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

2. 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

3. 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

4. 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
R2S
R2D
R5S
R5D
R6U
L56p
230 3
98.7%
L34p&L12pu
256 11
95.9%
L12pd
L12su
L12sd
Total
486 14
97.2%
CMS Tracker Week, TOB Module Production, April 25-29

5. 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 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

6. 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

7. 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

8. 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

9. 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

10. 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

11. 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

12. 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 – 7990 were tested during April 5 – April 18 period
Modules and 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

13. 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:
ChangeCool dummy
TempReached dummy dummy
-10 HardReset analoff analoff
CheckEnv dummy dummy
CheckEnv dummy dummy
HardReset pllinit pllinit
PedRun i2cpedpeak pedpeak
CalProfRun i2ccalpeak calpeak
CMS Tracker Week, TOB Module Production, April 25-29

14. Overall US Production Quality
Summary of the quality of the production
Hybrid Testing: 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

15. 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

16. 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

17. 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