Run II Crate Assembly ------------------------- Initial Rev. 15-NOV-1995 Most Current Rev. 17-NOV-1995 This file contains descriptions of how to assemble many of the components that make up the logic crates, power supplies, and racks that are used in the Run II Trigger Framework. Assembly of the P2-P3 Backplane ------------------------------- The components for the P2-P3 Backplane are assembled in the following order: install the 10-Point power connectors on the backplane, install the PEM studs on the backplane, install the ERNI connectors on the backplane, install the PEM studs in the power bars, install the power bars on the backplane. P2-P3 Backplane 10-Point Power Taps ------------------------------------ The 10-Point power taps are installed in the backplanes first. These are AMP part number 55558-4. Make sure that there is no foreign material on the raw backplane PCB before starting installation of the 10-Points. The 10-Points are installed from the back side of the PCB. The back side is identified by the two rows of rectangles of white silk screen running down the middle of it. Install all 21 of the 10-Point power taps. Use cardboard sheets on the foot of the press to absorb the ends of the pins of the 10-Points. These pins will stick through the front surface of the backplane by about 1/2 mm and the cardboard absorbs this small length of the pin. Use the aluminum too jig tool to support the 10-Point as it is pressed into the backplane. Install the nylon pad over the upper press die before pressing on the aluminum 10-Point jig tool. Pump the press to between 800 and 900 psi when setting the 10-Point power taps. Most of the movement of the 10-Point into the backplane PCB will take place at about 500 psi. P2-P3 Backplane PEM Studs -------------------------- A total of 80 PEM studs are installed in the backplane. These are PEM part number KFH-440-12ET. These are arranged in 4 rows or 20 studs. The studs are installed from the front side of the backplane. All 20 studs in a row are lightly pressed by hand into the backplane. Then the board is turned over so the the support jig that receives the threaded part of the studs during the pressing operation can be placed over the studs. The backplane support jig assembly is then turned back over so that the press can push down on the heads of the studs until they are flush with the front surface of the backplane PCB. The aluminum jig with one small foot is placed under the top die of the press. Make sure that there is a layer of duct tape between this jig and the upper die in the press. Make sure that the G10 spacer is on the foot of the press. Slide the backplane support jig assembly into the press. Pump the press to bring the upper die with the small foot jig down over the center of a PEM stud. Pump the press to 800-900 psi. P2-P3 Backplane ERMI Connectors -------------------------------- Two types of ERNI 160 pin press-in connectors are used in the backplane. The ERNI part number 013164 has long pins on all 5 rows and ERNI part number 913593 which has long pins in the two outer rows and short pins in the center row. The 013164 with long pins in all 5 rows is used in only 4 locations on the backplane. These are: slot #1 in P2 and P3, and slot #21 in both P2 and P3. The 913593 part with the short pins in the center row is used in all other locations, i.e. slots #2 through #20 in both P2 and P3. These ERNI connectors are installed using the the ERNI die in the bottom of the press and the MSU Machine Shop made die in the top of the press. Make sure that the backplane PCB is clean before starting to install these connectors. It is vital that no foreign material becomes trapped under one of these connectors. Verify that the connector is properly oriented in the backplane PCB before pressing it in. These connectors are installed from the front of the backplane and they must be oriented so that the mounting screw holes in the backplane PCB line up with the mounting screw holes in the connector. Note that the ERNI die used in the bottom of the press must be oriented to fit the half of the backplane that you are inserting connectors into. When you are finished installing connectors in one half of the backplane, the bottom ERNI die must be rotated 180 degrees to finish installing connectors in the other half of the backplane. To install a connector, start by pressing it lightly by hand into the backplane. Insert it into the front side of the backplane and verify that it is properly oriented WRT the mounting screw holes. Invert the backplane PCB (so that the connector body is down that the connector pin are up) and lower the connector over the bottom ERNI die. while supporting the backplane with one hand, pump the press to bring the top die down so that it just start to cover the connector pins. With the hand that is supporting the backplane, slightly lift and wiggle the connector to verify that all of its pins are freely inserted into the upper die. When you have verified that all of the connector pins have started into the upper die, then continue pumping the press and allow the connector body to fall back down so that the bottom ERNI die is fully inserted into it. When the press reaches about 3000 psi the pins should start moving into the backplane. continue pumping the press until it holds 3500 to 3600 psi. P2-P3 Backplane Copper Power Bar Assembly ------------------------------------------ HFHS-032 P2-P3 Backplane Assembly onto the Card File -------------------------------------------- 12 mm screws with nylon washers cut center ribs of the insulating strips used on the center support bar to provide clearance for the 10-Point pin stubs.