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Summary: LCM integration & PRR (in particular: integration rehearsal of last week)

Status of Control Module integration. Summary: LCM integration & PRR (in particular: integration rehearsal of last week) Preparation for xCM production. Control Module production. Reception. (transportation). It consists of the following processes:. Storage. Component level.

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Summary: LCM integration & PRR (in particular: integration rehearsal of last week)

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  1. Status of Control Module integration Summary: • LCM integration & PRR (in particular: integration rehearsal of last week) • Preparation for xCM production M. Circella, ANTARES-SC meeting, CPPM April 2004

  2. Control Module production Reception (transportation) It consists of the following processes: Storage Component level Integration Module level Test Packing (+storage) (transportation) M. Circella, ANTARES-SC meeting, CPPM April 2004

  3. Control Module production: scenario All activities under definition based on the following considerations: • Time constraints (schedule request: one working LCM produced in two days) • Manpower needs (one person?) • Safety requirements: power & grounding during functional tests, ESD protection, fibre handling • Quality Control approach: detailed procedure for each operation, development of tools • Traceability & test needs Target: Full system defined and working in time for the construction of the MILOM modules (according to the current schedule: by end of June 2004) LCM integration test for LCM PRR: necessary step to check the overall design of the module from the integration point of view and in particular to spot out all possible (minor) modifications to the module components before the mass productions start M. Circella, ANTARES-SC meeting, CPPM April 2004

  4. LCM integration tests for PRR • First test performed in week 12 (March): report available at http://www.ba.infn.it/~circella/LCM/LCM_int_first_report.pdf • Complete rehearsal of the integration performed in week 16 (last week): procedure and report available at http://www.ba.infn.it/~circella/LCM/LCM_integration_test_prr_10.pdf http://www.ba.infn.it/~circella/LCM/LCM_int_second_report.pdf Conclusion after both tests: ***NOT READY*** (but not so far away from readiness…) M. Circella, ANTARES-SC meeting, CPPM April 2004

  5. LCM PRR integration test report • Difficulties concerned: • Missing or wrong specifications on screw sizes, screwing torque, thread locker decisions made on the site • Not all components available: the nylon ring and the 1 M resistor for connection to the flange, a few screws, the plastic tubes and their brackets were missing • spare parts (most from the PSL) recycled or adapted • 3. Not all boards in final configuration: • - ‘glue’ problem on the backplane • - LCM_CLOCK without fibre tray • - cooling plates of the crate out of specifications? • not possible to test the final LCM configuration • 4. Integration supports not available • not possible to test the final procedure • Most serious problem: electrical contact between crate and titanium (flange + tube) M. Circella, ANTARES-SC meeting, CPPM April 2004

  6. Module integration (summary) 0. (Get all components and tools at hand) 1. Assemble a complete module before making any tests 2. Power and optical margin test: check that the voltage and current values are acceptable when powering up the module with a test board (SUMO) inserted between the power box and the crate and that the optical transmission work with proper attenuators inserted along on the optical fibres. Then remove the SUMO and mount the power box on the module 3. Functional test M. Circella, ANTARES-SC meeting, CPPM April 2004

  7. crate LCM integration procedure (rehearsal of) (0. Get all proper components and tools at hand) Result step 0: not all components available (+ a few specification errors) • assemble the crate (backplane included), and fix the gas venting tube to it Option: fix the fibre spiral tube as well! • Comments: • no supports needed for this step • it is not convenient (or possible?) to mount the spiral tube at this step M. Circella, ANTARES-SC meeting, CPPM April 2004

  8. Result step 1: • backplane: excess of glue on coaxial cables, coaxial cables not labelled • ground cables from backplane: what is the ideal position? • insertion of the coaxial cables in the trays of the backplane holders difficult • brackets for the plastic tubes can not be mounted without modifying the crate LCM integration test (details) possible modifications to the crate and backplane M. Circella, ANTARES-SC meeting, CPPM April 2004

  9. crate LCM integration procedure (rehearsal of) • Fix the crate to the titanium flange flange • Comments: • preferred orientation is horizontal (supports needed) • no (more) alignment holes in the flange and couronne 1 M. Circella, ANTARES-SC meeting, CPPM April 2004

  10. Result step 2: • difficult alignment of flange and crate (rehearsal made with crate vertical due to missing supports) • difficult insertion of the kapton ring • missing 1 M resistor • wrong screws used for the resistor (due to missing specifications) • difficult to get crate and flange isolated (due to flange’s washers? plastic inserts of the screws?) • improve documentation • develop integration supports • fix the nylon rings to the crate? • check again all screws with torque specifications • modifications to flange or crate? M. Circella, ANTARES-SC meeting, CPPM April 2004

  11. LCM integration procedure (rehearsal of) (old version support) 3. …then the (flange+crate) block is fixed on its support… Comment: support not available during this test M. Circella, ANTARES-SC meeting, CPPM April 2004

  12. LCM integration procedure (rehearsal of) Power box SUMO test board 4. …the crate is connected to the power box through a power supply test board (SUMO: Supply Monitor) Comment: SUMO board not used during the test 5. ...then we insert the boards one at a time M. Circella, ANTARES-SC meeting, CPPM April 2004

  13. Result step 5: • fibre spiral tube not initially fixed to crate. It needs to be fixed to the table and elongated up to 70-80 cm • wrong screws used for DAQ and CLOCK cooling bases (due to missing • specifications) • improve documentation • develop integration supports M. Circella, ANTARES-SC meeting, CPPM April 2004

  14. LCM integration procedure (rehearsal of) Power box SUMO test board 6. …when all boards are inserted we fix the fibre spiral tube to the crate, then we make all connections to the test bench (power, fibres, flange connectors) and make the power and optical power margin tests Option: we mount at least one of the cooling plates before the power+optical power margin and/or the functional tests Comment: step 6 not made during the rehearsal M. Circella, ANTARES-SC meeting, CPPM April 2004

  15. LCM integration procedure (rehearsal of) 7. …remove the SUMO board and fix the power box to the crate 8. functional tests!! Comment: steps 7-8 not made during the rehearsal M. Circella, ANTARES-SC meeting, CPPM April 2004

  16. LCM integration procedure (rehearsal of) 9. …(assuming the test is ok) prepare for shipping (old version LCM) M. Circella, ANTARES-SC meeting, CPPM April 2004

  17. What to do at the line integration site 10. If necessary, remove the protection from the bottom flange 11. Install/replace the o-rings of the bottom flange 12. Install the titanium cylinder and mount the container on the line Comment: only step 12 relevant for this rehearsal Result step 12: contact between crate and titanium container! Solved by putting kapton tape on the short edges of the cooling plates M. Circella, ANTARES-SC meeting, CPPM April 2004

  18. PBS and bar-code General formula for traceability: PBSNumber/VersionNumber.SerialNumber (rule: one individual PBS number used to identify only components which are always completely interchangeable) Is this THE rule? Are there exceptions? • Notes added after the meeting: • the rule above is no longer endorsed by the Steering Committee (therefore the discussion of page 22 needs to be updated) • the traceability format remains valid, with the SerialNumber to be a unique number for ONE object of a given PBS (i.e., the SerialNumber increases independently of the VersionNumber) M. Circella, ANTARES-SC meeting, CPPM April 2004

  19. LCM configurations There are 3 kinds of LCM’s (leaving aside the MILOM and IL needs): (a) LCM connected to 3 OM’s (b) LCM connected to 3 OM’s and a LED beacon (c) LCM connected to 3 OM’s and an acoustic receiver (d) LCM connected to sound velocimeter/CTD Proposal - let us define a ‘version number’ to discriminate among them: 1 for LCM (a) 2 for LCM (b) 3 for LCM (c) 4 for LCM (d) (5, 6, ... for future needs – 0 for the ‘no-version’ option) Note: there is indeed one PBS number for all LCM’s and MLCM’s M. Circella, ANTARES-SC meeting, CPPM April 2004

  20. MLCM configurations There are 2 kinds of MLCM’s (leaving aside the MILOM and IL needs): (a) MLCM connected to 3 OM’s (b) MLCM connected to 3 OM’s and a LED beacon Proposal - let us define a ‘version number’ to discriminate among them: 1 for MLCM (a) 2 for MLCM (b) (3, 4, 5, ... for future needs – 0 for the ‘no-version’ option) Note: there is indeed one PBS number for all LCM’s and MLCM’s (so the LCM and MLCM versions should be enumerated together) M. Circella, ANTARES-SC meeting, CPPM April 2004

  21. SCM configurations There are 2 kinds of SCM’s (leaving aside the MILOM and IL needs): (a) SCM connected to acoustic TX/RX, pressure sensor and sound velocimeter (b) SCM connected to the instruments in (a) + a laser beacon Proposal - let us define a ‘version number’ to discriminate among them: 1 for SCM (a) 2 for SCM (b) (3, 4, 5, ... for future needs – 0 for the ‘no-version’ option) M. Circella, ANTARES-SC meeting, CPPM April 2004

  22. PBS updates Suggested changes: • crates: the current PBS has only 2.1.01 LCM_CRATE => we would need two PBS numbers for LCM_CRATE and MLCM_CRATE • backplanes: the current PBS has only 2.1.02 LCM_BACK and 2.2.02 SCM_BACK => we would need three numbers for LCM_BACK-1 (for LCM-V1 and LCM-V3), LCM_BACK-2 (for LCM-V2), and LCM_BACK-3 (for LCM-V4); 2 numbers for MLCM_BACK-1 (for MLCM-V1) and MLCM_BACK-2 (for MLCM-V2); and 2 for SCM_BACK-1 (for SCM-V1) and SCM_BACK-2 (for SCM-V2). Then, we will add more numbers if/when needed • LCM flange: the current PBS has only 1.3.2 LCM_CONTAINER => we would need three different numbers for the different flanges (for the three LCM configurations). Should we also introduce different PBS numbers for the flanges and the other parts of the containers, as for the SCM case? • LCM_DAQ/SC: the current PBS has only 2.1.17 LCM_DAQ/SC => we would need three different numbers for MLCM_DAQ/SC, LCM_DAQ/SC and SCM_DAQ/SC • MLCM_DWDM: the current PBS has only 2.1.16 MLCM_DWDM => we would need EITHER 5 different PBS numbers OR the version number used to specify the different wavelengths (or are there other options?) • SCM_REP: the current PBS has only 2.2.04 SC_REP => we would need two different numbers for SCM_REP1 (serving 3 sectors) and SCM_REP2 (serving 2 sectors) • LPB: the current PBS has only 2.2.11 POWER_BOX. It is indeed the same object used inside the LCM/MLCM/SCM, but in case of the xLCM it will be powered at +380 V, in the SCM it needs to be powered at +48V: the difference is made by the connector => shall we give a PBS number to the connector and its cable? [h) should we also worry about the different SCM flanges?] See notes on pages 18, 19, 20 Further suggestion: double-check all labels and avoid using numbers in labels when not strictly needed (so: LCM_BIDICON => MLCM_BIDICON ; SCM_WDM1 => SCM_WDM ; SCM_BACK1 => SCM_BACK-1/SCM_BACK-2 ;) M. Circella, ANTARES-SC meeting, CPPM April 2004

  23. LCM main components • LCM-V1 (configuration with just 3 OM’s) is composed of: - 1 LCM_CRATE PBS-2.1.1 (*) - 1 LCM_BACK-1 PBS-2.1.2 (*) - 1 POWER_BOX PBS-2.1.11 (*) - 1 titanium flange PBS-1.3.2 (*) [the rest of the container will be installed at the level of line integration] - 1 COMPASS_MB PBS-2.1.3 - 3 ARS_MB PBS-2.1.4 - 1 LCM_DAQ/SC PBS-2.1.17 (*) - 1 LCM_CLOCK PBS-2.1.7 Note: PBS-related issues exist for items marked (*) Then, • LCM-V3 (configuration with 3 OM’s and an acoustic receiver) comprises in addition: - 1 ACOUST_RX_PREAMP PBS-2.1.8 - 1 ACOUST_RX_DSP PBS-2.1.9 - 1 ACOUST_RX_CPU PBS-2.1.10 • LCM-V2 (configuration with 3 OM’s and a LED beacon) comprises in addition: - a fourth ARS_MB PBS-2.1.4 (but we have to replace LCM_BACK-1 with LCM_BACK-2) • for LCM-V4 LCM_BACK-1 should be replaced with LCM_BACK-3) [Beware: the flange is different for each configuration] M. Circella, ANTARES-SC meeting, CPPM April 2004

  24. MLCM main components • MLCM-V1 (configuration with just 3 OM’s) is composed of: - 1 MLCM_CRATE PBS-2.1.1 (*) - 1 MLCM_BACK-1 PBS-2.1.2 (*) - 1 POWER_BOX PBS-2.1.11 (*) - 1 titanium flange PBS-1.3.2 (*) [the rest of the container will be installed at the level of line integration] - 1 COMPASS_MB PBS-2.1.3 - 3 ARS_MB PBS-2.1.4 - 1 MLCM_DAQ/SC PBS-2.1.17 (*) - 1 LCM_CLOCK PBS-2.1.7 - 1 MLCM_DWDM PBS-2.1.16 (*) - 1 MLCM_SWITCH PBS-2.1.18 - 1 (M)LCM_BIDICON PBS-2.1.05 Then, • MLCM-V2 (configuration with 3 OM’s and a LED beacon) comprises in addition: - a fourth ARS_MB PBS-2.1.4 (but we have to replace MLCM_BACK-1 with MLCM_BACK-2) [Beware: the flange is different for the two configurations] Note: PBS-related issues exist for items marked (*) M. Circella, ANTARES-SC meeting, CPPM April 2004

  25. SCM main components • SCM-V1 (configuration without a laser beacon) is composed of: - 1 SCM_CRATE PBS-2.2.01 - 1 SCM_BACK-1 PBS-2.2.02 (*) - 1 POWER_BOX PBS-2.1.11 (*) - 1 titanium flange PBS-1.2.6.2 (*) - 1 COMPASS_MB PBS-2.1.3 - 1 SCM_DAQ/SC PBS-2.1.17 (*) - 1 SCM_CLOCK PBS-2.2.05 - 1 SCM_WDM PBS-2.2.03 (*) - 1 SCM_REP1 + 1 SCM_REP2 PBS-2.2.04 (*) - 1 SCM_DWDM PBS-2.2.16 - 1 ACOUST_RXTX_EM PBS-2.2.07 - 1 ACOUST_RXTX_PREAMP PBS-2.2.08 - 1 ACOUST_RXTX_DSP2 PBS-2.2.09 - 1 ACOUST_RXTX_DSP1 PBS-2.2.10 - 1 ACOUST_RXTX_CPU PBS-2.2.11 - 1 ACOUST_RXTX_POW PBS-2.2.12 Note: PBS-related issues exist for items marked (*) Then, • SCM-V2 (configuration with a laser beacon) comprises in addition: - 1 ARS_MB PBS-2.1.4 (but we have to replace SCM_BACK-1 with SCM_BACK-2) [Beware: the flange is different for the two configurations] M. Circella, ANTARES-SC meeting, CPPM April 2004

  26. Control Module minor components (1) For integration of each xCM the following components are also needed: 1. small parts for the crate assembly, namely: 1.1 the screws to fix couronne 1 to the titanium flange; 1.2 the plastic inserts for these screws; 1.3 the nylon rings to be put between couronne 1 and the flange for LCM/MLCM; 1.4 the screws to fix the LPB to couronne 2; 1.5 the mini-screws to mount the backplane into its support bars; 1.6 the bolts to fix the ground connections from the backplane to the crate; 1.7 the screws to fix the backplane to couronne 2 1.8 the brackets to install the two plastic tubes (with screws+washers); 1.9 the screws for the cooling bases of LCM_DAQ/SC and LCM_CLOCK (LCM/MLCM/SCM), MLCM_DWDM and MLCM_SWITCH (MLCM), SCM_DWDM and SCM_WDM (SCM) M. Circella, ANTARES-SC meeting, CPPM April 2004

  27. Control Module minor components (2) Then we need also: 2. the 1 MΩ resistor to be installed between the crate and the flange for LCM/MLCM (with its screws) 3. the LPB connector terminated by the wires to be soldered to the backplane (with its screws) 4. the HV cable for the LPB (with the screws for the connector) 5. the gas venting tube and the fibre spiral tube 6. the thread locker(s) 7. the thermal gel for the cooling plates M. Circella, ANTARES-SC meeting, CPPM April 2004

  28. implications for component delivery to the integration sites traceability implications (PBS) Component reception: assumptions Very strong recommendation: Every single board should arrive to the xCM integration site ready to be integrated in a Control Module It implies that at the xCM integration sites there will be: - no modifications to any board - no wire or component soldering - no check of board configuration M. Circella, ANTARES-SC meeting, CPPM April 2004

  29. Implications for component delivery to the xCM integration sites We expect that: • the titanium flange arrives with all cables terminated with the connectors to plug to the backplane; it should have no o-ring (or, at least, no ‘final’ o-ring) and possibly it should be provided with proper protections for the connectors and the inner surface • the backplanes arrive equipped with all components properly installed (as needed!), including the power wires and the connector to plug to the LPB, the coaxials and any other cable • the LPB arrives equipped with its HV connector and wires • each board arrives exactly in the configuration it should be (i.e., as identified by its traceability label: PBSNumber/VersionNumber.SerialNumber) • for all components we expect to receive an accompanying test report and to be able to trace the product history through the bar code label (we will use it as well to update the history of the integrated modules) - ... (this list will be updated according to the integration test results) M. Circella, ANTARES-SC meeting, CPPM April 2004

  30. Component reception at the xCM integration site Therefore we need that: - each component is accompanied by a proper test report (= a PBS compliance certificate) - traceability is possible through the bar code label Actions upon reception: • visually inspect the components • check the accompanying documentation • interact with the database to update the product history M. Circella, ANTARES-SC meeting, CPPM April 2004

  31. Component storage at the xCM integration site - ‘Standard’ laboratory conditions needed for storage and integration • ESD protection required for all sensitive components (i.e., electronics boards and LPB) at all times • storage room needs under evaluation (most serious requirement from mechanical pieces) M. Circella, ANTARES-SC meeting, CPPM April 2004

  32. Packing (and delivery) • Transportation logistics provided by IN2P3 “Cellule Logistique” • Flange transportation box will be used for module delivery M. Circella, ANTARES-SC meeting, CPPM April 2004

  33. Work in progress... • In progress (due for xCM PRR): • PBS list • component configuration (namely, define possible changes) • integration procedure • integration supports and tools (all or just what is essential?) • documentation Target: complete rehearsal has to be made in time for LCM PRR M. Circella, ANTARES-SC meeting, CPPM April 2004

  34. Work to be done... • To be done (due for end June for LCM): • definition of intermediate (power, optical power margin) tests • transportation boxes for components and modules • storage containers/conditions • bar code traceability (requires reader and software) • complete integration table • define and implement test benches! • define test scenario (including: failure modes, module repair line) • documentation M. Circella, ANTARES-SC meeting, CPPM April 2004

  35. Critical items... • What’s critical: • Quality Control directives needed (in time for PRR?) • Test bench status unsatisfactory (needed for production) • the Pisa group can contribute more • no ‘MLCM training’ currently possible • possible conflict in Bari for finalization of the SCM and MLCM test benches M. Circella, ANTARES-SC meeting, CPPM April 2004

  36. Implications • Should the LCM PRR wait to have the full Quality Control system implemented? • Is the integration of the MILOM LCM’s really needed in July? (SCM and MLCM due in September) • Can we enable the Pisa group to work on the module integration and on the development of the test bench at Pisa? (needed: onshore clock system, ethernet fibre connection, a complete LCM) M. Circella, ANTARES-SC meeting, CPPM April 2004

  37. SCM test bench development (ongoing work at Bari) • General definition essentially done • Implementation delay due to unexpected problem with the ethernet link • Implementation essentially stopped because: - acoustics system control is not possible with the DAQ/SC software - lack of detailed documentation on other tests • Current status of the test bench: - it manages SC and clock communications with the SCM - it can drive the SCHarness through the state machine - it can query and decode SC data all in an integrated Labview software M. Circella, ANTARES-SC meeting, CPPM April 2004

  38. LCM test bench development (ongoing work at Catania and Pisa) • General definition started • Getting the LCM to acquire data was a tough job, due to poor documentation • Current status of the test bench: - it manages DAQ/SC and clock communications with the LCM - it can drive the DAQ/SCHarnesses through their state machines - it can query and decode SC data - it can drive data acquisitions with emulated signals from a pulser all in an integrated Labview software M. Circella, ANTARES-SC meeting, CPPM April 2004

  39. MLCM test bench development • Definition essentially linked to the LCM case (except for the MLCM-LCM communications and ethernet switching) • Implementation should inherit both from the SCM and LCM test benches (not yet defined what to inherit from which test bench...) • Hardware for the MLCM-LCM ethernet connections purchased but not yet integrated M. Circella, ANTARES-SC meeting, CPPM April 2004

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