Status of the Tracker Outer Barrel Joe Incandela University of California Santa Barbara for the US and CERN Tracker Groups Comprehensive Review June 28, 2005

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 2 Covered in this talk Past year: Overcame problems with hybrids and sensors Adapted to a shorter production schedule US production lines were reworked to be as robust as possible Upgraded US production capacity by factor of 3 original plans Recent Milestones Good module components are flowing Frames and sensors are well off critical path Hybrids still pace production but rates will rise US module production has ramped to ~65% of peak Quality is close to what we anticipated and improving. Mechanics and integration preparations proceeding well at CERN Current issue: Rods Rod component procurements and assembly nearing completion Seeing potentially serious problems with rods (as we expected) that must be dealt with now despite potential schedule disruptions. I will summarize US activity followed by CERN

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 3 US Tracker Group Brown University R. Hooper, G. Landsberg, H.D. Nguyen, C. Pehlevan, T. Hartman, H.Y. Jung University of California, Riverside (UCR) G. Hanson, H. Liu, G.Y. Jeng, G. Pasztor, A. Satpathy, R. Stringer University of California, Santa Barbara (UCSB) A. Affolder, S. Burke, C. Campagnari, F. Garberson, D. Hale, J. Incandela, S. Jaditz, P. Kalavase, S. Kyre, J. Lamb, D. Stuart, D. White + technicians University of Illinois, Chicago (UIC) E. Chabalina, C. Gerber, L. Nigra, T. Ten Fermilab (FNAL) S. Cihangir, M. Demarteau, D. Glenzinski, H. Jensen, A. Ronzhin, J. Spalding, L. Spiegel, S. Tkaczyk + technicians University of Kansas (KU) P. Baringer, A. Bean, L. Christofek, D. Coppage Mexican Consortium: Cinvestav: H. Castilla, R. Perez, A. Sanchez Puebla: E. Medel, H. Salazar San Luis Potosi: A. Morelos University of Rochester (UR) R.Demina, R. Eusebi, Yu. Gotra, E. Halkiadakis, S. Korjenevski, S. Lockwood D. Miner, P. Tipton + technicians

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 4 US Module Assembly Plates Now in useproposedTotals Plate TypesUCSBFNALUCSBFNALActual If add R7 at FNAL TOB R-phi7815 TOB Stereo3477 TEC R5 R-phi333 R5 Stereo333 TEC R6555 TEC R73538 Totals We are now setup to process at most 20 plates (60 modules) per day. A much larger number of plates was prepared to allow us to adapt to whatever variations may occur in component deliveries and tracker needs.

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 5 US Production Cycle Quick test hybrids on ARCGantry makes modules. Modules test on ARC Assemble rods from modules Rod burn-in Rods shipped to CERN Thermal cycled module Wire bond Final pinhole test on ARC Wire bond Thermal cycle hybrids

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 6 US Production Steps/Status TaskCapacityManpower issuesSoftware Issues? Hardware Issues? Hybrid Bonding & Thermal Cycle 84/dNoneNo Module Assembly 50/dNoneNo Module Bonding>50/dNoneNo ARC Testing>50/dNoneNo LT Testing200/wkNoneNo ARC LED>50/dNoneNo Reinforcing>50/dNoneNo Rod Assembly8/dNoneNo Single rod test>8/dNoneNo Multi rod test>32/wkNoneYes DAQ Component shortages and/or failures can limit production testing capacity in future

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 7 TEC R7 TEC R6 TEC R5P TEC R5S TOB r-phiTOB stereo Modules Assembled in the US

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 8 UCSB TEC Production Module Production R5N, R5S, R6 and R7 Designed built commissioned: Assembly plates, wirebond fixtures, carrier plates, shipping boxes All TEC production equipment is commissioned except for R7. General capacity issues Could saturate our production capacity with TEC production (30/d) Actual rate depends on need and availability of parts as well as TOB production parts availability and schedule Bonding and Testing capacity adequate LT testing capacity limit is ~100 per week but could eventually be mostly TEC if necessary (since TOB burn-in will be shifted to rods) or it will have to be sampled

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 9 US Components Inventory HybridsSensorsFrames FNALUCSBFNALUCSBFNALUCSB STHPITSTHPITSTHPITSTHPIT 4 chip L56pu R5p R5s R R As of 6/27/05: Plenty of sensors and frames on hand Hybrids are the critical path components

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 10 Quality assurance program at University of Rochester  Total number of sensors received 2351 since October 2004 (only OB1 and OB2 HPK silicon microstrip detectors)  Corresponds to 89 production batches  All batches are qualified for production 254 sensors(*) have been fully tested 4 Rejected – damaged during shipment * Last shipment of 532 sensors is being tested. As of 6/14/05

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 11 US Module Assembly

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 12 (All quantities are up to June 24th 2005) US Module Assembly Grade ABF% Passing L12pu % L12pd % L12su % L12sd % L34p % L56p % R5N % R5S % R % R % Total %

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 13 Sensor-to-sensor-alignmentMetrology

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 14 Sensor-to-sensor-alignment  ~ 7-8  m UCSB FNAL Metrology Specification is  30  m (i.e. range shown on x axis)

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 15 US Hybrid Testing

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 16 US Hybrid Testing Recovered 11 hybrids this week Approaching 99% yield

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 17 ARCS Testing Results

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 18 UCSB ARCS Testing Results UCSB 1016 Tested 1006 Grade A 3 Grade B 7 Grade F Past 2 weeks: 17 bad out of 56,196 channels (0.030%) Total UCSB Production: 322 bad strips in (0.046%)

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 19 US ARCS Testing Status Have slowed in most recent week due to shortage of hybrids at FNAL and commissioning of R7 production at UCSB US capacity is 300 modules per week.

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 20 US LT Testing Status

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 21 US LT Testing Status US Capacity is 200 per week

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 22 US module production (to June 10) US will build >8,000 modules US peak Capacity ~ modules per week. One week peak so far = 185

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 23 Further Planning US will help accelerate TEC schedule R7 production at FNAL in Autumn at modules per day. Plate design were transferred from UCSB for FNAL modifications. FNAL will fabricate and commission the plates. UCSB making additional wirebond fixtures, shipping boxes UCSB will also transfer all programs related to testing. FNAL will manufacture carrier plates, LT test plates etc. Second hybrid line UCSB overseeing hybrid assembly at Amtech (GS substrates) Initial results are comparable to HSA. New tooling has been ordered to improve bonding. Expect to be ready for 200/wk production in mid-July Riverside repair and diagnostics center nearly online

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 24 Diagnostic Facility at UC Riverside ARC Test Test stand is operational Able to reproduce problems found at production sites Long Term Test All hardware components (except TPO) are in hand Debugging test stand Will be operational shortly Other capabilities Optical inspection and probe station

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 25 Rods Overview Basic components procured Assembly of frames is nearing completion Integration of modules on rods is understood Rate of ≳ 8/d in the US should not be a problem … Testing has been problematic US rod production was halted Persistent I2C communication errors seen on 30-50% of rods Recent and very substantial effort to understand and remedy Communication is marginal Simple solutions exist but we are not sure how robust A better solution probably requires some redesign Secondary issues of header errors and failures in LT tests are also under study Header errors were also observed at CERN recently while operating rods in the Cosmic Rack for long periods, but it may not be the same effect as seen in the US…

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 26 Tests of I2C errors Guido Magazzu & Wim Beaumont Visited FNAL then UCSB May 30 to June 7 Many studies performed. Most, but not all, mysteries resolved. Full Report is available Problem: different RC time constants on the I2C clock lines (to hybrid and optohybrid) Causes transitions to occur at non-ideal relative times Margin we have to play with is less than ~7 ns Can be made more robust by adding a rad-hard buffer on each hybrid line. Work is underway

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 27 Tests at UCSB RodModErrors 192jumper no i2c errors (warm, cold cycle) (some header errors) 361R=820 ohm no errors (warm, cold cycle) 498R=0 no errors (warm, cold cycle) 498R=0 single PS no errors (warm, cold cycle) noise OK 20R=3 kOhm error "23" in Wim's i2ctest.sh Most of the proposed solutions worked in Tests at UCSB Situation at FNAL is less clear – under investigation

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 28 Current planning Restarted rod production Each of UCSB and FNAL will modify 6 Layer#6 rods by adding a jumper across optical and readout hybrid I2C lines. Then they will go through an extended LT test. We will follow with 4 more groups of 6 rods each site and ship 60 rods to CERN for integration exercises In parallel: a redesign of ICC card If the first 60 rods shipped to CERN are reasonably error free, we will continue rod production to complete one complete end of Layer 6 Further rod production will await new ICC card Will also refit the already completed Layer 6 rods when cards are available This plan allows us to get more experience with large number of rods in various situations. Should help us uncover any further residual problems.

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 29 Frame production in Helsinki Rod frame production in Helsinki complete. 753 good frame produced compared to 760 possible and 688 needed in TOB (target was > 723, i.e. > 5% spares) Geometry of each frame is checked The positions and orientations of the 12 module positioning pins relative to the frame, as defined by the rod support spheres, are the most critical dimensions. Data goes into the production database Translated to precision in module positioning, RMS = 40 microns - excellent result

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 30 Rod cabling at CERN Discovered end of March: Microscopic solder residues on 2 (out of 3) types of PCBs Potential source of corrosion in the presence of humidity Restarted assembly after re-cleaning ~60% of rods are now cabled Continuing smoothly 100% yield with experienced technicians Rate > 5 rods per day Example of a dirty board Before After

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 31 TOB wheel construction: complete Mechanics complete and rotated into final position Precision elements of disks and cylinders glued on a single jig yielding typically  30  m relative precision Relative positioning of disks and cylinders limited only by measurement system precision (  100  m) A major achievement by Antti Onnela and the DT2 technical crew!

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 32 Thermal screen operational Wheel ready for insertion in the tracker support tube and… The tube with thermal screen are already in the assembly clean room. Wheel on assembly chariot Wheel ready

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 33 Ongoing work on mechanics Installation of TIB support rails now a high priority Production of cooling manifolds Production and installation of services support elements (first on mock-up: a combined TOB/TIB cabling test next month)

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 34 There is sufficient storage facilities available to house production rods before/after acceptance test Rod CERN Box: 3-rod capacity, dry air line T/RH probes interlocked to PS Mobile source + scintillator DAQ (XDAQ + RCMS) ready migrating to new OS Scenario with automatic scan of all sensors finalized 1/2 room temperature includes control of HV power supply Scan of rod label  DAQ configured from DB Up-loading results to DB still to be defined “XY table” test setup Located in “rod clean tent”  source on moving arms Scintillator moving with source

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 35 TOB integration TOB integration is done by cooling segments One cooling segment = 8 to 22 rods fed by the same manifold, that serves as common ground (the TOB cooling system has soldered joints) Several preparation tasks - on auxiliary workbenches clean rod cooling pipe and leak test prepare and register optical ribbons pre-cable rod with optical ribbons select, test and register power cable In addition: Production and testing of the 88 cooling manifolds Production and validation of all Digital Optohybrid Modules (92 in the TOB)

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 36 Preparation work - status DOHM production 5 prototypes successfully produced Assembly and testing procedure defined Cleaning and leak-checking of pipes Fixtures ready Sophisticated He leak detection system commissioned TK assembly room plumbing ready Rod pre-cabling with optical ribbons Fixtures ready Connection scheme defined, ribbons prepared Rod insertion Sophisticated tool commissioned long ago

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 37 Preparation work - status Cable production Acceptance test and labeling scheme defined Now finalizing all lengths (nearly done) Manifold production Procedure defined and tested Connection points along manifolds finalized Cooling loop integration procedure has been defined Current plan relies upon ability to operate ctrl ring with FE off May need to be modified depending on choice of solution to the I2C problem – but, hopefully not. Test setup for cooling segment test Power supplies received, cables being modified. Still missing FEDs and trigger system.

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 38 Special case: layer TOB6- Due to small clearance to support tube Layer 6- integrated with wheel outside support tube Test with incomplete plumbing and temporary power cables Then, finally can Insert TOB in support tube Then we will run at operating temperature Complete and leak check all plumbing Complete cabling and test functionality

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 39 Regarding Schedule Priorities It is of primary importance to install a tracker that will perform well for the duration that it is needed. “There is no reward for the on-time delivery of a detector that does not work” – H. Frisch I2C problem and consequent delays It is important to note that ALL integration and commissioning tasks are faster and more reliable if the problems that we encounter are immediately treated. A well considered solution to the I2C problem will save more time than it costs in the long run. Recovering lost time We will likely have to revisit the planning and adapt somewhat to the situation at hand in order to recover delays where possible. e.g. The US is preparing to build up a substantial, well experienced integration team that could complement the CERN team and help advance the schedule In the past, we have run 24 hour shifts, 7 days per week for up to several months when necessary in the US…

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 40 Summary US production lines have completed 25% of TOB >99% yield and >99.95% good channels Production rates of modules/day and ≳ 8 rods/day can be achieved, provided that we have adequate parts flow and stable multi-rod qualification testing Rod frames production in Helsinki is complete I2C communication problem is understood Rod integration and testing has restarted in the US TOB Wheel is basically ready Integration should start soon Large capable team at CERN US to send large team as soon as all production is stabilized

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 41 Conclusions Excellent progress In module production Preparation of mechanics for final assembly Excellent progress In understanding the small residual problems we are now encountering Not only will we solve them, but in doing a proper job of addressing them we will be able to install a better understood and more reliable detector. We will recover schedule We plan a substantial influx of experienced personnel to CERN The new integration center will provide an excellent working environment and the 25% test system will provide a major step in preparing the tracker for physics as soon as possible after the LHC turns on. We are very optimistic that the TOB will meet all requirements!

Additional Slides

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 43 Modules Enter Bonded, Untested Modules Shelf ARCS Testing If Failed If Passed Can We Fix It? Yes Repairs Repaired Modules Shelf Needs Repair Shelf in Bonding Room Failed Modules Shelf No Good ARCS Tested Modules Shelf LT Testing Bad Thermal Cycle, Needs Retest Shelf Chosen for LT Test? TEC or TOB? TEC or TOB? TEC Thermal Cycled Ready For Shipping Shelf TOB Thermal Cycled Ready For Rod Assembly TEC Not Thermal Cycled Ready For Shipping Shelf TOB Not Thermal Cycled Ready For Rod Assembly No Yes If Passed If Failed TEC TOB Is the Problem Understood? Undiagnosed Modules Shelf YesNo TECTOB Module Testing Flowchart

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 44 AOH FE-Hybrid SCL SDA 82  Parasitic on FE Hybrid C H Parasitic on AOH C A C H > C A Present Electrical circuit

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 45 (Main) Solutions under investigation R=82 Ohms  R=0 Ohms As implication for power-on sequence. Would need to power-on control and F.E. at the same time Most robust from I2C stand point Tune one of the R to equalize RC R to AOH ~ 820 ohm Jumper across resistance Forces same RC

Tracker Outer Barrel, J. Incandela, UCSB - June 28, 2005 – Comprehensive Review slide 46 AOH FE-Hybrid SCL SDA 82  Parasitic on FE Hybrid C H Parasitic on AOH C A PSU Control PSU FE before Solution 6