Installation and Testing Installation and Testing of Optical of Optical

HarnessesHarnesses

John Matheson Rutherford Appleton Laboratory

Schedule for test and assembly

Outline of required tests

Acceptance testing

Assembly to discs

Final testing

Schedule for Test and Schedule for Test and Assembly: BarrelAssembly: Barrel

• B3: 64 harnessesB3: 64 harnesses

• B4: 80 harnessesB4: 80 harnesses

• B5: 96 harnessesB5: 96 harnesses

• B6: 112 harnessesB6: 112 harnesses

B3: 50 days April 02 -> June 02

B4,B5,B6: Oct 02 -> Mar 03

delivery -> installation ~35 days• 1 man hour for acceptance test

• 2hr for assy to barrel / final test

Schedule for Test and Schedule for Test and Assembly: ForwardAssembly: Forward

• D1,D7,D8: 16 D1,D7,D8: 16 harnesses/discharnesses/disc

• D2,D3,D4,D5,D6: 24 D2,D3,D4,D5,D6: 24 harnesses/discharnesses/disc

• D9: 12 harnesses/discD9: 12 harnesses/disc

• Total 360 (2 end caps)Total 360 (2 end caps)

• services to discs 7/10/02 on (90 days) => 10hr/harness

• 3 full-time technical staff foreseen for assembly/testing of services for barrels and discs

Barrel HarnessBarrel Harness

• DORIC and VDC

• opto package

• power tapes, redundancy system

• many traces and connections

Forward HarnessForward Harness

• forward harness consists of opto packages and optical fibres only

• latest version - no plastic cover

• test LI, responsivity in DC conditions

Test Fixture for Forward Test Fixture for Forward Plug-insPlug-ins

• equivalent to forward module

• design will be transferred to 6 PCBs

• allows testing of BER

What measurements do What measurements do we need ?we need ?

• VCSEL LI curves

• pin diode responsivity

• radiation hardness (batch acceptance)

• BER scan/BER long term

• thermal cycling/burn-in (during manufacture)

• power tape continuity ?

• power tape insulation ?

BER testing: TTC linkBER testing: TTC link

SLOG

LITMUS

OPTIF

TTC link results: BER scanTTC link results: BER scan

TTC BER Scan

0.0

0.1

0.2

0.3

0.4

0.5

0.6

0.7

0 100 200 300

OptIF DAC Value

BE

R

dog-leg1

dog-leg2

dog-leg3

dog-leg4

dog-leg5

dog-leg6

• vary light power into p-i-n diode

• allows definition of working range

• BER scans < 5 min

VCSEL LI CurvesVCSEL LI Curves

SCTLV

SLOG

SCTLV

• scan I using SCTLV

• measure photocurrent in LAPD

• 50% duty cycle

• 5 min. setup/run time

LAPD

DMM

PIN ResponsivityPIN Responsivity

SCTLV

SCTLV

LED

DMM supply

LAPD

• measure I in pin bias line

• LEDs for reproducibility

• LAPD used to calibrate LEDs

• 10 min. setup/run

Acceptance testing at Acceptance testing at RALRAL

Both harnesses:

• responsivity 10 min

• VCSEL L-I curve 5 min

• BER scans data and TTC 30 min

Barrel harness additional:

• HV insulation resistance 5 min

• continuity/shorts 5 min

• redundancy system 10 min

Total time: barrel = 1 hr, forward = 45 min

Forward harness Forward harness installation: installation: assembly formerassembly former

• services assembled to former

• former used to populate quadrant

• after 4 quadrants, align cooling blocks

Forward harness Forward harness installation: procedureinstallation: procedure

• cooling pipes soldered on jig

• mount services on front former

1. dummy modules

2. cooling pipes

3. power tapes

4. opto-harnesses• transfer services to disc

• fix cooling blocks temporarily

• connect patch panels

test each quadrant whilst re-populating the former because:1. quicker

2. next step, align and glue blocks

• turn disc over and repeat

Final testing during Final testing during installationinstallation

Both harnesses:

• responsivity 0 min

• VCSEL L-I curve 0 min

• BER scans data and TTC 30 min

• BER long-term 60 min

Barrel harness additional:

• HV insulation resistance 0 min

• continuity/shorts 5 min

• redundancy system 10 min

Total time:

barrel = 1 hr 45 min, forward = 90 min

• procedures for installation and testing are well defined

• expect 3 technicians for harnesses

• 1 man-hour/harness, acceptance

• 2 hours / harness, test + installationSchedule is achievable but requires care in execution

• first barrel will arrive April 02, timescale less critical

• will allow refinement of procedures