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HV Filter Card Wiring Procedure

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					CCLRC Engineering and Instrumentation Department – Instrumentation Division – Detector Engineering Group


HV Filter Card Wiring Procedure                                                    Version 1.0 Draft
CMS-ECAL-EE Super Crystal Assembly
A.B.Lodge R63, G23.                                                                                06 January 2006

High Voltage Filter Card (+Umbilical) connection to Super Crystal.

SCOPE
The main aim of this document is to outline all the necessary procedures that should be followed during
the assembly and wiring stage of the overall construction of each and ever Super Crystal (SC). All full
SCs consist of 25 Vacuum Photo Triodes (VPTs), each VPTs is connected by 3 wires Anode (white),
Dynode (blue) and Cathode (yellow). The 25 crystals are constructed into a matrix of 5 by 5 crystals.
Each VPT is connected to 1 of 5 (5 channel) HV Filter Cards, these cards are mounted to the back of
the SC Interface Plate. The connection to each VPT is made using the Anode, Dynode and Cathode
wires.
There are 2(Anode and Dynode) HV supply cables required by each SC, these 2 coaxial cables form
part of the SC Umbilical and are connected directly to 1 of the SC HV Filter Cards. Each HV supply is
then bussed from 1 HV Filter Card to the next until all 5 cards are connected. These connections along
with individual ground connections are made during the assembly/wiring process.
The document also covers items such as Safety, Equipment, Components and Associated Documents.
This procedure has been produced as a guide and hopefully to help in the production of all SC’s,
changes can be made if easier/better or more productive ways are found. The SC Umbilical design is
still to be finalised therefore the photograph may not be truly representative of the final design although
the assembly/wiring procedures should remain virtually identical.

WORKING AREA CONDITIONS
It is important that the working area is kept clear of dust and derbies and not allowed to accumulate.
The area is to be free from any unnecessary items that might form contaminates. All equipment / tooling
used in this area are to be clean and contaminate free.

   Clean Area .
                              0       0
   Temperature Controlled 20 C +/- 3 C.
   Low Humidity (when working with HV).
   Controlled Environment – Restricted Access.

SAFETY
Practices shall conform to the Factories Act and the COSHH regulations.

   RAL and CERN Health and Safety Rules.
   COSHH Assessment.
   Risk Assessment.

APPLICABLE DOCUMENTS
These documents are kept under the relevant Web pages of Dr. D.Cockerill.
The listed documents will only be required in the event of unforeseen problems or difficulties
encountered during the assembly and wiring process.

165-IS001 – Super Crystal Unit Build (this sheet)
165-IS002 - Alveolar Unit Measurement
165-IS003 – Vacuum Pototriode Tube Preparation
165-IS004 – Crystal Preparation
165-IS005 – Dispenser Settings and Syringe Filling
165-IS006 – Bonding VPT to Crystal
165-IS007 – SCU Assembly Jig Preparation
165-IS008 – Alveolar Unit Preparation
165-IS009 – End Stop Preparation
165-IS010 – Insert Preparation


File Name: b8a89453-60c1-463a-91a7-ccf63efb5976.doc
Print Date: 27/02/12                                                                                   Page 1 of 13
CCLRC Engineering and Instrumentation Department – Instrumentation Division – Detector Engineering Group


HV Filter Card Wiring Procedure                                                    Version 1.0 Draft
CMS-ECAL-EE Super Crystal Assembly
A.B.Lodge R63, G23.                                                                                06 January 2006

EQUIPMENT
Soldering Station (Weller or Metcal).
Selection of soldering bits.
Solder Reel Type RS 555-235 60/40 Tin Lead 500mg.
Water Bottle.
IPA(Isopropyl Alcohol) dispenser bottle. RS 497-303.
Ethanol Bottle ( Vapour venting wash bottle).
Small Engineering Rule.
Masking Tape ( 25mm.).
Protective Plastic Gloves.
Selection of Side Cutters & Flat Nosed Pliers.
Safety Glasses.
Wire Strippers.
Tissues and Paper Towels.
Selection of Tweezers.
Scalpel + Blades( Swan Morton).
Selection of small Cleaning Brushes.
Selection of Screw Drivers.
Set of Allen Keys.
Optical – Visor + Light.
Pen & Note Pad.




                                                      Figure 1.

         Typical set of Tools used in the Assembly and Wiring of a Super Crystal.

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Print Date: 27/02/12                                                                                   Page 2 of 13
CCLRC Engineering and Instrumentation Department – Instrumentation Division – Detector Engineering Group


HV Filter Card Wiring Procedure                                                    Version 1.0 Draft
CMS-ECAL-EE Super Crystal Assembly
A.B.Lodge R63, G23.                                                                                06 January 2006




                                                      Figure 2.

    Typical set-up showing a Super Crystal mounted in an Assembly Jig sitting on a
                  Pump-Up Trolley (for ease of assembly and wiring).



PARTS LIST

Before starting any wiring or assembly work, ensure that you have a full kit of parts as follows:
             Super Crystal.
             Super Crystal Traveller document.
             HV Filter Card Assembly ( 5 Cards + Umbilical) full tested.
             Temperature Sensor Assembly (tested & calibrated) + Fixing Screw + Thermal Compound.
             Card Mounting Brackets (10).
             Bracket to Interface Plate Stainless Steel Screws (10).
             Bracket to PCB Nylon Screws (10).
             Disposable – Foam Assembly Screen.




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Print Date: 27/02/12                                                                                   Page 3 of 13
CCLRC Engineering and Instrumentation Department – Instrumentation Division – Detector Engineering Group


HV Filter Card Wiring Procedure                                                    Version 1.0 Draft
CMS-ECAL-EE Super Crystal Assembly
A.B.Lodge R63, G23.                                                                                06 January 2006



VISUAL INSPECTION




                                                      Figure 3.

         Co-axial version of the 5 HV Filter Cards and Umbilical Wiring Assembly.
                  Note this may change depending on the finally agreed design proposal?

A thorough visual inspection of the 5 HV Filter Cards and Umbilical Wiring Assembly must be carried
out before any attempt is made on fitting the cards to the SC. Items to be check are as follows:

        Check for complete cleanliness of all cards and solder joints.
        Check quality of all solder joints (dry joints, incomplete wetting, solder spill shorts or copper
         whiskers).
        Are there any damaged or incorrectly place components.
        Damaged or broken wires.
        Incorrectly labelled signal wires.

Note: any problems identified at this stage must be rectified or replaced, before the assembly and
wiring of the Super Crystal can continue.




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Print Date: 27/02/12                                                                                   Page 4 of 13
CCLRC Engineering and Instrumentation Department – Instrumentation Division – Detector Engineering Group


HV Filter Card Wiring Procedure                                                    Version 1.0 Draft
CMS-ECAL-EE Super Crystal Assembly
A.B.Lodge R63, G23.                                                                                06 January 2006


Filter Card and Umbilical Wiring Assembly Test
If there is an independent Filter Card and Umbilical Wiring Assembly Test System and Procedure
available at this time, they must be carried out and passed in accordance with the procedure before
continuing.

Super Crystal to Assembly Jig Orientation and VPT Cable Lay




                                                      Figure 4.

                                            VPT Natural Cable Lay.

As seen in the above photo the VPT wires have a natural lay. The natural lay of the wires can be used
to advantage by having them all point the same way.

There are two versions of Super Crystal Unit and the wire lay is different for each type

    1. Version 1 – the wires to point to the left of the notch in the Insert
    2. Version 2 - the wires to point up, away from notch in the Insert

Refer to document 165-IS003 for a fuller description of this topic.


The Super Crystal should be positioned in the Assembly Jig, with the jig sitting on a pump up trolley as
shown in Figure 5. This arrangement gives the maximum flexibility for movement and height adjustment
whilst assembling and wiring the HV Filter Card and Umbilical Assembly to the SC.




File Name: b8a89453-60c1-463a-91a7-ccf63efb5976.doc
Print Date: 27/02/12                                                                                   Page 5 of 13
CCLRC Engineering and Instrumentation Department – Instrumentation Division – Detector Engineering Group


HV Filter Card Wiring Procedure                                                    Version 1.0 Draft
CMS-ECAL-EE Super Crystal Assembly
A.B.Lodge R63, G23.                                                                                06 January 2006




                                                      Figure 5.

                      VPT Natural Cable Lay and Super Crystal Orientation.


SC Assembly and Wiring sequence
Disposable – Foam Assembly Screen

The disposable foam assembly screen should now be carefully fitted to the SC as shown in Figure 6.
Carefully feed the VPT wires through the slots cut into the foam screen, it is recommended that the
process is started at one end, one slot and work through to the other end and last slot of the VPT.
Great care must be taken to ensure that no derbies fall into any of the holes of the interface plate as
this could cause potential problems with HV shorts and HV Breakdown at a later stage. This would then
be very difficult to rectify.

VPT Wire Trimming and Tinning

With all the VPT wires now protruding through the screen, very carefully measure and cut the excess
cable length from each VPT. Using a rule or measuring stick trim all VPT wires to a length of 55mm.
from the top face of the Interface Plate (I/P).

         Trim all VPT wires to a length of 55mm. from Top Surface of the I/P.

All wires should then be carefully stripped(5mm) and tinned, this will then enable connection to HV
Filter Cards at a later stage. See Figure 7. Showing details.



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Print Date: 27/02/12                                                                                   Page 6 of 13
CCLRC Engineering and Instrumentation Department – Instrumentation Division – Detector Engineering Group


HV Filter Card Wiring Procedure                                                    Version 1.0 Draft
CMS-ECAL-EE Super Crystal Assembly
A.B.Lodge R63, G23.                                                                                06 January 2006




                                             Figure 6.
                             Disposable – Foam Assembly Screen Fitted.




                                               Figure 7.
                                     VPT Wires Trimmed and Tinned.



File Name: b8a89453-60c1-463a-91a7-ccf63efb5976.doc
Print Date: 27/02/12                                                                                   Page 7 of 13
CCLRC Engineering and Instrumentation Department – Instrumentation Division – Detector Engineering Group


HV Filter Card Wiring Procedure                                                    Version 1.0 Draft
CMS-ECAL-EE Super Crystal Assembly
A.B.Lodge R63, G23.                                                                                06 January 2006

Fixing the PCB Brackets, HV Cards and HV Supply Link Wires

First solder the HV Supply Link Wires ( 50mm) to the first HV Filter Card, also including the ground
connection wire or braid as shown in Figure 8. This picture also shows the HV Card mounting brackets
fixed to the card using the 3mm. Nylon screws supplied in the kit of parts. Make sure that the brackets
are attached in the correct way (orientation) as shown in the picture.
Next mount the first card to the Interface Plate of the SC as shown in Figure 9. Use the 3mm. S/Steel
screws supplied in the kit. Note the tape on the VPT wires to ease assembly.




                                                      Figure 8.

                                 HV Supply Link Wires & PCB Brackets.




                                                      Figure 9.

                                        First HV Filter Card Mounted.


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Print Date: 27/02/12                                                                                   Page 8 of 13
CCLRC Engineering and Instrumentation Department – Instrumentation Division – Detector Engineering Group


HV Filter Card Wiring Procedure                                                    Version 1.0 Draft
CMS-ECAL-EE Super Crystal Assembly
A.B.Lodge R63, G23.                                                                                06 January 2006

Soldering and Trimming and Cleaning VPT Leads

Now that the first HV Filter Card has been mounted you can start connecting all VPT leads to the HV
Filter Card. I suggest you start on the edge furthest away from you and work towards your self. Push
the VPT lead from the back of the card through the card and solder from the front. See Figure 10.
Very carefully trim the excess wire from the front and very thoroughly clean each soldered joint using
Isopropyl Alcohol (IPA) or Ethanol and a small stiff brush, blow dry with an air line. Continue until all 5
channels are connected.




                                            Figure 10.
                               Soldered VPT wire connections C, D & A.




                                           Figure 11.
                           Trimmed and cleaned all VPT wire connections.
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Print Date: 27/02/12                                                                                   Page 9 of 13
CCLRC Engineering and Instrumentation Department – Instrumentation Division – Detector Engineering Group


HV Filter Card Wiring Procedure                                                    Version 1.0 Draft
CMS-ECAL-EE Super Crystal Assembly
A.B.Lodge R63, G23.                                                                                06 January 2006

Mounting/Connecting second and remaining HV Filter Cards

Connect HV Supply Link wires and PCB Fixing Brackets as described previously. Before screwing the
second HV Filter Card to the SC Interface Plate, solder the HV Supply Link cables from the first card to
the second. Pass the cable ends through from the front of the second card and solder, trim and clean
from the back. See Figure 12.
Continue by connecting all VPT leads as described previously, don’t screw each HV Filter Card to the
SC Interface Plate until all solder connections have been made, wires trimmed and solder joints
cleaned. It is much easier to make these connections with the board floating or loosely screwed.
Continue as above with the 3 remaining HV Filter Cards.




                                                     Figure 12.

                  Mounting and Connecting the Second and remaining Cards.


Now that all 5 HV Filter Cards have been connected to the SC and the cards mounted on SC Interface
Plate, carefully remove the Foam Assembly Screen (which will need to be cut). Ensure that no derbies
(wire trimmings) fall into any of the holes of the interface plate as this could cause problems with HV
shorts and HV Breakdown at some stage. This would then be very difficult to rectify once the SC is
mounted on to a Dee.
Continue by mounting the SC Housing and make the ground connections from all of the HV Filter
Cards. Figure 13. Shows a picture of an older design proposal used on the earlier Super Crystals
although the principle remains the same. The connections might be made using single/multiple wires or
braids. There will be a connection on 2 opposite sides of the SC Housing. All screws, washers and nuts
should be included in the kit of parts.


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Print Date: 27/02/12                                                                                   Page 10 of 13
CCLRC Engineering and Instrumentation Department – Instrumentation Division – Detector Engineering Group


HV Filter Card Wiring Procedure                                                    Version 1.0 Draft
CMS-ECAL-EE Super Crystal Assembly
A.B.Lodge R63, G23.                                                                                06 January 2006




                                              Figure 13.
                                    Ground connection to SC Housing.

Mounting of the SC Umbilical & Monitoring Fibre Support Brackets

The SC Umbilical & Monitoring Fibre Support Brackets should now be fitted. The brackets will be fitted
in an appropriate position depending on the type of SC i.e. There are 2 different types of SC depending
on which Quadrant of the ECAL End Caps they are to be mounted. The different types of SC are
achieved by having 2 different types of Interface Place. Each type of Interface Plate has a slightly
different hole orientation to that the other, and this determines the position of the support brackets. See
Figure 14.

Mounting of SC Temperature Sensor.

The SC Temperature Sensor should now be screw to the SC Interface Plate using the appropriate Heat
Sink Compound and fixing screw, both of which should be supplied in the SC Kit of Parts.

SC Lifting Plate / Handles and Cover.

The SC Lifting Plate and Cover can now be attached using the appropriate 6mm. S/Steel cap head
screws. See Figures 15 and 16.

SC Testing
The SC is now ready to start the testing, see the appropriate SC Test Procedures for full details.
See Figures 17.


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Print Date: 27/02/12                                                                                   Page 11 of 13
CCLRC Engineering and Instrumentation Department – Instrumentation Division – Detector Engineering Group


HV Filter Card Wiring Procedure                                                    Version 1.0 Draft
CMS-ECAL-EE Super Crystal Assembly
A.B.Lodge R63, G23.                                                                                06 January 2006




                                                Figure 14.
                                       SC Umbilical Support Bracket.




                                                     Figure 15.

                                 SC Fitted with Lifting Plate and Cover.

File Name: b8a89453-60c1-463a-91a7-ccf63efb5976.doc
Print Date: 27/02/12                                                                                   Page 12 of 13
CCLRC Engineering and Instrumentation Department – Instrumentation Division – Detector Engineering Group


HV Filter Card Wiring Procedure                                                    Version 1.0 Draft
CMS-ECAL-EE Super Crystal Assembly
A.B.Lodge R63, G23.                                                                                06 January 2006




                                               Figure 16.
                           SC Fitted with Lifting Plate, Handles and Cover.




                                                   Figure 17.
                                                  SC for Testing.



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