CMS ME CSC HV system production readiness review
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CMS ME CSC HV systemCMS ME CSC HV systemproduction readiness reviewproduction readiness review
Alex MadorskyUniversity of Florida
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July 2004, PNPI 2
UF/PNPI HV system architectureUF/PNPI HV system architecture
Card 72
Counting Room Detector Area
Long Distance HV Cables ~ 100 m long
SHV Connectors on both ends
Primary HV Supply
Multiwire HV Cable ~ 12 m long
LEMO REDEL Connectors on both ends
Three Main Units: Primary HV Supply, Master Distribution Card, Remote Distribution Card One Primary HV Supply per up to 9 Master Distribution Cards Master Distribution Card: 1 Input, 8 Independent Outputs One Master Distribution Card per 8 Remote Distribution Cards Remote Distribution Card Type 1: 1 Input, 30 Independent Outputs
(One Card per one ME 23/2 Chamber) Remote Distribution Card Type 2: 1 Input, 36 Independent Outputs
(One Card per two ME1 Chambers)
Card 1
Card 9
Card 1
Master Distribution
Card
Remote Distribution
Card Type 1
Remote Distribution
Card Type 2
Multiwire HV cables, 100 m, one per 18 distribution boards
•Primary HV power supplies: off the shelf, one per distribution rack, 8 total
•Master board: One output per distribution board. Regulates voltage 0-4KV (VMAX), measures current on each output.
•Remote Distribution board: powers one large or two small chambers (36 outputs max). Regulates voltage 1KV down from VMAX, measures current on each output. Each output can be disconnected from HV if necessary.
•Total number of individually controlled HV channels: 8856
Master boards Distribution
board 36
Distribution board 30
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July 2004, PNPI 3
HV system grounding diagramHV system grounding diagram
~ 100 m
Opticalcoupler
HV return wire
Notes:
- HV return wire connects to building ground only through chamber shell.
- In all modules there are safety connections from HV return wire to building ground
- Rack enclosures, chamber shells and cable shields formFaraday cage that extends from the primary HV power supply down to chambers, and completely encloses all HV leads, control cables and HV return wire.
- There is individual HV return wire for eachdistribution rack, to break ground loops between disks and racks.
CMS ME CSC HV system grounding
Opticalcoupler
Z load(multiple)
Primary HV power supply (floating output)
Distributionboard
Chamber
30 or 18 HVoutputs
To other distribution boardsin the rackMaster board
Control room Disk
To other master boards in the same rack
HV rack
Chamber shell connects to disk
0-4KVregulators
1KV downregulators
15 m (average) cable
Building ground
Board / module / rack enclosure
Safety connection. Does not allow the HVreturn wire float more than a few voltsfrom the building ground
HV distribution rack
Control computer
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July 2004, PNPI 4
Distribution boardsDistribution boards
Two types of distribution boards:
• 36 channels (two small chambers) – 139 boards
• 30 channels (one large chamber) – 159 boards
• Parts procurement, SMT assembly: UF
• Final assembly and tests: PNPI
Each channel:
• Controls voltage 1 KV down from input voltage
• Measures output current
Control connector
Power connectors
HV input
HV outputs
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July 2004, PNPI 5
Master boardMaster board
Master board:
• Each output drives one distribution board
• Controls HV from 0 to 4KV on 8 outputs
• Measures current on each output
• Provides low negative voltage for fuse control circuit
Input HV
8 output HV connectors
Control and LV power connector
• 46 boards to produce
• Parts procurement, SMT assembly: UF
• Final assembly and tests: PNPI
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July 2004, PNPI 6
Host cardHost card
Host card:
• Sits in PCI bus of the control computer
• Able to control up to 16 Distribution or Master boards
Xilinx JTAG connector, for FPGA configuration
Control cable connector.
PCI connector
• 20 boards to produce
• Parts procurement, assembly: UF
• Tests: PNPI
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July 2004, PNPI 7
Scope of the productionScope of the production
Component Quantity (ME4/1 included)
Pre-production quantity
UF PNPI
1KV regulator boards 8856 + 1216 spares = 10,072
360 X X
4KV regulator boards 304 + 96 spares = 400 16 X X
Relay boards 304 + 96 spares = 400 16 X X
Distribution boards – 30 channels (DB-30) 144 + 15 spares = 159 0 X X
Distribution boards – 36 channels (DB-36) 126 + 13 spares = 139 10 X X
Master boards (MB) 38 + 8 spares = 46 2 X X
Host Cards 28 + 3 spares = 31 2 X X
Distribution crates 30 + 3 spares = 33 1 X
Master crates 8 + 1 spare = 9 1 X
Patch-panels 16 + 2 spares = 18 0 X
Long HV cables 18 + 2 spares = 20 1 X
Long control cables 20 + 3 spares = 23 0 X
Miscellaneous and off-the-shelf components As required + 10% spares As required X
Total number of individually controlled HV channels: 8856 (spares not included, ME4/1 included)
Production items (fan-out cables not included):
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July 2004, PNPI 8
Overall production organizationOverall production organization
Project leader Project engineer Chamber group liaison
Guenakh Mitselmakher Alex Madorsky Andrey Korytov
UF Production coordinator
Alex Madorsky
See UF production diagram on page 10
PNPI Production coordinator
Victor Golovtsov
See PNPI production diagram in V.Golovtsov’s presentation
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July 2004, PNPI 9
UF responsibilityUF responsibility
Development and production managementPre-production prototype construction and testingTest stands constructionTest procedures verification, instructionsOff-the-shelf components procurementBare PCBs manufacturingAutomated SMT assemblyUS labor and components contingency
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July 2004, PNPI 10
UF production organizationUF production organization
Production coordinator
Alex Madorsky
Technician:
Arkadi Averbukh
Student assistants
• Quality assurance (tests)
• Repairs
• Database maintenance
• Shipping and handling
Distributors
Assembly houses
Machine shops
Software engineer:
Victor Barashko
Test software maintenance
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July 2004, PNPI 11
UF Quality AssuranceUF Quality AssuranceBoards tested:
Distribution boardsMaster boards
Visual test:
Presence of all componentsValuesOrientation
Electrical test:
Control bus interfaceDACADCs ID register
Results of all tests are inserted into production database
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July 2004, PNPI 12
UF production statusUF production status
All parts for Distribution, Master and Host boards are purchased PNPI received all parts and equipment necessary to begin production Remaining test stand equipment and all production components shipped to
PNPI Distribution boards:
68 boards SMT-assembled 68 SMT-assembled boards shipped to PNPI
Master boards: 20 boards SMT-assembled 4 SMT-assembled boards shipped to PNPI
Host cards: all boards assembled
Distribution crate: prototype assembled and tested Master crate: prototype assembled and tested Test stand software development finished for Distribution and Master boards
Binary release and step-by-step instructions are available via web-page (along with other information):
http://www.phys.ufl.edu/cms/emu/hv/ Access to source code via CVS Production database similar to chamber database is kept in text files
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July 2004, PNPI 13
PNPI responsibilityPNPI responsibility
Simple mechanical components manufacturedPre-production and production manual assemblyPre-production and production testingPNPI labor and space contingency
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July 2004, PNPI 14
PNPI test stand typesPNPI test stand typesRegulator board test stand
Uncoated boards at 1KV Coated boards at 4KV
Assembled Distribution and Master board test stand Full parametric testing of assembled boards Calibration
Voltage setting Voltage measurement Current measurement
Long term test stand Burn-in Parameter verification after burn-in
Total 11 tests for each board. Results of all tests are inserted into production database.
Most of the test stand components provided by UF.More details on test stands in the presentation by V.Golovtsov.
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July 2004, PNPI 15
PNPI production statusPNPI production status
Completely assembled and tested:10 Distribution boards 2 Master boards
PNPI production organization details to be shown in the presentation by Victor Golovtsov.
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July 2004, PNPI 16
Additional documentsAdditional documents
Filename (hyperlink). To open files, start presentation (F5) and click hyperlinks.
Description
DS001.txt Database file for Distribution board #001 (see example on page 17)
T01_M001.log.txt Log file for test #01 for Master board #01 (see example on page 18)
uf_visual_instructions.doc UF visual test instructions
uf_electrical_instructions.doc UF electrical test instructions
HV_Tests_User_Manual.doc PNPI test instructions (in Russian)
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July 2004, PNPI 17
Database file for Distribution board (fragment)Database file for Distribution board (fragment)
File name: DS001
Date : April 21 2004Time : 10:00Name : L.SergeevType : Assembly_fullComments : R00001,R00002,R00003,R00004,R00005,R00006,R00007,R00008,R00009,R00010,R00011,R00012,R00013,R00014,R00015,R00016,R00017,R00018,R00019,R00020,R00021,R00022,R00023,R00024,R00025,R00026,R00027,R00028,R00029,R00030,R00031,R00032,R00033,R00034,R00035,R00036,V001
Date : April 22 2004Time : 10:00Name : N.IsaevType : TestTest : 1Result : FailComment : Bad Test1
Date : April 22 2004Time : 10:00Name : S.VolkovType : DiagnosisReference : U32Partnumber : ADS7818EBComment : Bad chip
Date : April 22 2004Time : 10:00Name : S.VolkovType : SolutionReference : U32Partnumber : ADS7818EBComment : Replace chip
• All records are in fixed format• Records are easy to import into production database• Production database is being developed
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July 2004, PNPI 18
Test log file example (fragment)Test log file example (fragment)
File name: T01_M001.log
========================================================
Test1 results 04-02-2004 18:33:20Board ID001 30 channelsHV Tests Software Ver.1.0
+5V 2493 - O'k-5V 1306 - O'kInterlock - On
Point1- No data
Point2Voltages: 552 549 547 553 549 553 552 550 551 550 552 553 551 550 551 550 548 546 536 545 551 549 542 549 552 551 553 551 547 547Channels: 1 4 6 7 9 11 12 13 15 21 25 26 27 28Out of range 530 +/- 20
Currents: 2506 2514 2555 2552 2539 2546 2569 2539 2540 2517 2534 2537 2475 2513 2532 2520 2490 2558 2532 2561 2536 2524 2603 2461 2511 2540 2509 2545 2512 2551
Point3Voltages: 801 798 797 801 798 801 800 798 801 798 800 802 799 798 799 799 797 795 785 794 799 797 791 795 800 798 801 800 796 795Channels: 1 4 6 9 12 27Out of range 780 +/- 20
Currents: 2502 2504 2544 2540 2531 2535 2558 2533 2537 2511 2530 2533 2473 2511 2529 2521 2489 2558 2531 2561 2535 2521 2599 2460 2511 2540 2509 2544 2512 2550
• Each test generates a log file• All relevant information is inserted into log file• Log file is appended if this test is run multiple times
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July 2004, PNPI 19
Pre-production system testsPre-production system tests
Minimal system segmentOne primary power supplyOne Master board8 Distribution boards288 channels8 chambers connected to Distribution boardsOne of the chambers is connected to FAST DAQ
Parametric testsCheck if the system matches all specificationsSee results on few next slides
Tests with chamberGround & Power configuration as close as possible to real
detectorResults are in the presentation by A. Denisov
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July 2004, PNPI 20
Pre-production system testsPre-production system testsWiring diagramWiring diagram
Primary HV source
Masterboard
Distributionboards
FASTDAQ
SHV cables
Regular HVfanout cables(Kerpen)
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July 2004, PNPI 21
Pre-production system testsPre-production system testsGrounding diagramGrounding diagram
Opticalcoupler
Control and HV cable length ~ 3 m
Opticalcoupler
HV return wire
CMS ME CSC HV system groundingPNPI test setup
Notes:
- HV return wire connects to building ground only through chamber shell.
- In all modules there are safety connections from HV return wire to building ground
- There is individual HV return wire for eachdistribution rack, to break ground loops between disks and racks.
Z load(multiple)
ChamberDistributionboard
Primary HV power supply (floating output)
30 or 18 HVoutputs
To other distribution boardsin the rackMaster board
DiskSimulation
Control roomSimulation
HV rack
To other master boards in the same rack
0-4KVregulators
Regular 15 m fan-out cable
1KV downregulators
Building ground
Safety connection. Does not allow the HVreturn wire float more than a few voltsfrom the building ground
Board / module / rack enclosure
HV distribution rack
Control computer
8 SHV cables. HV return wire is connected to the braid of these cables
Ripple generator
Compare with page 3
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July 2004, PNPI 22
Test of specification requirementsTest of specification requirements
Parameter Requred Provided
Maximum output voltage, Vmax 4000V 4000V
Voltage regulation, each channel Vmax-500V Vmax-1000V
Voltage regulation resolution, each channel
<= 50V ~1V
Channel to channel voltage difference 20V max 17V
Voltage output Floating Yes
Maximum output current per channel 100 uA 100 uA
Maximum output current of the board 40uA*number of outputs
Yes
Individual output trip speed <= 1s <=1s
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July 2004, PNPI 23
Test of specification requirementsTest of specification requirementsParameter Requred Provided
Trip level, programmable 1 to 100 uA 1 to 100uA
Trip level setting resolution 1uA 1uA
Hardwired maximum current per channel
100uA ~350uA
Mutual influence of channels (during trips)
No trips on other channels
OK
Voltage measurement resolution, per output
10V 1V
Current measurement resolution 100nA 100nA, 10nA possible*
Channel to channel measured current difference
10% of measured value
10% of measured value
Rate of voltage change, programmable
2 to 50 V/s 2 to 1000 V/s
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July 2004, PNPI 24
Test of specification requirementsTest of specification requirementsTest result conclusions:
Pre-production system works fine in normal conditions. In the conditions of very high humidity (above 80%) increased
leakages were observed in some channels. Steps are taken to improve the system performance in high humidity conditions:
Coating process is modified to provide better coating quality
Triple coating Slots are made in critical high-voltage gaps on PCBs Quality assurance will include humidity chamber tests
Maximum current per channel without software trip: about 350 uA. Not a problem, according to Andrey Korytov.
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July 2004, PNPI 25
Pre-production system tests with chambersPre-production system tests with chambers
Control room simulation
HV Distributionrack simulation
Disk with chamberssimulation
FAST site
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July 2004, PNPI 26
ScheduleScheduleMilestone Details
DB-XX – Distribution board with XX outputsMB – Master board
Date Respon-sible
Pre-production system finished and tested 10 DB-36 + 2 MB (360 channels) September 25 ’04 UF, PNPI
External Production Readiness Review September 30 ’04 UF, PNPI, review committee
Production start October 4 ’04 UF, PNPI
Shipment of SMT-assembled boards to PNPI, pre-tested 76 DB23 MB
October 10 ’04 UF
First shipment to CERN 18 DB-368 DB-304 MB
November 30 ’04 PNPI
Shipment of SMT-assembled boards to PNPI, pre-tested 76 DB23 MB
January 15 ‘05 UF
25% of the boards shipped to CERN 48 DB-3012 DB-3612 MB
January 30 ‘05 PNPI
50% of the boards shipped to CERN 48 DB-3012 DB-3612 MB
Apr 15 ’05 PNPI
Shipment of SMT-assembled boards to PNPI, pre-tested 90 DB March 15 ’05 UF
75% of the boards shipped to CERN 48 DB-3012 DB-3612 MB
July 1 ’05 PNPI
100% of the boards shipped to CERNEnd of production
6 DB-3084 DB-366 MB
September 1 ’05 PNPI
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July 2004, PNPI 27
Development in progressDevelopment in progressMiscellaneous components are being developed in UFNot critical for production
Patch panels for HV and control cables See “Scope of production” slide for quantities Finish by January ‘05
Cables from Master boards to Distribution boards Length to be defined, about 100 meters HV cables
KERPEN halogen-free cables, same as Distribution-to-chamber cables One prototype is assembled (120 m) Production in CERN
Control cables Amphenol Spectra-Strip halogen-free round-n-flat
See “Scope of production” slide for quantities Finish by January ‘05
Pending approval from “Cable committee” chaired by Gerard Faber
Internal Distribution and Master rack cables HV cables – coaxial with SHV connectors, ~3 m (800 pcs) Control cables – Flat twisted pair, ~3 m (60 pcs) Finish by January ‘05
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July 2004, PNPI 28
Low Voltage Requirements for Low Voltage Requirements for Remote Distribution CardsRemote Distribution Cards
Parameter Min Max
Positive voltage 7 V 8 V
Negative voltage -8 V -7 V
Current on both channels
300 mA
Power per distribution board
4.2 W 4.8 W
Ripple/noise 100 mV
• Low voltage power will be provided by CMS AC/DC LV system
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July 2004, PNPI 29
SoftwareSoftware
Linux driver for HostCard (V. Barashko, UF) Multiple Host Cards Multiple Distribution and Master boards Main functionality finished
DIM server (V. Barashko, UF) Works with Linux driver Compatible with CERN slow control software (PVSS) Main functionality finished
Chamber database (V. Barashko, UF) In development
Operator interface program (V. Barashko, UF) Simple text-mode version ready GUI conceptual design underway
PVSS shell for slow control (Marina Giunta (CERN), Valery Sytnik (UC Riverside)) Specification is in preparation in UF
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July 2004, PNPI 30
HV system software structureHV system software structure
Host cards
PCI driver
Slave DIM server
Control computer #2
Host cards
PCI driver
Main DIM server
Control computer #1
Host cards
PCI driver
Slave DIM server
Control computer #3
Chamberdatabase
Operator’s GUI PVSS application
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July 2004, PNPI 31
DIM server command exampleDIM server command example
Field name Example Note
Chamber name ME2/3-12 Real chamber name, as marked
Segment number 3 Segment number in the chamber
Action 23 Action code (set voltage, set trip current, set ramp up speed, etc.)
Data field … Action-specific data in high-level units (voltage in volts, current in amperes, etc.).
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July 2004, PNPI 32
HV system software reliabilityHV system software reliabilityCritical pieces of software:
PCI driver DIM server
Critical software-dependent functionality: Interlock Trip
Software may crash for the variety of reasons: Bugs Power failure Computer failure Operator mistake …
How to detect any possible software crush: Hardware “watchdog” Such devices are available for about $130
What to do on software crush: Kill primary HV power supply / supplies that are controlled by the crashed computer Reset computer by turning power off and on
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July 2004, PNPI 33
Operator shell screenshotOperator shell screenshotPCI:0:6, Card:0 dataslot:0, ioaddr:0xE2D8E000Module:0xd: state:OFF, type:RDB 36, ID:0, Chans:36, ILock:0Ch# Vmon Imon Vset Vcur RmpUp RmpDn Vmax Imax Vtrip Itrip Relay Fuse State Status V mkA V V V V V mkA V mkA---------------------------------------------------------------------------------------01| 0 0.0 2752 0 18 18 4000 100 0 0 0 0 OFF OFF02| 0 0.0 2745 0 18 18 4000 100 0 0 0 0 OFF OFF03| 0 0.0 2745 0 18 18 4000 100 0 0 0 0 OFF OFF04| 0 0.0 2761 0 18 18 4000 100 0 0 0 0 OFF OFF05| 0 0.0 2757 0 18 18 4000 100 0 0 0 0 OFF OFF06| 0 0.0 2756 0 18 18 4000 100 0 0 0 0 OFF OFF07| 0 0.0 2756 0 18 18 4000 100 0 0 0 0 OFF OFF08| 0 0.0 2749 0 18 18 4000 100 0 0 0 0 OFF OFF09| 0 0.0 2754 0 18 18 4000 100 0 0 0 0 OFF OFF10| 0 0.0 2735 0 18 18 4000 100 0 0 0 0 OFF OFF11| 0 0.0 2748 0 18 18 4000 100 0 0 0 0 OFF OFF12| 0 0.0 2748 0 18 18 4000 100 0 0 0 0 OFF OFF13| 0 0.0 2742 0 18 18 4000 100 0 0 0 0 OFF OFF14| 0 0.0 2756 0 18 18 4000 100 0 0 0 0 OFF OFF15| 0 0.0 2761 0 18 18 4000 100 0 0 0 0 OFF OFF16| 0 0.0 2739 0 18 18 4000 100 0 0 0 0 OFF OFF17| 0 0.0 2748 0 18 18 4000 100 0 0 0 0 OFF OFF18| 0 0.0 2741 0 18 18 4000 100 0 0 0 0 OFF OFF
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July 2004, PNPI 34
Distribution boardDistribution board
• 36 channels (two small chambers) – 139 boards
• 30 channels (one large chamber) – 159 boards
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July 2004, PNPI 35
Master BoardMaster Board
• 46 boards to produce
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July 2004, PNPI 36
Host CardHost Card
• 20 boards to produce
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July 2004, PNPI 37
1KV regulator1KV regulator
• 10,072 boards to produce
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July 2004, PNPI 38
4 KV regulator4 KV regulator
• 400 boards to produce
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July 2004, PNPI 39
HV Relay boardHV Relay board
• 400 boards to produce
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July 2004, PNPI 40
Distribution crateDistribution crate
• Made from standard ELMA parts, except side panels (custom length)• Houses 9 distribution boards• No backplane
• 30 crates to make• Parts procurement: UF• Assembly: CERN
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July 2004, PNPI 41
HV Distribution CrateHV Distribution Crate
• 30 crates to produce
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July 2004, PNPI 42
Distribution RackDistribution Rack
Fan unit & heat exchanger
Distribution crate
Distribution boards
HV and control cables patch panel
Output HV cables to chambers
Need from CMS:
1. Racks
2. Fan units & heat exchangers
3. Strain reliefs
4. Space in front and behind the racks
5. Low Voltage power for distribution boards
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July 2004, PNPI 43
Pre-production results Pre-production results Problem Proposed solution Person
responsible for correction
Some wires in HV tails are ripped out
HV wire routing must be done with routing fixture, allowing some slack
Volkov, Astashin (PNPI)
At least one wire in HV tail is fixed in-house
Do not try to repair HV tails – it is a complicated procedure. Please use the other one. Damaged HV tails must be shipped to UF for repairs.
Volkov, Astashin (PNPI)
Incorrect types of screws are used in mechanical assembly
Use screws in accordance with the assembly drawing.
Volkov, Astashin (PNPI)
Holes in side bars are not in-line, which makes installing them difficult
Use conductor to drill holes in side bars Astashin (PNPI)
Side bars don’t have any finish Drawing requires anodizing, but we can consider other finish, such as brushing
Madorsky (UF), Astashin (PNPI)
Thread in some holes of the side bars is not deep enough
Make thread in accordance with drawing Astashin (PNPI)
Material for side bars is too soft (?)
Purchase material locally Golovtsov, Astashin (PNPI)UF responsible for payment
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July 2004, PNPI 44
Pre-production results Pre-production results
Problem Proposed solution Person responsible for corrections
Nylon stand-offs are not tightened well enough
Tighten nylon stand-offs with torque-controlled screwdriver
Volkov, Astashin (PNPI)
Plastic handle on the front panel is attached upside-down
Attach plastic handle in accordance with drawing
Volkov, Astashin (PNPI)
On Master boards, LEMO connectors don’t have heat shrink insulator
Put heat shrink insulator in accordance with drawing.
Volkov, Astashin (PNPI)
Jumpers on the boards are not set up as required
Add the “shipping” jumper positions to the test instructions (UF), follow that instructions (PNPI)
Madorsky (UF), Volkov (PNPI)
GND socket is connected to the board with wire
Wire is not shown on assembly drawing, since GND socket is already in contact with board’s case.
Volkov (PNPI)
The spring in some fuses does not jump out as expected when fuse is blown
Modification of fuse soldering procedure required. Manual cleaning required to remove coating bridges.
Volkov, Astashin (PNPI)
DAC amplifier “rings” on some boards
3pF capacitor is required in feedback. Madorsky (UF), Volkov (PNPI)
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July 2004, PNPI 45
Pre-production resultsPre-production results
Procedure modification Person responsible for corrections
Distribution board: R62, JP52 – remove Volkov (PNPI)
Master board: R52 - remove Volkov (PNPI)
Remove ventilation holes on Side bars (Distribution and Master boards) Madorsky (UF), Astashin (PNPI)
Software modification for Burn-in test Madorsky, Barashko (UF)
Additional equipment Price Purchased by
Payment source
Ultrasonic cleaner $1.5K PNPI UF
Drying hood $2.5K PNPI UF
Thermostat $1.2K PNPI UF
Assembly workstation $1.2K PNPI UF
Computer for additional test stand $0.8K PNPI UF
Aluminum for side bars $1.5K PNPI UF
Humidity chamber $16K UF UF