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Overview of CCM Production and Testing for Boards 3 & 4 for Enhanced Performance

This document outlines the production and testing plan for 130 Boards 3 and 4 of the CCM project, highlighting key activities, timelines, and costs. The process includes PO placement, PCB assembly, functionality testing at FNAL, and shipping to CERN. Critical tasks such as radiation testing and installation coordination with CMS are detailed. The project aims to enhance CCM reliability and efficiency, estimating labor and costs involved in the installation and testing phases. Overall, the initiative promises substantial improvements in performance with manageable investment.

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Overview of CCM Production and Testing for Boards 3 & 4 for Enhanced Performance

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  1. CCMResources

  2. Project Cost Overview • Boards 3&4 (production boards-130 each type ) • Eng. changes and designer layout work – Done • Tech time to place POs and gather parts, place POs for PCBs/board assembly. • Tech time for functionality testing at FNAL. Eng/tech time for debugging. Shipping to CERN. • Radiation Testing (chips at CERN, CCMs at MGH) • CCM testing at 904: Eng. Time+Travel + Physicist Travel + student COLA • I&C at Point 5: Russian Tech(s) time + student COLA (2) • 1 Teams of 2 Techs to harvest and reinstall CCMs (Arefiev+ Smirnov/Epshteyn (if available)) + 2 students to modify CCMs and test

  3. Production Boards 3&4 • 108 CCMs needed for HB/HE/HO • Full Production – 130 boards of each type (includes spares + test stands + test beam) • 130 additional along with 25 prototype • PCB fabrication (2 weeks) • Parts procurement (3 days – 1 week) • PCB assembly (2 weeks) • Boardtesting + debugging (20 days) [tech + physicists] • Should take 2.5-3 months after project approval/funding (slower due to holidays). Parts procurement can start as soon as project is approved, but some parts have long lead-times. • If rad testing is required, it will need to be done simultaneously to meet the installation schedule.

  4. I&C Summary • CCM installation • CMS has scheduled access time for the jumper intervention to resolve the RBX data loss problems • CCM will already need to be unstacked. Swapping out boards 3&4 is straightforward • 130 sets of new Boards 3 & Board 4 will be ready (tested with 10 day burn-in) by 1 May 2013 • There is sufficient access to have extended functionality testing time in CMS inthe proposed CCM intervention plan • HCAL is in close communications with TC for coordinating the LS1 activities

  5. I&C Cost estimate • Labor needed (Jan-Aug) • Skilled techs to remove/install CCMs from RBX (2-3 Russian techs) • 2 teams of 2 students for work in 904 (4 students total – could have international contribution here) • Test and burn-in CCM boards • Stack/unstack of CCM cardpack • Clipping jumper • Install new Boards 3 & Board 4 • Test modified CCMs • Labor in current LS1 planning for CCM jumper work (US/Protvino) • Russian techs • 2 students • Additional 2 students needed for CCM Board 3&4 work • International HCAL may provide the additional 2 students needed ($0 cost) • If not, the incremental cost is COLA for 2 students for 9 months (US rates) • 1000 kCHFx 9 x 2 = 18000 kCHF (x1.1 for exch rate) = $19800 • If needed, we can provide 1 physicist for testing at CERN • $8k travel (per month) • Total labor needed for I&C is an incremental change to the current US HCAL LS1 labor plan • $19800 + $8k = $27800 • Cost range ($0 -$27800), depending on international support and required physicist travel support

  6. Summary Boards 3&4 Cost (130 additional boards of each type)

  7. Summary • New Board 3&4 design will make the CCM more robust to QPLL failures • This redundancy is built into the new ngCCM but did not exist in the old design. • CCM production schedule and I&C plan is tight, but achievable • The full 130 sets of Board 3 & 4 will be tested/burned-in by May 1, in time for installation • Overall incremental cost in terms of CCM interventions already planned in LS1 (jumper removal) is not large. • Cost of the production quantities of new CCMs should be looked at in view of the cost to support the CCM hardware in the past • 1 FTE (Dick + grad student) per year • While this maintenance need won’t disappear completely, we hope it will be greatly reduced to <<1 FTE

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