1. CMS Tracker Week, CERN, 19-23 Apr 2004 22 Apr 2004CMS Tracker Week - Module ProductionSalvatore Costa - Catania Module Production ___________ Report on the Catania Status Salvatore Costa Università di Catania and INFN – Sezione di Catania

2. 22 Apr 2004CMS Tracker Week - Module Production2 Salvatore Costa - Catania Outline 1.Module accounting 2.Bonding: 1.Production rate 2.Bonding experience 3.Pull Test results 4.Failure analysis 3.ARCS & LT Tests 1.ARCS test analysis 2.LT test analysis 4.Usage of central DB 5.Logistics & transportation of modules

3. 22 Apr 2004CMS Tracker Week - Module Production3 Salvatore Costa - Catania Module Accounting Module Type  TotalIB34IB12phi Received from Bari Gantry 612833 Bonded58 (51 in DB)2730 ARCS tested56 (47 in DB)2729 OK532627 bad312 LT tested49 (0 in DB)2722 OK492722 bad000

4. 22 Apr 2004CMS Tracker Week - Module Production4 Salvatore Costa - Catania Production Rate Initially slow due to bonding commissioning ( we lacked long-standing experience with previous bonding jobs ), but now on schedule. To illustrate our progress…: –First box received, with 8 Modules, was completed (bonded + ARCS tested) 23 days after arrival –Last 2 boxes, with 9 Modules each, have both been completed within 2 working days after arrival Current bonding capability is 4-5 Modules/day Long Term keeps up with no difficulty with current incoming flux of ~1 9-Module box / week

5. 22 Apr 2004CMS Tracker Week - Module Production5 Salvatore Costa - Catania Bonding Experience Became full-blown Bonding Center on 5 Dec 2003 –Previously designated Bond Repair Center Had passed official CMS Qualification Tests (“bond test # 1 & 2”) Bonding experience with previous experiments: none Equipment: –2 Hughes 2470-II bonders 1991, 1987 automatic but no Pattern Recognition or bond foot deformation feedback –1 ATV GM-100 pull tester manual  Machine downtimes: each time a new machine fault occurred that we had not seen before. Time spent to learn to locate the source of the fault, what action to take and with what procedures. Higher probability of bond failures or accidents

6. 22 Apr 2004CMS Tracker Week - Module Production6 Salvatore Costa - Catania Bond Pull Tests Results 5g IB34 IB12phi sampling

7. 22 Apr 2004CMS Tracker Week - Module Production7 Salvatore Costa - Catania Bond Failure Analysis 53 Modules 34048 bonds repairedunrepairable # modules affected %# strips affected %# modules affected %# channels affected % Totals 44845631.651019290.08 Machine failures 42805061.48713.2140.04 Bond foot misplacement 23.890.026 to stick 428050647.640.012 Pinholes (caused by bonding?) 11.910.003 Operator mistakes 23.8570.1735.7150.04 Mishandling 11.970.0223.870.02 Wrong ref 11.9500.15 Wrong par (lifts, pinholes) (1)(1.9)(384)(1.11)11.980.02

8. 22 Apr 2004CMS Tracker Week - Module Production8 Salvatore Costa - Catania Bond PA-Sen in TIB L1&2 correct misplaced

9. 22 Apr 2004CMS Tracker Week - Module Production9 Salvatore Costa - Catania ARCS Test Analysis All tests performed following the official TIB procedure ARCS 7.0 used for long time (7.1 installed & operational but not yet fully tested) Tony’s macro used initially, starting mid March Riccardo’s update (now v3.1.0) Flagging efficiency with Riccardo’s macro: ~ 100% Out of 53 good modules, 51 are grade A, only 2 are grade B –No IV problems –A total of 55 defective “strips” found over 34048 bonded strips 29 caused during bonding 26 pre-existing: Sen pinholes + APV-PA bond opens + Hyb faulty chan open chan

10. 22 Apr 2004CMS Tracker Week - Module Production10 Salvatore Costa - Catania ARCS Analysis: IV We wrote a script which queries DB to compare measured IV with the Sensor one. We also implemented Temperature correction. NO IV problems up to now IV data not available for all the sensors

11. 22 Apr 2004CMS Tracker Week - Module Production11 Salvatore Costa - Catania Long Term Test Analysis 49 modules tested with TIB Official Scenario (about 72 h) –Some modules retested with a 1-night scenario due to failure on the last record –First, cold & last records always recorded Some failures of the sw before Marco’s patch on I 2 C 1 failure due to DAQ problems with Lt_1.22 No failures since Lt_1.24 was installed Riccardo’s macro used for the analysis (now v3.1.0) No new defective strips appeared after LT test –From time to time some noisy strips appear and disappear

12. 22 Apr 2004CMS Tracker Week - Module Production12 Salvatore Costa - Catania 3 Bad Modules In 3 Modules, all from the very last group of Modules received, we have observed plain failure of the ARCS Test after bonding (they had passed with flying marks the test upon arrival): 2 Modules (30200020035289, 303) fail Fast Tests’ Low Voltage test: I(V2.50) = ~850 mA (max 750 mA) –Bonds are among the best we’ve made, both mechanically and aesthetically –No visually evident damage from possible mishandling –ESD? 1 Module (30200020035305) fails to power up the Hybrid –Damage to connector?  Has something changed in our working environment or procedures?  All these modules’ Hybrids are marked with Alan’s blue dot  Deep investigation needed to understand these problems

13. 22 Apr 2004CMS Tracker Week - Module Production13 Salvatore Costa - Catania Usage of central DB Bonding data always timely uploaded to TrackerDB since the beginning for all ARCS & LT data, xFLAG 1.4.3 has been used to produce XML files: 53 ARCS + 49 LT –XML files checked for consistency with root files and macro’s output No serious problems reported Only few root files need to be redone due to old ARCS bug in the header –86% of ARCS XML files already uploaded –LT XML files not yet uploaded

14. 22 Apr 2004CMS Tracker Week - Module Production14 Salvatore Costa - Catania Logistics & Transportation No major problems with modules received from Bari –In first 2 boxes only the styrofoam blocks on the sides were too far apart, so Modules (on transport cradles) slipped out of their slots, but no damage to the modules resulted. Problem was quickly corrected in newer boxes –Some dirt (mainly small [fabric?] fibers) We blow a 1.5 atm air jet on Module before starting visual inspection Our storage space in clean room can hold ~8 more boxes (72 Modules), –After, better to start shipping to Pisa –or we will have to figure out how to carve out more storage space

15. CMS Tracker Week, CERN, 19-23 Apr 2004 22 Apr 2004CMS Tracker Week - Module ProductionSalvatore Costa - Catania ARCS & LT Test The Catania CMS Module Production Crew S. Costa, N.Giudice, F.Noto, F.Raimondo, C.Sutera, C.Tuve Inspection, Test on arrival, Bonding S. Albergo, M. Chiorboli, M. Galanti, G. Gatto, A.Tricomi