Installation and testing of optical harnesses
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Installation and Testing of Optical Harnesses. 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 Assembly: Barrel. B3: 64 harnesses B4: 80 harnesses

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Installation and Testing of Optical Harnesses

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Installation and testing of optical harnesses

Installation and Testing of Optical Harnesses

  • 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 assembly barrel

Schedule for Test and Assembly: Barrel

  • B3: 64 harnesses

  • B4: 80 harnesses

  • B5: 96 harnesses

  • B6: 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


Installation and testing of optical harnesses

Schedule for Test and Assembly: Forward

  • D1,D7,D8: 16 harnesses/disc

  • D2,D3,D4,D5,D6: 24 harnesses/disc

  • D9: 12 harnesses/disc

  • 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 harness

Barrel Harness

  • DORIC and VDC

  • opto package

  • power tapes, redundancy system

  • many traces and connections


Forward harness

Forward 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 plug ins

Test Fixture for Forward Plug-ins

  • equivalent to forward module

  • design will be transferred to 6 PCBs

  • allows testing of BER


What measurements do we need

What measurements do 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 link

  • SLOG

LITMUS

BER testing: TTC link

OPTIF


Ttc link results ber scan

TTC link results: BER scan

  • vary light power into p-i-n diode

  • allows definition of working range

  • BER scans < 5 min


Vcsel li curves

SCTLV

SCTLV

VCSEL LI Curves

SLOG

DMM

  • scan I using SCTLV

  • measure photocurrent in LAPD

  • 50% duty cycle

  • 5 min. setup/run time

LAPD


Pin responsivity

SCTLV

SCTLV

PIN Responsivity

DMM

supply

LED

LAPD

  • measure I in pin bias line

  • LEDs for reproducibility

  • LAPD used to calibrate LEDs

  • 10 min. setup/run


Acceptance testing at ral

Acceptance testing at RAL

  • 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 installation assembly former

Forward harness installation: assembly former

  • services assembled to former

  • former used to populate quadrant

  • after 4 quadrants, align cooling blocks


Forward harness installation procedure

Forward harness installation: 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 installation

Final testing during installation

  • 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


Installation and testing of optical harnesses

  • procedures for installation and testing are well defined

  • expect 3 technicians for harnesses

  • 1 man-hour/harness, acceptance

  • 2 hours / harness, test + installation

Schedule is achievable but requires care in execution

  • first barrel will arrive April 02, timescale less critical

  • will allow refinement of procedures


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