1. Module Preparation-ANL01
Task	Description	Date				Work Crew
1.1	Setup Module	12-1-99				RJM, MN, RR
1.2	QC0: Initial Inspection	12-5-99				RJM
Item		OK		Not OK : List problems and repairs
Residual Glue		X
Spring Pins				3 pins were in slots, Dean made a tool to fix them
Plate/Weld Bar Edges		X
Submodule Shims and Spacing				No shims with module -  installed 1-14-00
Pained Surfaces				Many slots have paint in slots - see notes
Slot Widths				Some slots too narrow, mostly due to paint - see notes
Contaminants		X
Task	Description	Date				Work Crew				Comments
1.3	Clean out Slots									See notes
1.4	Cover Holes in Girder	April 00				MN				Task added, done out of sequence
1.5	Clean Module Surfaces	1-6-00				MN
1.6	Mark Cell  Boundaries	1-10-00				Mike Nila
1.7	Install Cell & PMT Labels	1-10-00				NM
1.8	Ream Girder Rings	1-11-00				R. Weerts				Task added

NOTES:
1.2
This module was the first received from ANL.  There were problems due to the thickness of the paint.  The tile slots had been checked with a gauge at ANL and most of the excess paint had been cleared from these slots.  Unfortunately, we did not realize that there was also a problem with paint in the profile slots.  See further notes below.

 

2. Tile Installation-ANL01
Task		Description	Date						Work Crew
2.1		Measure gaps for shims	1-14-00						RJM - See note
2.2		Install Shims	1-14-00						RJM
2.3		Record Tile Batch Numbers	1-6-00						RJM - See note
2.4		Insert Tiles	1-6-00						DS,MN,RJM,Dan,Desmond
2.5		Insert Special ITC  Tiles	1-26-00						MN
2.6	QC1: Tile Inspection		1-6-00					See note
Item			OK		Not OK : List problems and repairs
Tile Color			X
Tile Sizes			X
Tile End Surfaces			X		Removed paint chips after installation
Tile Wrappers			X		Sleeves come loose on about 20%
Task		Description	Date					Work Crew
2.7		Install Rods	1-7-00,5/9/00					RJM, NM-RW,AR

NOTES:
2.1 We made a gauge to measure the gaps quickly.  The gap sizes in unit of 0.1 mm are recorded on a data sheet. The number and location of shims, 1/2,3/4,1 mm thicknesses, are ltabulated to make the gaps 4:4.-1/4 mm wide.  The shims are made of polystyrene.  The ones in the layer 1 and 11 slots are premade in the shape of the tiles, but longer so that they come to the edges of the master plates.
We also have to shim in other locations to make the profiles stay in the grooves.  These shims are made in strips about 20 mm wide with double sided tape to hold them in place.

2.3 Tile batch numbers and other component ID numbers are recorded on a special form that will be linked to this page.

2.4 Tiles were inserted and then removed after the profiles were inserted and then removed to clean the paint out of the profile grooves. See additional notes in section 4.

2.6 When we removed the tiles we noticed some discoloration on some of the sleeves, usually close to the source holes.  On some there were additional patches on the surfaces of sleeves.  We believe that this was due to paint, water or some other contaminent that was on the inside surface of the slots.  No damage was noticed on the surface of the tiles.

2.7  Rods were installed, then removed and used in module ANL03.  We later reinstall the rods when new ones were received from ANL.  Meanwhile, we used plastic tubes to hold the tiles in place.

 

3. Fiber Preparations-ANL01
Task	Description		Date				Work Crew
3.1	Install LED Light Tubes		See note
3.2	Install Aspirin Tubes		1-12-00				D. Dumont, R. Weerts
3.3	Install Fixation Rails		1-6-00				MN
3.4	Label Laser Fiber Bundles		1-24-00				MN, see note
3.5	Install Laser Fiber Bundles		1-24-00				MN
3.6	Record Laser Fiber #						No numbers
3.7	Cover Girder Area		April, 00				Added, See note
3.8	Install ITC Fiber Supports		April, 00				RJM , see note

NOTES:
3.1  The initial light tube that we made using fluorescent lamps proved to be unusable.  It was impossible to get a uniform illumination and the tubes were too easily broken.  We used a 5 LED source to check this module while a full length LED light tube was being constructed.

3.4, 3.6  These laser fiber bundles did not have numbers.  Also, the individual fibers do not have labels.  We found this to be a problem when routing these fibers,  we did not know which fiber went to which PMT.  We put labels on these fibers, but they did not stay on.  More effort will be needed to do this right.

3.7 We found that the ends of the fibers would get caught on the lower surface of the girder when the profiles were being installed.  To prevent this, we cover the girder area with a plastic sheet during the profile installation, and remove it before making the fiber bundles.

3.8  We did not like the original method of supporting the connector ends of the ITC scintillator fibers (just using the poly bag).  These ends of the fibers were not well suported during installation and the bags made it hard to test the fibers and to make a good light seal.  We designed another system using a small panel attached to the ITC end plate.
 

 

4. Fiber/Profile Installation-ANL01
Task	Description				Date				Work Crew
4.1	Setup Profile Cart
4.2	Record Profile Batch Numbers				5-12				RJM
4.3	Insert Profiles/WLS Fibers				2-10, April				Jason, MN, RW, Desmond: See notes
4.4	Install Fiber Separator Wires				April				MN
4.5	Install ITC Fibers				1-26				RJM
4.6	Record ITC Fiber #				1-26				RJM
4.7	Separate fibers by depth				4-20				Ana, Robin
4.8	Make subbundles				4-20				Ana, Robin
4.9	QC2: Verify Sorting				4-21				RJM
Item			OK	Not OK : List problems and repairs
Fiber Lengths			X	Found two  fibers that had come loose from profiles
Fiber Counts			X
Depth Sorting			X	See notes
Visual Light Levels			X	See notes
4.10		Remove Fiber Separator Wires			4-21				MN

NOTES:
4.3
Profile insertion was a major problem on this module.  Initially we were delayed by not having a profile insertion tool.  When we got a couple of tools from CERN and Barcelona, neither seem to work well.  A lot of force was required to get the profile into the slots and many of the profles were being mashed or split.  We spent a lot of time trying different modifications of the tool, centering the tiles, replacing profiles, etc.  We eventually realized the problem was due to paint that was reducing the width and depth of the profile slots.

We made a tool to clean out the profile slots.  This consists of a pair of saw blades ground to give a 3.9 mm wide cut, mounted in a handle with a runner to control the depth of cut at 2.5 mm.  This tool was run through all of the profile slots on the second module, ANL-3, and we proceded with profile insertion on that module to confirm that this was indeed the solution to the problem.  We found that the profile insertion on ANL-3 was much better than on ANL-1.  So, we decided to remove the profiles and tiles from ANL-1 and use the tool on this module.

A profile removal tool was made to remove the profiles without stressing the profiles or fibers.  This is consists of a sliding wedge fo Teflon  that runs under the fiber and lifts the profile from the slot.  The tile and profile insertion an ANL-1 were then redone.

The profile insertion tools that have are still not satisfactory.  The CERN tools, made of Teflon, are worn so that they don't compress the profiles enough to fit into the slots.  The Barcelona tool worked well but was returned to ANL.  We made several tools, similar to the Barcelona tool, but with fewer parts, all made of polyurethane instead of plated brass, aluminum and Teflon.  We found that the polyurethan was good for the body of the tool that runs against the steel plates but was not good for the part that slides over and compresses the profile.  The paint on the sides of the profile is rubbed off and clogs the tool.  We will make a Teflon insert that will be in contact with the profile (as in the Barcelona and CERN tools).

4.5
There were several problems with installing the ITC fiber assemblies.

The holes were clogged with paint and had to be retapped.  The mounting plate was designed for 6 mm screws but the holes in the ITC end plate has 4 mm screw.  We added washers.  The tapped holes also were too shallow in this module, so we got shorter screws.

The profiles slide off of the fibers when attaching the fiber assembly.  We removed the cardboard spints and taped the profiles to the guide plate.

The standard profile insertion tool dosen't work on these profiles because the top of the profile is not free to insert into the tool and the base of the tool is too wide to clear the neighboring profile that is not yet into the slot.  Some of the profile were inserted by hand.  We made a special profile tool with an open design to do this job.

We were not satisfied with using the polyethelene sleeve to hold the connector ends of the ITC scintillator fiber ribbons.  This was ackward to attach, interfered when we had to make the module light tight, and had to be removed to test these fibers.   We designed a better method, consisting of a panel attached to the ITC end plate with holes to insert the connector ends.  Panels and mounting brackets are being made and will be distributed to the other EB instrumentation sites.

4.9

The fibers were sorted by depth after all profiles had been inserted, rather than trying to sort each profile as it was inserted.  The fibers were then counted and collected into the subbindles, two subbundles per cell.  Lengths (2 cm) of sort silicone tubing was put over each subbundles.  Several diameter of tubing were used to match the size of the subbundle.  The tubing is used later to clamp the subbundles after the fiber ends are registered.

We used a short version of the LED tube to check the fiber sorting and bundling.  This was very effective and will be even easier when full length LED tubes are made.  Several sorting errors were found and fixed on this module.
 

5. Fiber Routing-ANL01

Task

Description

Date

Work Crew

5.1

Route Sub-bundles To  Aspirin Tubes

5-4-00

Robin, Anna

5.2

Route the Laser Fibers

5-4-00

Robin, Anna

5.3

QC3: Verify Fiber Routing

5-9-00

RJM

Item

OK

Not OK : List problems and repairs

Odd Side

See note

Even Side

See note

5.4

Insert Gluing tubes

5/4:9

Anna,RW,MN

5.5

Insert Teflon Rods

5/4:9

Anna,RW,MN

5.6

Register and Secure  Fibers in Aspirin Tubes

5/4:9

Anna,RW,MN

5.7

Insert Dummy fibers

5/9

MN

5.8

QC4: Check Fiber Damage

5/9

RJM

Item

OK

Not OK : List problems and repairs

Broken fibers

X

Stress Crazing

X

Cladding Damage

X

Fiber Curvature

See notes

Fiber Contact

X

5.9

Secure the Sub-bundles

5/4:9

Anna,Rw, NM

NOTES:
5.3
Laser fibers are not routed correctly on the odd side.  B15 is interchanged with A15, D5 is interchanged with A14, E3 is routed to D4, D4 is routed to C10, C10 is routed to E3.  On the even side D4 and E4 are interchanged.  Since the timing differences are small (< 2 ns) I decided to leave them rather than risk taking everything apart.  We need a better system for labeling these fibers.

54.-5.6
These operations are done done at the same time.  We insert the gluing tube and the teflon rods into one of the bundles, register the ends and clamp around the silicone tubing with a cable tie while holding the fiber bundle pointed toward the aspirin tube.  That bundle is then inserted all the way into the aspirin tube. The laser fiber and Teflon rods are added to the second bundle and it is registered, clamped and inserted.

5.7
After all bundles have been inserted into the aspirin tubes we go around again and insert the dummy fibers while holding the bundles all the way into the bottom of the aspirin tubes.  The dummy fibers effectively lock the bundles in place.  We then mark the bundles at the surface of the aspirin tube to be able to check later.

5.8
There were several problems with the routing on the even side.
Some of the laser fibers have too much stress on them where they are routed around the bundles of fibers.   Some of the D5 fibers were stressed passing through the B13 bundle.  The A15  passed through the D6 bundle in the wrong place.  These problems were fixed by rerouting the bundles.

The silicon tubing used on this side was not cut into consistent lengths - some are too long.  We will cut them more carefully in the future.  They were also not being tightened at a consistent distance from the ends of the fibers. Some were too close and interfered with each other.  Also, some fibers get caught on the these tubes and are trapped between the silicone tubing and the aspirin tubes when the bundle is inserted into the aspirin tube.  These problems were fixed.
 

 

6. Glue fiber bundles-ANL01
Task	Description			Date				Work Crew
6.1	Prepare Glue Cartridges			5-11-00				RJM
6.2	Glue Odd Side			5-11				RR, NM, RJM
6.3	Glue Even Side			5-11				RR, NM, RJM
6.4	Reserve Samples of Epoxy			5-11				RR, NM, RJM
6.5	Epoxy Cure
6.6	Remove Teflon Rods

NOTES:
Our gluing procedure is as follows:
1.    Setup the supplies:  TV camera and monitor to view inside of girder, 3 cartridges containg 45 cc each of BC 600 components in 4:1 ratio, 3 mixing nozzles, the gun for the mixing cartridges,  4 syringes (30 cc), plastic pistons for the syringes, caps for the syringes, the pneumatic dispenser for the syringe set for continuous flow at 8 psi.
2.   Fill the first syringe from the mixing cartridges to within 50 mm of the top. Insert a plastic piston and push it into the syringe until it is in contact with the glue.  Attach the hose from the pneumatic dispenser.  Remove the cap on the syringe and bleed out any air.
3.    Attach the syringe to the leur lock fitting on the end of the first filling tube. Mark the level on the syringe with the grease pen to monitor the amount.
4.    Inject the  glue while someone watches the bottom of the aspiring tube on the TV monitor.  You should be able to see as the glue covers the bottom of the aspirin tube.  If the glue level looks too thick, the fiber bundles may not be pushed in all the way.  Also check for any air bubbles.
5.     Continue to fill until the glue starts to come out the slot in the aspirin tube or around the fibers.  This should be after the piston in the syring has moved 5-10 mm.
6.    Fold the fill tube to crimp it closed, remove the syringe, and tape the tube to hold the crimp.
7.     Repeat this on the next location.  When the syringe has less than 1 cm of glue left, empty this into a new syringe and fill that syringe from the mixing cartridge. You can do one side of the module with 2 syringes.  The syringes have to be disposed in a special container but you can throw the mixing cartridges into the trash.  Each side takes 1/2 - 3/4 hr.
8.    Go around each aspirin tube again.  Check that the bundles are still inserted to the line that was marked.  Make sure that no fibers from neighboring bundles are laying on the area where they might get stuck by glue wicking out of the aspirin tubes.

Glue Test with corn syrup: used 2.1 cc of liquid to fill.
 

7. Polish Fiber Ends-ANL01
Task	Description		Date					Work Crew
7.1	Setup the Polishing  Machine		5-12					RJM
7.2	Polish Fibers, Side A		5-16					MN
7.3	Polish Fibers, Side B		5-16					MN
7.4	Remove Polishing  Machine		5-16					MN
7.5	QC5: Inspect Fiber Ends		5-17					RJM See Notes
Item		OK			Not OK : List problems and repairs
Surface Quality		X
Visual Light Level					2 Problems, See Notes

NOTES:
Polishing Fixture Alignment Procedure-
1) Mount fixture with all alignment screws loose, mounting nuts finger tight (with weight of fixure supported)
2) Align transition ring with ringson fixture- be careful with this- watch for interference with the end plate or girder.
3) Align horizontally.  With the straight edge against rings inside of the girder slide out to the first ring in the fixture.  Move fixture until this is good on both sides.
4) Align vertically.  SImilar technique as 3) except using the top surface of the rings in the fixture.
5) Align horizontal & vertical angles.
6) Check all alignments.

QC5 Notes-
1) Fibers E-4, PMT2 were pulled back from end of tube; not polished.  We cut them at surface of A. tube & inserted a new A. tube.
2) PMT18 looks like 2 buried fibers; remove aspirin tube.
 
 
 
 

 

8. Secure fiber bundles-ANL01
Task		Description			Date				Work Crew
8.1		Cut dummy fibers			5-17				Anna
8.2		Cut Gluing tubes
8.2		Tie FiberBundles to Rails			5-23				AR & RW
8.3		Install Cotton Belt			5-30				MN even side

 
 

10. Close up-ANL01
Task	Description			Date				Work Crew
10.1	Cover Module with Plastic Sheet			5-24				RJM, RR
10.2	Cover Girder Ends
10.3	Install Plastic Source Tubes
10.4	Cover Source holes
10.5	Tape ITC Fiber Support  Panels
10.6	Install Shipping Cover

NOTES:
Tape Profiles 5-28 RJM Odd Side
 
 
 

This page maintained by: - RJM
Last Update: 07/11/00 by: -CJW