Tracker Status Report

March 5, 2004

1. Thermal Vacuum Testing (N. Mazziotta)

a. The test set-up has been completed outside the chamber, until step number 220 in the (unfilled) Test Log - Step by Step Procedure sheet that can be found on the EM TV Bari web site (the filled Test Log, will be posted in the next days).

b. The thermocouples are being plugged to patch panels and the inner cables (signals, thermistors and heaters power supply lines) are being plugged to the IN connectors. All these operations will be completed according to the planned schedule, and the chamber was closed Friday.

c. Pump down has started and at last notice was at 200mbar. The thermal balance test will start Monday.

2. Mid Tray Production

a. Plyform is assembling the first 10 panels.

b. ESPI testing on those panels will be done next week.

c. The following week the tungsten and bias circuits will be installed.

3. Bottom Tray Closeouts

a. The drawings have been completed and will likely be checked over and ready for release by COB today.

b. COI has produced all the M55J parts and bonded them together with the carbon-carbon material.

c. M. Nordby et al. will visit COI when the drawings are released and the PO in place to go over the drawings.

d. Closeouts for 2 trays will be ready 2 weeks after that, followed by one tray per day.

4. Bottom Tray Titanium Parts and Flexures

a. Advanced Machining in San Diego has the contract for these parts.

b. M. Nordby, David Rich, and SLAC QA visited this vendor on Tuesday and redlined the drawings, which we hope to release today.

c. Advanced Machining is confident that they will complete the job (for 18+ towers) by April 9. We do not yet have a firm date for the first articles.

5. Bottom Tray Static Test (E. Swensen)

a. Hytec completed a detailed write-up on how to assemble and use the test fixture.

6. Mechanical Engineering (E. Swensen)

a. Hytec is currently working on a report on the stress analysis of the bottom-tray/Grid interface. They are hoping to have the first draft complete by COB today, and plan to review and finalize next Monday and Tuesday, with release by Wednesday.

b. Next Hytec will begin working on transfer of the Tracker tower FEM to SLAC. That is expected to take 2 days.

c. Finally, Hytec will write the test report for the static qualification test on the bottom tray, requiring approximately 2 weeks. That should largely close out the contract with Hytec.

7. Bias Circuit Fabrication

a. 50 new bias circuits are in production and nearly completed. They will be shipped to SLAC for QA inspection next week.

b. R. Johnson will hand carry the circuits to Pisa March 15.

8. PWB Machining and Inspection

a. 25 boards were completed and inspected at the new vendor, Diamond Machining, with satisfactory results.

b. SLAC QA will visit this vendor very soon, with the expectation that they will be approved to do the dimensional inspection as well as the machining for the remainder of the flight production.

9. Pitch Adapter Receiving and Inspection (D. Rich)

a. The dimensional inspection is still in progress at SLAC.

b. We have screened approx. 200 units so far. There were four groups of 50 measured. The averaged rejection rate is 12%.

10. Nano-Connector Fabrication

a. The first flight male connector lot was shipped to Teledyne with the other MCM parts.

b. Several redesigned female connectors were received from Omnetics and underwent some qualification testing at SLAC for the mechanical integrity of the jack screws and metal shell. The results were very good.

c. The order has been released to Omnetics, and connectors are expected in 5 weeks.

11. ASIC Fabrication, test, and dicing

a. The remaining GTRC-V7 wafers are at GDSI for lapping, dicing, and inspection.

12. MCM Test System

a. The detailed procedures have been updated according to all comments received and should be released soon.

b. The last tweaks on the software are being made, and the code should be released into CVS next week.

c. The second system was moved to the SLAC cleanroom and is being set up (the first system is at Teledyne).

13. MCM Assembly and Test

a. Preproduction: 9 MCMs were received by SLAC this week. Several of the last 10 MCMs, tall versions with GTRC-V7 chips, are in pre-encapsulation test and inspection today. They, plus already tested tall boards and the last short board, will then proceed to encapsulation, conformal coat, and final test. That will close out the preproduction sometime next week.

b. Flight production: All parts are in hand, and Teledyne has been ready to roll for the past week but is waiting for the PO to wind its way through the SLAC bureaucracy, hopefully to Teledyne by COB today.

14. MCM Burn-In and Acceptance Test System

a. The system was moved from UCSC to the SLAC cleanroom and is functional and ready for the next batch of preproduction MCMs.

b. Comments on the procedure document were received and incorporated, and the document should be released very soon.

15. MCM Qualification

a. The procedure document, LAT-TD-02366, is still out for review.

b. 5 MCMs have been in the chamber for some time undergoing 200 cycles for qualification testing (still in progress).

c. The plates for holding MCMs in the thermal-vacuum chamber and on the vibration table were completed.

16. Sidewall Manufacture

a. The Plyform EM sidewall coupons are under test for thermal conductivity, and results are expected and eagerly anticipated Monday.

17. Flex Circuit Fabrication and Test (H. Sadrozinki and Jeff Tice)

a. Parlex has the order for the C0 EGSE cables. The lead-time for delivery is around 4 weeks.

b. C4/C5 and C6/C7 had major interference problems, which now are solved.

c. We expect all mechanical layouts to be finished by next Wednesday.

d. Electrical layout will be slow due to new person, but should be done by end of March. The PRR could be held at that time.

e. Work is in progress to set up mockups for testing the cable installation and gluing into the Grid.

18. Drawings and Parts (Jeff Tice)

a. Jeff is close to having a new system on the web for tracking the status of Tracker flight parts, materials, and drawings.

19. Tracker Test Script Development (L. Latronico)

a. Minitower test scripts are now being completed with addition of TOT calibrations.

b. After full test at SLAC, the full test suite will be adapted to the stacked-tray and full tower configurations.

c. A draft of the tower test plan to be delivered to I&T will be circulated asap in the TKR team.

d. MCM test procedures will be documented first in view of the first flight MCM delivery

20. Mini-Tower Testing (H. Tajima)

a. A major part of the new TKR script suite has been tested with the mini-tower at SLAC.

b. Several problems found, and most of them were fixed.

c. The method to obtain an MCM number for each layer needs to be decided. (In discussion with I&T online people.)

d. We still need to consider how to conduct multiple tower testing (parallel or series).

21. Fabrication database (L. Latronico)

a. Incoming of flight honeycomb, closeout recorded; general interface for material incoming in progress

b. Flow-tracking for tray assembly in place up to mechanics; will work on including relevant test data from electrical tests

c. NCR and QA system under test

d. Tower test database need to be developed

e. First batch of MCM data transferred from UCSC, need to finalize few details but works fine

f. Stacked tray and tower test script procedures