1. Tracker Week April ‘03G.Sguazzoni1 FE hybrid assembly and quality assurance The hybrid team: Alan Honma, Michael Poettgens, Gabriella Pasztor, Bernd Reinhold, G.S. Bruno Wittmer CERN –EP Division “...resistance of hybrids is not futile…”

2. Tracker Week April ‘03G.Sguazzoni2 Assembly procedure @ CERN  Hybrid assembly test  Test during thermal cycle(s)  Pitch Adapter (PA) gluing at the gantry  (PA bonding)  Bare Hybrid (no Pitch Adapter)  Reception test 12 3

3. Tracker Week April ‘03G.Sguazzoni3 Hybrid reception ‘fast’ test  Check that no damage occurred during shipping  Fast ARC test FHIT like  will be replaced by FHIT

4. Tracker Week April ‘03G.Sguazzoni4 Gantry PA assembly  First 50 TOB hybrids glued @ the gantry… all good!!!  Hyb+PA  TOB: 16/plate  Gantry time  1h  Curing  8h  Spacer+PA  TOB: 64/plate  Gantry  30min  Curing  8h  Typical requested throughput  52 hyb/day  Handling and preparation is a limiting factor  First 50 TOB hybrids glued @ the gantry… all good!!!  Hyb+PA  TOB: 16/plate  Gantry time  1h  Curing  8h  Spacer+PA  TOB: 64/plate  Gantry  30min  Curing  8h  Typical requested throughput  52 hyb/day  Handling and preparation is a limiting factor

5. Tracker Week April ‘03G.Sguazzoni5 Hybrid assembly results  RMSs (in  m ) indicate assembly precision within bonding requirements  All hybrids have been bonded successfully!!!  stability as the glue cures checked and fine!!!  RMSs (in  m ) indicate assembly precision within bonding requirements  All hybrids have been bonded successfully!!!  stability as the glue cures checked and fine!!! ~14~11 ~42 ~43 50 (  x 1,  y 1 ) (  x 2,  y 2 ) x1x1 y1y1 y2y2 x2x2

6. Tracker Week April ‘03G.Sguazzoni6 Post PA assembly tests ...to insure that:  the hybrid is still alive after many operations  the PA bonds are OK  no opens, no shorts!  the hybrid+PA survives…  …a cooling cycle (T ROOM  –20 o C  T ROOM )  …multiple (~10) thermal cycles (to emulate CMS shutdowns)  We need a nice test setup!!! Sample test!!!

7. Tracker Week April ‘03G.Sguazzoni7 The nice test setup  Located in the new CERN Gantry Clean ROOM TestBox Electronics Water/Gas management Water/Gas management Chair Status screens Water leak detector

8. Tracker Week April ‘03G.Sguazzoni8 Test setup block diagram

9. Tracker Week April ‘03G.Sguazzoni9 Test Box  4 hybrid slots  standard/stereo  N 2 /dry air flushed  temperature sensors  humidity sensors  Cooling/Heating:  300W Peltier element (24V-14A)  T LOWEST ~ -25 o C with max load (4 running hybrids) hybrid on the test plate

10. Tracker Week April ‘03G.Sguazzoni10 Readout & GUI  ARC based readout  automatic cycling/testing of all loaded hybrids  TCP/UDP communication with slow control application  Ready soon:  DB compliant output  “One-button” test

11. Tracker Week April ‘03G.Sguazzoni11 Slow control: hardware  Aachen Cooli box   controller  RS232 interface  Peltier driving  Temperature/Humidity sensor readout  safety interlocks ...custom patched for:  gas/water flow meter  NIM-TTL pulser driving

12. Tracker Week April ‘03G.Sguazzoni12 Slow control: software  Temperature monitor  Humidity monitor  Peltier current  Safety  TCP UDP  Temperature regulation  Water & gas flow Custom version of Aachen Cooli Devive Controller – ACDC (LabVIEW)

13. Tracker Week April ‘03G.Sguazzoni13 Post PA assembly tests  Typical test sequence during a cooling cycle  Hybrid ON*  Ped, Noi  Pulser  Short Detection  Hybrid OFF* *Added after problem with hybrid in cold (see later) T ROOM  –20 o C ~25 min/4 hybrids

14. Tracker Week April ‘03G.Sguazzoni14 Long term cycles  Sample test!!!  emulates ~10 CMS running-shutdown periods  Each cycle  same tests as the single cycle… T ROOM  –20 o C ~5 hours/4 hybrids  last cycle: stronger! (T ROOM  –25 o C  +35 o C)

15. Tracker Week April ‘03G.Sguazzoni15 Noise issues for hybrid+PA  No reference plane below PA  PA is a weak point wrt noise injection ampli channel  GND lines connected to the support plate by a wide copper strip  Hybrid  ARC FE Hybrid GND plane Hybrid Al support plate PA line ARC FE adaper

16. Tracker Week April ‘03G.Sguazzoni16 Noise comparison  Grounding scheme comparison PA lines length structure BAD grounding NEW grounding

17. Tracker Week April ‘03G.Sguazzoni17 Short detection  1 SHORT = 2 channels lost

18. Tracker Week April ‘03G.Sguazzoni18 Short detection principle  Calibration signal is sent every 4 channels  PIN HOLE like effect may also contribute IN OUT ch. #N ch. #N+1 CAL signal

19. Tracker Week April ‘03G.Sguazzoni19 Short detection  Simple and effective threshold criterium SHORTs Pulse shape Pulse heights

20. Tracker Week April ‘03G.Sguazzoni20 The first (detected) short!  Short = bonding problem PA APV

21. Tracker Week April ‘03G.Sguazzoni21 Open detection  OPEN = 1 channel lost

22. Tracker Week April ‘03G.Sguazzoni22 Pulser hardware ARC NIM pulser trigger NIM to TTL start out 50  “antenna” very close (~1mm) to the bond pads Peak - InvOFF  Pulser ON  Peak Mode  Optimal latency OPENS

23. Tracker Week April ‘03G.Sguazzoni23 Open detection: basics Removed Hybrid-PA bonds or scratch on PA lines*  Spikes in the pedestal profile!!! Removed Hybrid-PA bonds or scratch on PA lines*  Spikes in the pedestal profile!!! On-board CM subtraction  Pedestal ~unchanged On-board CM subtraction  Pedestal ~unchanged *even quite close to the bonding pads

24. Tracker Week April ‘03G.Sguazzoni24 The open-detection criteria  Optimal to detect isolated opens Difference wrt neighbours Mean Subtracted Pedestal OPENS in our test hybrid

25. Tracker Week April ‘03G.Sguazzoni25 The TOB outcome so far…  78 received  Reception TEST  72/74 good; 2 not OK  11  FNAL & 5  UCSB  2  ‘ TEC1.1 ’  Aachen  Assembled  48/48 good  Bonded  45/45 good  Thermal cycle test  Standard: 20/20 good  20  FNAL;  Long term: 8/9 good, 1 fails in cold  14846/14848 good bonds; 1 short, no opens

26. Tracker Week April ‘03G.Sguazzoni26 Pedestal  Large non-uniformities Max-Min APV wise  Pedestal cuts in module-test draft procedure ~ too tight Pedestal Pedestal APV wise Preliminary!!!

27. Tracker Week April ‘03G.Sguazzoni27 Hybrid+PA Noise  Normalized Noise cuts (  20%) in module test draft procedure -20 o C ROOM  Noise increases in cold  Peltier current? Preliminary!!! Noise Noise

28. Tracker Week April ‘03G.Sguazzoni28 The faulty hybrid: i.e. the kind of nasty problems we are supposed to discover  The hybrid fails only @–20 0 C  No APVs output but answers to I 2 C commands  other strange behaviors (current, DCU readings)  only a certain command sequence induces the failure; otherwise the hybrid works perfectly  Test procedure modified to foresee hybrid OFF/ON & initialization before any group of tests  First crude investigation:  No visible defect  MUX chip???  …further study needed

29. Tracker Week April ‘03G.Sguazzoni29 Test Station throughput  Target:  Nominal: 32 hybrids/day  UCSB will take over TOB bonding and testing – they are duplicating the setup  4 hybrids  40 min (preparation+test)  Limiting factors  Cooling time  Loading/Unloading  (40min/4hyb) * 32hyb ~ 5h  Effective production request could be higher…  A second “CERN” teststation is in preparation  (Cooling cycle test could be done on sample basis or dropped in case no problems are found)

30. Tracker Week April ‘03G.Sguazzoni30 Conclusion Hey folks, is there someone willing to test hybrids on a large scale?!?!…