1. Integration and Test 14 October 2008 Martin Nordby

2. LSST Camera Systems Integration 2 Contents Introduction Cryostat assembly and integration flow Test plans during focal plane integration Focal plane integration process Cryostat integration process Camera integration Integration facilities

3. LSST Camera Systems Integration 3 Introduction Guidelines we have used in developing the camera design and I&T plans –All sub-assemblies are pre-assembled and fully verified by unit-level testing prior to delivery and integration into the Camera –“For-the-record” verification tests of deliverable sub-assemblies are used as gates for accepting hardware prior to integration –The integration process—and subsequent de-integration and servicing—should minimally disturb neighboring components or break their verification Documents describing integration and test plans (collection-87 in the Camera I&T directory): –LSST-1141-D, “Cryostat Assembly and Integration Sequence” Detailed, step-by-step sequence for assembling the cryostat and integration raft towers Includes mechanical and electrical integration process and the fixturing and test equipment needed Identifies verification testing –LSST-6175-A, “Camera Integration and Test Plan” Overall plan for I&T operations, including facility operations, standard operating procedures, safety Includes detailed sequence for integrating the camera Identifies verification testing and calibration efforts Includes mechanical and electrical integration process and the fixturing and test equipment needed –LSST-6176-A, “SLAC Bldg 33 Camera I&T Facility Layout” Detailed layout of the SLAC clean room facility and concepts for the big mechanical fixturing –LSST-2119-D, “Camera Integration and Test Flow Chart” Graphical flow-chart showing the integration and test sequence for all major camera components

4. LSST Camera Systems Integration 4 Cryostat Integration and Test Flow From LSST-2119-D, “Camera Integration and Test Flow Chart” For details, see LSST-1141-D, “Cryostat Assembly and Integration Sequence”

5. LSST Camera Systems Integration 5 Verification Test Cycle for Raft Towers Raft Tower assembly –CCD acceptance testing at BNL –Raft tower verification testing Raft Tower acceptance testing –Incoming re-testing of raft towers as they arrive at SLAC –Functional test of raft towers in preparation for integration in the cryostat Post-integration testing –Warm functional/continuity check of raft towers and RCC modules –Periodic cold performance testing of the partially-integrated focal plane Full cryostat verification testing –Cold verification testing of the entire focal plane –Final cold metrology flatness measurements

6. LSST Camera Systems Integration 6 Test Progression for Focal Plane Integration Prerequisite tests –Engineering cryostat To work through details of the design, integration plans, and operations of the cryostat –Full-up cryostat functional testing The cryostat is tested as an assembly before any silicon is installed This include structural proof testing, vacuum- and pressure-testing, thermal system performance testing, and early work on the metrology system Four integration and test phases –Functional rafts Install “dummy rafts” that function like real ones (mass, cg, structural pre-loads, thermal, heaters and sensors) Test the cryostat and the insertion tooling with these rafts –Dead silicon Install rafts with dead silicon to partially populate the focal plane Prove out the system using assemblies with tight clearances Run metrology scans to qualify the flatness measurement process –Engineering-grade rafts Mechanically and electrically integrate fully functioning raft towers with out-of-spec detectors Run warm and cold metrological and electrical systems tests Cool down and test the entire data-flow chain –Science-grade rafts Integrate raft towers with science-grade CCD’s Run successive metrology scans and functional tests as the focal plane is being built up

7. LSST Camera Systems Integration 7 Focal Plane Integration Process 1. Insert Raft Towers from below 3. Install Raft Control Crates from above Cryostat held in its nominal zenith-pointed orientation Grid Front flange where L3 mounts Feedthrough flange Cryo Plate Cold Plate 2. Connect flex cabling

8. LSST Camera Systems Integration 8 Cryostat Exploded View L3 Flange Assembly Grid with Raft and Flexures Cryo Plate and Pumping Chimneys (Shroud not shown) Cold Plate Back end MLI Cage Feedthrough Flange, Pump Plate, and Pumping Plenum Cryostat Housing

9. LSST Camera Systems Integration 9 Cryostat Assembly Grid with Flexures Cryostat Housing Cryo Plate Cold Plate Back end MLI Cage and pump chimney Cryo Shroud

10. LSST Camera Systems Integration 10 Cryostat Close-Out L3 Flange Assembly Pump Plate Feedthrough Flange Pumping Plenum Vacuum-jacketed inlet/outlet lines

11. LSST Camera Systems Integration 11 Camera Integration 1. Camera body assembly 2. Filter exchange system integration 3. Shutter installation 4. Cryostat and Utility Trunk integration 5. Optics integration

12. LSST Camera Systems Integration 12 SLAC I&T Facility Layout Cleaning and gowning Room 104: camera integration Room 103B: cryostat integration Room 103A: mechanisms, optics, materials workstationsReceiving, storage Welding, leak testing Support electronics and workstations

13. LSST Camera Systems Integration 13 Cryostat Integration Facility—Plan View From LSST-6176-A, “SLAC Bldg 33 Camera I&T Facility Layout” Metrology systemAssembly standIntegration gantryCart

14. LSST Camera Systems Integration 14 Cryostat Integration Facility—Elevation View From LSST-6176-A, “SLAC Bldg 33 Camera I&T Facility Layout” Metrology systemAssembly standIntegration gantryCart Cryostat with valve box in cold-test configuration