TOB Module Production Overview and Plan Marcel Demarteau for the US CMS Tracker Group

Overview Module Production has resumed since late last year Most of these modules have been constructed with HPK sensors Production statistics to date (April 19, 2005) FNAL has assembled 348 TOB modules Of these only 19 are ST modules UCSB has assembled 354 TOB modules Of these only 21 are ST modules Production proceeding at comfortable steady pace of 12 per day at both sites Production has been held back until assembly and testing of rods will begin Just received the first shipment of re-qualified rod frames from CERN Outline: Hybrid testing Gantry Performance, ARC testing and LT performance CMS Tracker Week, TOB Module Production, April 25-29

Hybrid Testing Results: UCSB Failed Hybrids 3 with Shorts in PA Repairable 1 Smashed APV-PA Bonds 1 Major Scratch in PA 2 Failed Initial Inspection 1 Broken Ceramic 1 Bad Bond Feet 1 Weak Wire Bonds 2 with unknown failure Total of 12 failed hybrids out of 877 Pass Fail % Pass L12pd 0.00% L34p 319 4 98.76% L56p 347 5 98.58% R5N 65 2 97.01% R5S 47 100.00% R6 87 1 98.86% R7 Total 865 12 98.63% CMS Tracker Week, TOB Module Production, April 25-29

Hybrid Testing Results: FNAL Failed Hybrids 5 with Shorts in PA Repairable 7 Noisy channels; usually entire chip or chips Still under study 2 with too many open and noisy channels Total of 14 failed hybrids out of 500. Hybrid ID Pass Fail %Pass 2.2.1.220 R2S 2.2.2.210 R2D 2.2.1.520 R5S 2.2.2.510 R5D 2.1.1.600 R6U 3.2.1.500 L56p 230 3 98.7% 3.1.1.110 L34p&L12pu 256 11 95.9% 3.1.2.110 L12pd 3.1.2.120 L12su L12sd Total 486 14 97.2% CMS Tracker Week, TOB Module Production, April 25-29

Hybrid Testing Outstanding Issues The hybrid testing throughput is very high at both sites with excellent yields However, there are some outstanding issues: Initially about 10% retesting was required at FNAL Noisy edge channels – raise global ADC cut Shorts – pull one PA-APV wire and retest Not all of the failures are completely understood E.g., single channel shorts, entire noisy APV’s Testing takes about 55 minutes for 4 hybrids Meets current need (rate of <28 hybrids a day) but, Too long to for sustained peak rate New code available which will reduce testing times by 10-15 minutes Gives needed contingency for high rate production Code under validation and we are eagerly waiting for a new release CMS Tracker Week, TOB Module Production, April 25-29

Gantry Performance UCSB: FNAL: Summary of Mechanical Accuracy: TOB module assembly has been smooth. Can comfortable build 6 plates in an 8 hour day. Downtime of a several days due to bonder down time Working on consistently doing 6 plates/day and then plan to stretch it out to 7 or 8 per day FNAL: Currently have 6 TOB axial and 4 TOB stereo plates At peak, may need to build as many as 8 plates per day Unclear if there will be a mix of axial and stereo hybrids at the beginning of the peak period, so 2 more axial plates will be build Summary of Mechanical Accuracy: CMS Tracker Week, TOB Module Production, April 25-29

ARCS Testing Results: FNAL Failed Modules 3 – handling error 1 Bad DCU No failure attributable to module production Both failures appear to be hybrid or chip related Total of 4 modules did not pass A B F % A or B L12pu 12 100.00% L12pd 0.00% L12su L12sd L34p 103 2 98.00% L56p 228 1 99.02% Total 343 4 99.00% CMS Tracker Week, TOB Module Production, April 25-29

ARCS Testing Results: UCSB Failed Modules 1 with >2% Bad Channels Debris on sensor 1 Bad DCU 1 HV Shorted to CF Frame 2 with >20 mA Bias Current 1 leaky pinhole 1 scratched sensor 5 modules in total 1 of the 5 failures was caused during module production and testing: 3 failures due to problems in silicon prior to assembly 1 failure is a hybrid or DCU failure Working on validation of ARCS 8.0 Currently using ARCS 7.2 bugfix A B F % A or B L12pu 0.00% L12pd L12su L12sd L34p 85 1 2 97.73% L56p 237 99.17% R5N 32 97.06% R5S R6 24 100.00% R7 Total 378 3 5 98.70% CMS Tracker Week, TOB Module Production, April 25-29

Module Quality UCSB: Produced 375 modules using HPK sensors Total number of faulty channels for passing modules: 130.5 9 pinholes (plucked to be opens) Most induced at UCSB due to wirebonder problems; now fixed 47 shorts (plucked to be opens) All caused by scratches; now reduced by visual inspection 22 noisy channels 52.5 opens Few due to PA and bonding; most inherent in sensors Expected number of faults from QA at HPK: 41.5 Ratio expected to unexpected fault rate ~2 Percentage of bad channels: <.1% one sensor open is a half a bad channel number of shorted channels is total number of shorted channels CMS Tracker Week, TOB Module Production, April 25-29

Module Quality FNAL: For the 210 HPK modules produced in the period March 21 – April 22 Total number of faulty channels for passing modules: 58.5 11 pinholes (plucked to be opens) 16 shorts (plucked to be opens) 10 noisy channels 21.5 opens Expected number of faults from QA at HPK: 27 Ratio expected to unexpected fault rate of ~1 Percentage of bad channels: <.1% CMS Tracker Week, TOB Module Production, April 25-29

LT Testing Results: UCSB We are seeing a low level problem with low noise/mis-initialization of modules Found that there is usually a resistive connection between extender and backplane Reseating extender always fixes problem Will need to watch to see if problem is worsening with time Pass Fail % Pass L12pu 0.00% L12pd L12su L12sd L34p 84 100.00% L56p 223 R5N 34 R5S R6 15 R7 Total 356 CMS Tracker Week, TOB Module Production, April 25-29

LT Testing Results: FNAL Pass Fail % Pass L12pu 0.00% L12pd 12 100.00% L12su L12sd L34p 95 1 98.95% L56p 71 Total 168 99.40% Status: Modules 30200020007883 – 7990 were tested during April 5 – April 18 period Modules 30200020007883-7889 and 30200020007979-7990 passed LT testing successfully with grade A. Rest of all runs have problems when cold with the last records Data cannot be processed: afs backup, xml uploading 80+ modules need to be retested. CMS Tracker Week, TOB Module Production, April 25-29

LT Testing Issue: FNAL While switching APV modes, FEC server generates I2C errors for all modules, which corrupt the data after the first run Problem not observed at UCSB The problem seems to come from initialization of the APV in cold Fermilab turns the modules off after 1st record, waits for the temperature to go to -20C and then initializes them again. This is done a 3rd time for the second warm run UCSB just initializes them at the beginning and never turns them off Analysis: Error being compared to symptoms observed in rod readout Problems being investigated with help of Patrick Gartung Details: lt scenario: -10 ChangeCool -20 dummy -60 TempReached dummy dummy -10 HardReset analoff analoff -10 CheckEnv dummy dummy -3600 CheckEnv dummy dummy -10 HardReset pllinit pllinit -10 PedRun i2cpedpeak pedpeak -10 CalProfRun i2ccalpeak calpeak CMS Tracker Week, TOB Module Production, April 25-29

Overall US Production Quality Summary of the quality of the production Hybrid Testing: 1351 out of 1377 (98%) of the hybrids processed pass specification. Gantry Assembly: 683 out of 690 (99%) of modules pass mechanical specifications ARC Testing: 592 out of 599 (99%) of the modules ARCS tested are grade A or B. Only 1 failure is directly related to module production. Long Term Testing: 524 out of 525 (99.8%) of the modules LT tested are grade A or B. CMS Tracker Week, TOB Module Production, April 25-29

Conclusions Module Production has resumed in the US Currently building modules with HPK sensors To date about 10% of all TOB modules produced Production proceeding at comfortable steady pace of 12 per day at both sites, with peak capacity of 21 – 24 modules per day Production has been held back until assembly and testing of rods will begin Would like to see some issues resolved quickly New hybrid testing code Header error solution High yield of module production and modules are of excellent quality Both sites fully prepared to complete module production on schedule CMS Tracker Week, TOB Module Production, April 25-29

ARCS Testing Issues: UCSB Need to confirm cuts on TEC modules Getting some confusion between 1SO/2SO Have not produced TEC R6 modules in a year Working on validation of ARCS 8.0 Currently using ARCS 7.2 bugfix CMS Tracker Week, TOB Module Production, April 25-29

LT Testing Issues: FNAL Current situation: Rolled back to original 12 hrs scenario (without HardResets before each mode switching), testing 6 modules per run, performed 3 runs: 1 failed, 2 last passed. Patrick suggested to remove all HardResets Wim Beaumont is informed, received several suggestions... First records for all tested modules is OK, no difference with ARCS data. CMS Tracker Week, TOB Module Production, April 25-29