct.06) UPSFE: FM/FS board production and acceptance test completed for 7/9 boards (Dec.06) UHVG: reworked by VK; FM/FS production in progress, PCA delayed by components found out of specification (MIT) JINF: FM/FS production ongoing (MIT) U Power Distribution (UPD): U DAQ Electronics (U-Crate):

09/01/2007TIM Jan07, JSCAndreas Sabellek, IEKP 6 S9011AU Controller FM/FS Test Actel FPGAs with new Firmware are used Some resistors mounted wrongly (unsoldered according to latest BOM) 95001F: Short between two status lines on Actel pinout corrected (seen in functional test) Number of Boards tested: 4 (2 needed as FM) Testprocedure (before/after Coating and ESS): - Functional test via Lecroy communication - Signal and status lines tested with a DCDC converter (“needle” backplane used – no soldering on FM-boards necessary) - SSF test Summary of Test Results:

09/01/2007TIM Jan07, JSCAndreas Sabellek, IEKP 7 UDR2 DAQ Board FM/FS Test No problems or errors seen Test-backplane Number of Boards tested: 15 (12 needed as FM) Testprocedure (before/after Coating and ESS in Dec.06): - Functional test via AMSWire communication - Data acquisition with FM-Front-Ends - Current monitoring on Test-backplane - SSF test Dec.06

09/01/2007TIM Jan07, JSCAndreas Sabellek, IEKP 8 UPSFE FM/FS Test Actel replacement after Firmware modification done, but mounted pairwise into wrong position (see Report on replacement procedure) Some resistors with wrong values exchanged 95003F: FPGA off-signal failure; Actel problem in off-state, will be exchanged 95005F: one LR SSF failed after ESS; part failure found, will be exchanged Number of Boards tested: 9 (6 needed as FM) Testprocedure (before/after Coating and ESS): - Functional test via Lecroy communication - Linear Regulator test (28 circuits/board) on a Fusetest-backplane - Signal and status lines tested - Current monitoring - SSF test UPSFE board 14x2 LR test circuits Off-signal LEDsStatus Jumpers Summary of Test Results: Fusetest Backplane

09/01/2007TIM Jan07, JSCAndreas Sabellek, IEKP 9 Actel Replacement Procedure 1/2 Solution to misplaced Actel FPGAs proposed and done by CSIST: desolder and swap same ICs to correct position Thermal stress during desolder process is lower than in reflow soldering process of regular mounting Hot air nozzle Vacuum lifter Bottom fan 100°C FPGA pads have experienced 5 unavoidable de-/solder processes now Careful inspection necessary!

09/01/2007TIM Jan07, JSCAndreas Sabellek, IEKP 10 Actel Replacement Procedure 2/2 + Manual soldering Flux 5sec slide/edge

09/01/2007TIM Jan07, JSCAndreas Sabellek, IEKP 11 FM UPD Assembly Status CSIST technicians will follow UPD Assembly document prepared by Mike Schmanau Production of needed I-Frames for UPD boards was finished with priority in Dec 06 Cabling and soldering work on UPD boards is waiting for materials and tooling; most needed parts will arrive mid January Board typeNumber needed (two UPD Boxes) Now available for Box assembly Status S9048 Converter 66 fully tested S9056 Converter 66 fully tested S9053 Converter 22 fully tested S9011B Filter 20 Short Test will be performed by Mauro soon S9011AU Controller 24 fully tested Assembly discussion at CSIST

09/01/2007TIM Jan07, JSCAndreas Sabellek, IEKP 12 FM U-Crate Assembly Status JINF production and testing has to be finished UHVG production and testing has to be finished; PCA now waiting for new part supply CSIST accepted to produce three set of flight cables for us - materials will be delivered mid January - U Cabling document is being prepared (lenghts and procedure) - final cable lengths already partly verified on wooden mockup (Andrey) Board typeNumber needed (two U-Crates) Now available for Crate assembly StatusExpected date to be finish UDR Fully tested UPSFE 67 Fully tested UBP 22 Processing conformal coatingmid Jan 07 UHVG 120 PCA for 1 board done and tested by VK; waiting for new parts Feb 07? JINF 20 PCA for 1 board done; waiting for testJan/Feb 07

09/01/2007TIM Jan07, JSCAndreas Sabellek, IEKP 13 Time Schedule (updated) Delays: shipment of UPD assembly materials and tools to CSIST; late Chinese New Year holidays in February Full TRD readout test with FM Electronics will be performed in Aachen

09/01/2007TIM Jan07, JSCAndreas Sabellek, IEKP 14 Status Summary Board-level acceptance tests were completed for needed FM boards in December06 (excluding Uhvg and Jinf); two UPSFE boards still need part exchange Assembly of two FM set of UPD and U-Crate will start as soon as materials arrive at CSIST

09/01/2007TIM Jan07, JSCAndreas Sabellek, IEKP 15 Backup Slides

09/01/2007TIM Jan07, JSCAndreas Sabellek, IEKP 16 Actel off-signal Failure Consequence: two UHVG boards cannot be switched to ON state Lucky incident: after a replacement also observed on QM2 board with a new Actel Actel0 (on) output: high/low opens/closes transistor Actel1(off) output: constant drop 0.6 V UHVG input: Small current (which is OFF state)