Optics QC Check Sheet

MODULE : ANL-028 @ MSU	ATLAS TILECAL OPTICS INSTRUMENTATION CHECK LIST	Cover Sheet
		REF
		REV: 2.7 Mar. 21, 2001

TASK	DESCRIPTION	Ref. Page
1	MODULE PREPARATION	1
2	TILES INSTALLATION	2
3	ROUTING PREPARATION	3
4	PROFILES AND FIBRES INSTALLATION	4
5	FIBRES ROUTING	5
6	FIBRES BUNDLES GLUING	6
7	POLISHING AND CUTTING	7
8	SECURE FIBRES BUNDLES	8
9	QC6 SCAN	9
10	CLOSEUP	10

NOTES

Work crew should initial each task that they work on.

Supervisor should indicate the date as each task is completed.

QC person should fill in the report for each QC task. The QC tasks must be completed before subsequent tasks are started.

Work crew shold fill in the materials list for all items used.

Note any problems, deviations from procedures, suggestions, etc. in the space at the bottom and on the reverse side of pages.

1. Module Preparation

Task Description Date Work Crew

1.1 Setup Module 3/13/01 MN,RR,RJM,DD

1.2 QC0:
Initial Inspection 3/13/01 RJM

Item OK Not OK : List problems and repairs

Residual Glue X

Spring Pins X

Plate/Weld Bar Edges X

Submodule Shims and Spacing X

Pained Surfaces X

Slot Widths X

Contaminants X some rust on ITC end of girder

Task Description Date Work Crew

1.3 Clean out Slots 3/20/01 DK, AR

1.4 Clean out Source Holes 3/22 AR

1.5 Cover Holes in Girder 3/20 AR, RW

1.6 Drill & Tap Holes for belt and laser fiber connector yes ?

1.7 Clean Module Surfaces 3/22 AR, RW

1.8 Mark Cell Boundaries 3/22 AR, RW

1.9 Install Cell & PMT Labels 3/27 MR

1.10 Ream Girder Rings 3/22 RW

NOTES:

2. Tile Installation

Task Description Date Work Crew

2.1 Measure gaps for shims 3/27/01 MR

2.2 Install Shims 3/27 AR

2.3 Record Tile Pak Numbers 4/2 MR

2.4 Mask size 7 tiles YES ?

2.5 Insert Tiles 4/2 MR

2.6 Insert Special ITC Tiles 4/2 AR

2.7 QC1:
Tile Inspection 4/10 RJM

Item OK Not OK : List problems and repairs

Tile Color X

Tile Sizes X

Tile End Surfaces X

Tile Wrappers X

Task Description Date Work Crew

2.8 Install Rods 4/2 AR

NOTES:

3. Fiber Preparations

Task Description Date Work Crew

3.1 Install PMT Labels 3/27/01 MR

3.2 Label Bottom of Aspirin Tubes 3/27 MR

3.3 Install Aspirin Tubes and Washers 3/27 MR

3.4 Install Fixation Rails 3/27 AR

3.5 Install Belt Loops 4/13 MR

3.6 Cover PMT Labels 3/27 MR

3.7 Install Laser Fiber Bundles 4/9 RW

3.7 Record Laser Fiber # 4/12 AR

3.9 Cover Girder Area yes ?

3.10 Install ITC Fiber Supports 4/13 MR, DK

NOTES:

4. Fiber/Profile Installation

Task Description Date Work Crew

4.1 Setup Profile Shelves ? ?

4.2 Record Profile Batch Numbers ? ?

4.3 Insert Profiles/WLS Fibers ? ?

4.4 Install ITC Fibers 5/8/01 RJM

4.5 Record ITC Fiber # 5/8 RJM

4.6 Inspect the profiles 5/10 RJM

4.7 Install Fiber Separator Wires ? ?

4.8 Separate fibers by depth 5/14 AJB, AR

4.9 Make subbundles 5/14 AJB

4.10 Install LED light tubes 5/15 RJM

4.11 QC2: Verify Sorting 5/15 RJM

Item OK Not OK : List problems and repairs

Fiber Lengths Many fibers in layer B are long, may be detached

Fiber Counts X

Depth Sorting 4 Problems fixed

Visual Light Levels 3 problems

4.12 Remove Fiber SeparatorWires 5/15 AR

NOTES:
4.6, 4.11: There are many fibers, especially in the B layers, that have come detached from the profiles. Some of these were noticed and repaired during the profile insertion, but more were found when checking the lengths and light using the LED source tube. It appears that too little glue was being used for this batch of profiles.
While checking some of the profiles, I (RJM) find cases in the D5, D6 cells on the even PMT side where the paint from the masked tiles in layer 7 was smeared onto the tiles in layer 9, eg D6 tile #7. The paint had dried for a couple of days before the profiles were inserted. I think the tiles on this side were slightly higher than the spacer plates because the profiles were inserted first on the even side, and the profile tool was scraping them. I went through these cells and fixed all that I could find. I clean the paint from size 9 tiles with alcohol. I find several more cases where the B fibers are detached from the profile.

5. Fiber Routing

Task Description Date Work Crew

5.1 Setup the Routing Models 5/21/01 AR

5.2 Route Sub-bundles To Aspirin Tubes 5/21 AR

5.3 Route the Laser Fibers 5/21 AR

5.4 QC3:
Verify Fiber Routing 5/21 RJM

Item OK Not OK : List problems and repairs

Odd Side Cells X

Even Side Cells X

5.5 Insert Gluing tubes 5/25 AR

5.6 Insert Teflon Rods 5/25 AR

5.7 Register and Secure Fibers in Aspirin Tubes 5/25 AR

5.8 Insert Dummy fibers 5/25 AR

5.9 QC4: Check Fiber Damage 5/25 RJM

Item OK Not OK : List problems and repairs

Broken fibers X

Stress Crazing X

Cladding Damage X

Fiber Curvature X

Fiber Contact X

NOTES:

6. Glue fiber bundles

Task

Description

Date

Work Crew

6.1

Prepare Glue Cartridges

5/29/01

MN, RR

6.2

Prepare the TV Monitor

5/29

MN, RR

6.3

Inject the Glue

5/29

MN, RR

6.4

Reserve Samples & Rcord Batch numbers

5/29

MN, RR

6.5

Epoxy Cure

yes

6.6

Remove Cable Ties from Silicon Tubes

5/30

NOTES:

7. Polish Fiber Ends

Task Description Date Work Crew

7.1 Setup the Polishing Machine 5/30/01 MN

7.2 Prepare a Test Sample 6/1 MN

7.3 Polish Fibers 6/1 MN

7.4 Remove Polishing Machine 6/1 MN

7.5 Install camera/cleaner 6/1 RJM

7.6 Clean Out the Girder 6/1 RJM

7.7 QC5: Inspect Fiber Ends 6/1 RJM

Item OK Not OK : List problems and repairs

Surface Quality X

Visual Light Level X

NOTES:

8. Secure fiber bundles

Task Description Date Work Crew

8.1 Cut dummy fibers 6/4/01 AR

8.2 Cut Gluing tubes 6/4 MN

8.3 Tie Fiber Bundles to Rails 6/4 MN

8.4 Install Nylon Belt 6/4 RJM

8.4

10. Close up

Task Description Date Work Crew

10.1 Install Alum Tape over Profiles 6/8 RJM

10.2 Cover Module with Plastic Sheet 6/11 RJM

10.3 Cover Girder Ends 6/11 RJM

10.4 Install Plastic Source Tubes 6/11 RJM

10.5 Cover Source holes 6/11 RJM

10.6 Tape ITC Fiber Support Panels YES ?

10.7 Install Shipping Cover

NOTES:

Shimming Data Sheet

Measured Widths
(mm)
Shims Required

Gap # Tile Oddside Even side 1/2 3/4 1

1 1 5.0 5.0 1

2 1 4.6 4.8 1

3 1 4.6 4.4 1

4 1 4.4 4.4

5 1 4.6 4.4 1

6 1 5.2 5.2 1

7 1 4.2 4.2

8 1 4.2 4.2

9 1 4.6 4.4 1

1 11 4.2 4.4

2 11 4.2 4.2

3 11 4.2 4.2

4 11 4.0 4.4

5 11 4.2 4.2

6 11 4.0 4.4

7 11 4.4 4.0

8 11 4.0 4.4

9 11 4.0 4.2

NOTES: 1. Measure Tile Slot 1 at the bottom of the slot and Tile Slot 11 at the top

(where the widths are assumed to be minimum)

Required shims make the minimum slot width in the range 4:4.5 mm
Gaps are numbered starting at the ITC end.

Materials List

Tile Size	Color	Pkg.# (number of tiles) in order from ITC end
1	Y	161, 1195, 1200, 75, 1135, 1123, 653
2	Y	1397, 1429, 163, 1328, 1451, 1452, 1445
3	Y	1216(16), 608(19), 1144, 1046, 1129, 1293, 612, 1058(5)
4	Y	253, 347, 414, 490, 130, 254, 213
5	Y	82, 416, 479, 236, 5, 476, 483
6	Y	117, 113, 124, 144, 99, 138, 127
7	B	152(5), 545, 540, 202, 529, 164, 128, 140
8	B	472, 443, 47, 398, 390, 453, 451, 466
9	B	472, 314, 528, 476, 517, 551, 529, 171
10	B	229, 233, 54, 87, 10, 61, 53, 3
11	B	178, 195, 198, 142, 141, 197, 212
	Date of BATCH
WLS/profile	Long Profiles				Short Profiles
A12B11
A13B11					2-6
A13B12					2-6
A14B12					2-6
A14B13					2-6
A15B13					2-6
A15B14					2-6
A16B14					1-23
A16B15
C10
D4

ITC Fibers #:	Right: 39						Left:39

Aspirin Tubes :

Laser Fiber #'s	Odd Side: EB116			Even Side:EB115

Epoxy Batch #	Resin:60C124428		Hardner:701361110			Exp. Date:6/28/01

QC 2,3,4 Problem List

Tile Layer	Cell	Side	Tile *	Problem	Fixed ?
QC2
4	B15	ODD	25,26	Long fiber - check them	reglued
4	B13	EVEN	4	Low light	reglued
4	B13	ODD		fiber misrouted	yes, rjm
4	B13	ODD	20,22	long fiber, no light	reglued
5	B13	ODD		fiber misrouted	rjm
4	B13	ODD	6	long fiber	reglued
4	B13	ODD	29	long fiber	reglued
4	B12	ODD	4, 6	long fibers	reglued
4	B11	EVEV	11	long fiber	reglued
2	A15	ODD		misrouted	rjm
1	A15	ODD		misrouted	rjm

NOTE: Tiles are numbered from the beginning of the cell, starting at the tile closest to the ITC end of the module. Count every other profile to count the tiles. Odd tile layers start at the cell boundary (count from the first profile), even tile layers start with a spacer plate (count from the second profile). The tile counting stick makes it easier to locate the tiles.

QC6 PROBLEMS

This page maintained by: - RJM

3. Fiber Preparations
Task	Description	Date	Work Crew
3.1	Install PMT Labels	3/27/01	MR
3.2	Label Bottom of Aspirin Tubes	3/27	MR
3.3	Install Aspirin Tubes and Washers	3/27	MR
3.4	Install Fixation Rails	3/27	AR
3.5	Install Belt Loops	4/13	MR
3.6	Cover PMT Labels	3/27	MR
3.7	Install Laser Fiber Bundles	4/9	RW
3.7	Record Laser Fiber #	4/12	AR
3.9	Cover Girder Area	yes	?
3.10	Install ITC Fiber Supports	4/13	MR, DK

4. Fiber/Profile Installation
Task	Description				Date	Work Crew
4.1	Setup Profile Shelves				?	?
4.2	Record Profile Batch Numbers				?	?
4.3	Insert Profiles/WLS Fibers				?	?
4.4	Install ITC Fibers				5/8/01	RJM
4.5	Record ITC Fiber #				5/8	RJM
4.6	Inspect the profiles				5/10	RJM
4.7	Install Fiber Separator Wires				?	?
4.8	Separate fibers by depth				5/14	AJB, AR
4.9	Make subbundles				5/14	AJB
4.10	Install LED light tubes				5/15	RJM
4.11	QC2: Verify Sorting				5/15	RJM
Item			OK	Not OK : List problems and repairs
Fiber Lengths				Many fibers in layer B are long, may be detached
Fiber Counts			X
Depth Sorting				4 Problems fixed
Visual Light Levels				3 problems
4.12		Remove Fiber SeparatorWires			5/15	AR

8. Secure fiber bundles
Task	Description	Date	Work Crew
8.1	Cut dummy fibers	6/4/01	AR
8.2	Cut Gluing tubes	6/4	MN
8.3	Tie Fiber Bundles to Rails	6/4	MN
8.4	Install Nylon Belt	6/4	RJM

10. Close up
Task	Description	Date	Work Crew
10.1	Install Alum Tape over Profiles	6/8	RJM
10.2	Cover Module with Plastic Sheet	6/11	RJM
10.3	Cover Girder Ends	6/11	RJM
10.4	Install Plastic Source Tubes	6/11	RJM
10.5	Cover Source holes	6/11	RJM
10.6	Tape ITC Fiber Support Panels	YES	?
10.7	Install Shipping Cover

		Measured Widths (mm)		Shims Required
Gap #	Tile	Oddside	Even side	1/2	3/4	1
1	1	5.0	5.0			1
2	1	4.6	4.8	1
3	1	4.6	4.4	1
4	1	4.4	4.4
5	1	4.6	4.4	1
6	1	5.2	5.2			1
7	1	4.2	4.2
8	1	4.2	4.2
9	1	4.6	4.4	1

1	11	4.2	4.4
2	11	4.2	4.2
3	11	4.2	4.2
4	11	4.0	4.4
5	11	4.2	4.2
6	11	4.0	4.4
7	11	4.4	4.0
8	11	4.0	4.4
9	11	4.0	4.2