Integration and Test 14 October 2008

1. Integration and Test14 October 2008 Martin Nordby

2. Contents • Introduction • Cryostat assembly and integration flow • Test plans during focal plane integration • Focal plane integration process • Cryostat integration process • Camera integration • Integration facilities

3. Introduction • Guidelines we have used in developing the camera design and I&T plans • All sub-assemblies are pre-assembled and fully verified by unit-level testing prior to delivery and integration into the Camera • “For-the-record” verification tests of deliverable sub-assemblies are used as gates for accepting hardware prior to integration • The integration process—and subsequent de-integration and servicing—should minimally disturb neighboring components or break their verification • Documents describing integration and test plans (collection-87 in the Camera I&T directory): • LSST-1141-D, “Cryostat Assembly and Integration Sequence” • Detailed, step-by-step sequence for assembling the cryostat and integration raft towers • Includes mechanical and electrical integration process and the fixturing and test equipment needed • Identifies verification testing • LSST-6175-A, “Camera Integration and Test Plan” • Overall plan for I&T operations, including facility operations, standard operating procedures, safety • Includes detailed sequence for integrating the camera • Identifies verification testing and calibration efforts • Includes mechanical and electrical integration process and the fixturing and test equipment needed • LSST-6176-A, “SLAC Bldg 33 Camera I&T Facility Layout” • Detailed layout of the SLAC clean room facility and concepts for the big mechanical fixturing • LSST-2119-D, “Camera Integration and Test Flow Chart” • Graphical flow-chart showing the integration and test sequence for all major camera components

4. Cryostat Integration and Test Flow From LSST-2119-D, “Camera Integration and Test Flow Chart” For details, see LSST-1141-D, “Cryostat Assembly and Integration Sequence”

5. Verification Test Cycle for Raft Towers • Raft Tower assembly • CCD acceptance testing at BNL • Raft tower verification testing • Raft Tower acceptance testing • Incoming re-testing of raft towers as they arrive at SLAC • Functional test of raft towers in preparation for integration in the cryostat • Post-integration testing • Warm functional/continuity check of raft towers and RCC modules • Periodic cold performance testing of the partially-integrated focal plane • Full cryostat verification testing • Cold verification testing of the entire focal plane • Final cold metrology flatness measurements

6. Test Progression for Focal Plane Integration • Prerequisite tests • Engineering cryostat • To work through details of the design, integration plans, and operations of the cryostat • Full-up cryostat functional testing • The cryostat is tested as an assembly before any silicon is installed • This include structural proof testing, vacuum- and pressure-testing, thermal system performance testing, and early work on the metrology system • Four integration and test phases • Functional rafts • Install “dummy rafts” that function like real ones (mass, cg, structural pre-loads, thermal, heaters and sensors) • Test the cryostat and the insertion tooling with these rafts • Dead silicon • Install rafts with dead silicon to partially populate the focal plane • Prove out the system using assemblies with tight clearances • Run metrology scans to qualify the flatness measurement process • Engineering-grade rafts • Mechanically and electrically integrate fully functioning raft towers with out-of-spec detectors • Run warm and cold metrological and electrical systems tests • Cool down and test the entire data-flow chain • Science-grade rafts • Integrate raft towers with science-grade CCD’s • Run successive metrology scans and functional tests as the focal plane is being built up

7. Focal Plane Integration Process 3. Install Raft Control Crates from above Feedthrough flange 2. Connect flex cabling Cryostat held in its nominal zenith-pointed orientation Cold Plate Cryo Plate Grid Front flange where L3 mounts 1. Insert Raft Towers from below

8. Cryostat Exploded View Feedthrough Flange, Pump Plate, and Pumping Plenum Back end MLI Cage Cold Plate Cryo Plate and Pumping Chimneys (Shroud not shown) Grid with Raft and Flexures Cryostat Housing L3 Flange Assembly

9. Cryostat Assembly Back end MLI Cage and pump chimney Cryo Plate Grid with Flexures Cold Plate Cryo Shroud Cryostat Housing

10. Cryostat Close-Out Pump Plate Feedthrough Flange Pumping Plenum Vacuum-jacketed inlet/outlet lines L3 Flange Assembly

11. Camera Integration 1. Camera body assembly 4. Cryostat and Utility Trunk integration 2. Filter exchange system integration 5. Optics integration 3. Shutter installation

12. SLAC I&T Facility Layout Room 103A: mechanisms, optics, materials workstations Receiving, storage Cleaning and gowning Support electronics and workstations Welding, leak testing Room 104: camera integration Room 103B: cryostat integration

13. Cryostat Integration Facility—Plan View Metrology system Assembly stand Integration gantry Cart From LSST-6176-A, “SLAC Bldg 33 Camera I&T Facility Layout”

14. Cryostat Integration Facility—Elevation View Metrology system Assembly stand Integration gantry Cart Cryostat with valve box in cold-test configuration From LSST-6176-A, “SLAC Bldg 33 Camera I&T Facility Layout”