**CMS ENDCAP MUON**

#  POSITION MONITORING SYSTEM

**QUALITY CONTROL MANUAL**

Draft

May 11, 2001

EMPMS Group:

Fermilab, Northeastern University, Petersburg Nuclear

Physics Institute, University of Wisconsin-Madison

> Abstract:
>
> In this note, we designate the set of measurements, tests, logging,
> archiving
>
> for the Quality Assurance of Endcap Position monitoring system
> elements, for
>
> Assembly, Installation, and system maintenace.

**CONTENTS**:

1.  **Introduction**

2.  **Quality Control, Quality Assurance, Calibration Outline**

3.  **Recording and Archiving Information, Tracking**

    1.  Barcode

> 3.1.2 Items
>
> 3.1.3 Details
>
> **4. Quality Control of System Parts**

1.  Mechanical Parts

> 4.2 Electronics Parts, Printed circuit boards
>
> 4.3 Sensors, optical parts
>
> **5. Quality Control of System Subassemblies**

1.  Mechanical sub assemblies

2.  Mechanical assemblies

> 5.3 Commercial Electronic Units
>
> 5.4 Custom Electronics fabrications
>
> 5.5 DCOPs sensor assemblies
>
> 5.6 Cable assemblies/harnesses
>
> 5.7 Low voltage power supplies
>
> **6. Calibrations, Testing, Certification of System Subassemblies**
>
> 6.1 Analog sensor calibrations
>
> 6.2 DCOPS sensor calibrations
>
> 6.3 Electronics performance and burn in tests

4.  Cable assembly/harness testing

5.  SLM string test-certification on test bench

6.  Transfer Plate Measurements, calibration

> 6.7 Z tube measurements
>
> 6.8 MAB DCOPS sensor measurements, tests, calibrations

6.9 Tests, measurements, certifications of layer SLMs

**CONTENTS**:

> **7. Quality Control during System Installation-Commissioning**

7.1 Tests, measurements, certifications of layer SLMs

7.2 Tests, measurements, certifications of each YE (n)

> DAQ, electronics, laser gate, low voltage systems,
>
> grounds, earth shield, mechanical installations

3.  Tests, measurements, certifications of Transfer Line systems

> 7.4 Optical path, safety, mechanical protection, CSC

grounds, earth shield, mechanical installation --tests

and certification

**8. Quality Assurance during System Operation and Maintenance**

8.1 Tests, measurements, re-certifications of layer SLMs

in open maintenance and after re-closure

8.2 Tests, measurements, re-certifications of each YE (n)

> DAQ, lasers and laser gates, low voltage systems,
>
> re-check grounds, shields, mechanical installations
>
> in open maintenance and after re-closure

3.  Tests, measurements, re-certifications of Transfer Line systems

> after re-closure
>
> 8.4 Optical path protection, CSC grounds, earth shield, --tests

and re-certification

**1. Introduction**

> This document describes the elements of Quality Control and Assurance
>
> during the procurement of parts, commercial production of OEM, custom
> parts and
>
> subassemblies; group calibrations, measurements, testing, and
> certification of sensors
>
> and subassemblies; group quality assurance procedures in Installation
> and commissioning.
>
> The Quality Control-Quality Assurance plan encompasses all of these

phases and is characterized differently in each phase. There are many
detailed system elements with specific requirements. We divide the
system into two main outlines:

A.  Electronics

    1.  Commercial electronic units (Agilent Data Acquisition, serial
        port hubs)

    2.  Electronic circuit parts (ADCs, DSPs, CPLDs, Flash Memory)

    3.  Custom printed circuit boards

    4.  Custom circuit board assemblies (DCOPS Interface, Analog
        Interface, Low Voltage distribution, laser gating, Temperature
        sensor Interface)

    5.  Low Voltage supplies

    6.  Custom cable assemblies/harnesses

    7.  Analog Sensors and custom connectors

    8.  Temperature sensors and custom connectors

    9.  DCOPS Optical Sensors and Kapton cables

    10. Laser module assemblies

    11. Grounds, electronics protection, testing

B.  Mechanical

    1.  Alignment sensor mounting hardware for CSCs (ME1, ME2, ME3, ME4)

    2.  Alignment sensor mounting hardware for MABs

    3.  Transfer Line laser mount-articulation assemblies

    4.  Transfer plate mechanical parts

    5.  DCOPS sensor mechanical parts

    6.  DCOPS sensor mechanical assemblies

    7.  SLM Laser source articulation subassemblies

    8.  Transfer plate mechanical assemblies

    9.  Earth ground electronics enclosures, Transfer plate covers,
        Optical path tubes

    10. Z tubes and mounts

**2. Quality Control, Quality Assurance, Calibration Outline**

> Procedures, methods, and acceptance criteria are described in detail.
>
> At present, the tests described are considered mandatory.
> Non-conformity
>
> procedures are included which demonstrate tracking ability. All
> information
>
> will be in a common database used by all collaborators and sites. At
> present,
>
> productions of given sub-assemblies, sensors, electronics, etc are
> likely to be
>
> site specific, so all Quality control for a given production,
> calibration,
>
> certification can be coordinated at one site.

The Quality control tests are divided into four principle parts:

(1) Tests/measurements of commercial parts and sub assemblies

(2) Tests/measurements of assemblies, sensors in calibration and
    certification

(3) Tests/measurements in subsystem certification (burn-in, performance,
    reliability)

(4) Tests/measurements/configuration checks in
    Installation/commissioning

> Tests in each stage have pass/fail criteria specified. Testing will be
> by sampling for each production batch of parts and subassemblies. Some
> subassemblies are checked in great detail in assembly measurements and
> calibrations and in electronics burn-in/reliability tests. Any
> failures will be monitored and will trigger further extended testing
> to establish the integrity of the production and compliance of the
> vendor with QC specified in the contract.
>
> In the other stages, tests/measurements apply to all sensors and
> assemblies.

**3**. **Recording and Archiving Information, Tracking**

> All sub assemblies and assemblies in the system will have an ID number
>
> corresponding to a computer readable bar code. Minor parts used in sub
> assemblies
>
> will be identified by a batch number and an associated sub assembly
> group.
>
> The barcode marking sub assemblies and assemblies has the following
>
> structure:

3.  *52* NN LL *P* *QQQ* LMN M

> CMS EMU SITE ITEM DETAIL S N Check digit
>
> 3.1.1 Operational Sites

+-----------------------+-----------------------+-----------------------+
| Production Center     | Code                  | Fabrications, Tasks,  |
|                       |                       | *Coord*               |
+-----------------------+-----------------------+-----------------------+
| Fermilab              | 01                    | Analog sensors, DAQ,  |
|                       |                       |                       |
|                       |                       | *Mechanical parts,    |
|                       |                       | LV, electronics,      |
|                       |                       | cables*               |
+-----------------------+-----------------------+-----------------------+
| Northeastern U        | 02                    | DCOPS sensors,        |
|                       |                       | electronic            |
|                       |                       |                       |
|                       |                       | enclosures,           |
|                       |                       | calibrations          |
+-----------------------+-----------------------+-----------------------+
| Petersburg Nuclear    | 03                    | DCOPS electronics     |
| Phys Ins              |                       |                       |
+-----------------------+-----------------------+-----------------------+
| U Wisconsin- Madison  | 04                    | Mechanical parts,     |
|                       |                       | Integration, Project  |
|                       |                       | management            |
+-----------------------+-----------------------+-----------------------+
| Mechanical Fabricator | 05                    | CNC mechanical parts  |
+-----------------------+-----------------------+-----------------------+
| Electrical Fabricator | 06                    | PCB assembly-test     |
+-----------------------+-----------------------+-----------------------+
| Cable Fabricator      | 07                    | Cable/harness         |
|                       |                       | assembly              |
+-----------------------+-----------------------+-----------------------+

2.  Alignment System Items

+----------------------------------------------+------+------+---------+
| Item                                         | Code | Tag  | Co      |
|                                              |      |      | nfigure |
+----------------------------------------------+------+------+---------+
| ME1-3 Outer sensor mount                     | 01   | ID   | P =     |
|                                              |      |      | Left    |
|                                              |      |      |         |
|                                              |      |      | P =     |
|                                              |      |      | Right   |
+----------------------------------------------+------+------+---------+
| ME1-3 Inner sensor mount                     | 02   |      | P =     |
|                                              |      |      | Left    |
|                                              |      |      |         |
|                                              |      |      | P =     |
|                                              |      |      | Right   |
+----------------------------------------------+------+------+---------+
| ME1-2 Outer sensor mount                     | 03   |      |         |
+----------------------------------------------+------+------+---------+
| ME1-2 Inner sensor mount                     | 04   |      |         |
+----------------------------------------------+------+------+---------+
| ME234-2 Outer sensor mount                   | 05   |      | P =     |
|                                              |      |      | Left    |
|                                              |      |      |         |
|                                              |      |      | P =     |
|                                              |      |      | Right   |
+----------------------------------------------+------+------+---------+
| ME234-2 Inner sensor mount                   | 06   |      |         |
+----------------------------------------------+------+------+---------+
| ME234-2 Outer tower mount                    | 07   |      | P =     |
|                                              |      |      | Left    |
|                                              |      |      |         |
|                                              |      |      | P =     |
|                                              |      |      | Right   |
+----------------------------------------------+------+------+---------+
| ME2-1 Outer sensor mount                     | 08   |      | P =     |
|                                              |      |      | Left    |
|                                              |      |      |         |
|                                              |      |      | P =     |
|                                              |      |      | Right   |
+----------------------------------------------+------+------+---------+
| ME2-1 Inner sensor mount                     | 09   |      |         |
+----------------------------------------------+------+------+---------+
| ME3-1 Outer sensor mount                     | 10   |      | P =     |
|                                              |      |      | Left    |
|                                              |      |      |         |
|                                              |      |      | P =     |
|                                              |      |      | Right   |
+----------------------------------------------+------+------+---------+
| ME3-1 Inner sensor mount                     | 11   |      |         |
+----------------------------------------------+------+------+---------+
| ME4-1 Outer sensor mount                     | 12   |      | P =     |
|                                              |      |      | Left    |
|                                              |      |      |         |
|                                              |      |      | P =     |
|                                              |      |      | Right   |
+----------------------------------------------+------+------+---------+
| ME4-1 Inner sensor mount                     | 13   |      |         |
+----------------------------------------------+------+------+---------+
| MAB DCOPS sensor mount                       | 14   |      |         |
+----------------------------------------------+------+------+---------+
| Transfer plate support ME1                   | 15   |      |         |
+----------------------------------------------+------+------+---------+
| Transfer plate support ME2, ME3, ME4         | 16   |      |         |
+----------------------------------------------+------+------+---------+
| Item                                         | Code | Tag  | Co      |
|                                              |      |      | nfigure |
+----------------------------------------------+------+------+---------+
| Transfer laser support/actuator              | 17   | ID   | P=      |
|                                              |      |      | offset1 |
|                                              |      |      |         |
|                                              |      |      | P=      |
|                                              |      |      | offset2 |
+----------------------------------------------+------+------+---------+
| Transfer Plate ME1                           | 18   | ID   | P=      |
|                                              |      |      | offset1 |
|                                              |      |      |         |
|                                              |      |      | P=      |
|                                              |      |      | offset2 |
+----------------------------------------------+------+------+---------+
| Transfer Plate ME2                           | 19   | ID   | P=      |
|                                              |      |      | offset1 |
|                                              |      |      |         |
|                                              |      |      | P=      |
|                                              |      |      | offset2 |
|                                              |      |      |         |
|                                              |      |      | P=      |
|                                              |      |      | offset3 |
+----------------------------------------------+------+------+---------+
| Transfer Plate ME3                           | 20   | ID   | P=      |
|                                              |      |      | offset1 |
|                                              |      |      |         |
|                                              |      |      | P=      |
|                                              |      |      | offset2 |
|                                              |      |      |         |
|                                              |      |      | P=      |
|                                              |      |      | offset3 |
|                                              |      |      |         |
|                                              |      |      | P=      |
|                                              |      |      | special |
+----------------------------------------------+------+------+---------+
| Transfer Plate ME4                           | 21   | ID   | P=      |
|                                              |      |      | offset1 |
|                                              |      |      |         |
|                                              |      |      | P=      |
|                                              |      |      | offset2 |
|                                              |      |      |         |
|                                              |      |      | P=      |
|                                              |      |      | offset3 |
|                                              |      |      |         |
|                                              |      |      | P=      |
|                                              |      |      | special |
+----------------------------------------------+------+------+---------+
| Z tube assembly ME1-ME2                      | 22   | ID   |         |
+----------------------------------------------+------+------+---------+
| Z tube assembly ME2-ME3                      | 23   | ID   |         |
+----------------------------------------------+------+------+---------+
| Z tube assembly ME3-ME4                      | 24   | ID   |         |
+----------------------------------------------+------+------+---------+
| DCOPS sensor box                             | 25   | ID   |         |
+----------------------------------------------+------+------+---------+
| DCOPS CCD-FEB assembly                       | 26   | ID   |         |
+----------------------------------------------+------+------+---------+
| DCOPS sensor assembly                        | 27   | ID   | P=Left  |
|                                              |      |      |         |
|                                              |      |      | P=Right |
+----------------------------------------------+------+------+---------+
| LPX50 R sensor assembly                      | 28   | ID   | P=      |
|                                              |      |      | Outer   |
|                                              |      |      |         |
|                                              |      |      | P=Inner |
+----------------------------------------------+------+------+---------+
| Transfer-MEN2 outer cable extension          | 29   | ID   |         |
+----------------------------------------------+------+------+---------+
| MEN2-MEN1 inner cable extension              | 30   | ID   |         |
+----------------------------------------------+------+------+---------+
| LCP8-10 Z Potentiometer Assembly             | 31   | ID   | P=      |
|                                              |      |      | Input   |
|                                              |      |      |         |
|                                              |      |      | P       |
|                                              |      |      | =Output |
+----------------------------------------------+------+------+---------+
| Z4MW100 Laser distance sensor                | 32   | ID   |         |
+----------------------------------------------+------+------+---------+
| AD592 T sensor assembly                      | 33   | ID   | P=Inner |
|                                              |      |      |         |
|                                              |      |      | P=Outer |
|                                              |      |      |         |
|                                              |      |      | P=T     |
|                                              |      |      | ertiary |
+----------------------------------------------+------+------+---------+
| AppGeo900 Inclinometer Assembly              | 34   | ID   |         |
+----------------------------------------------+------+------+---------+
| DCOPS readout board                          | 35   | ID   |         |
+----------------------------------------------+------+------+---------+
| DCOPS LVDS cable (includes loop around       | 36   | ID   | P=pathN |
| Barrel)                                      |      |      |         |
+----------------------------------------------+------+------+---------+
| R sensor SLM cable                           | 37   | ID   | P=pathN |
+----------------------------------------------+------+------+---------+
| T sensor SLM cable                           | 38   | ID   | P=pathN |
+----------------------------------------------+------+------+---------+
| DCOPS JTAG,LVDS-RS485 Interface, Low voltage | 39   | ID   |         |
|                                              |      |      |         |
| distribution Board                           |      |      |         |
+----------------------------------------------+------+------+---------+
| Analog Interface, Low Voltage Distribution   | 40   | ID   |         |
| board                                        |      |      |         |
+----------------------------------------------+------+------+---------+
| DCOPS Interface-Serial Port,                 | 41   | ID   | P=pathN |
| Interface-Interface cable                    |      |      |         |
+----------------------------------------------+------+------+---------+
| AGILENT Input- Analog Inteface cable         | 42   | ID   | P=pathN |
+----------------------------------------------+------+------+---------+
| Laser Driver cable (3 SLM Station)           | 43   | ID   | P=pathN |
+----------------------------------------------+------+------+---------+
| SLMn T sensor -- T Interface cable           | 44   | ID   | P=pathN |
+----------------------------------------------+------+------+---------+
| ITEM                                         | Code | Tag  | Co      |
|                                              |      |      | nfigure |
+----------------------------------------------+------+------+---------+
| DCOPS power cable                            | 45   | ID   | P=pathN |
+----------------------------------------------+------+------+---------+
| ANALOG power cable                           | 46   | ID   | P=pathN |
+----------------------------------------------+------+------+---------+
| Transfer Z cable (SLM)                       | 47   | ID   | SLM#    |
+----------------------------------------------+------+------+---------+
| Transfer Inclinometer cable (SLM)            | 48   | ID   | SLM#    |
+----------------------------------------------+------+------+---------+
| SLM Laser driver cable (SLM)                 | 49   | ID   | P=pathN |
+----------------------------------------------+------+------+---------+
| 12v Low Voltage Regulator (DCOPS)            | 50   |      | P=layer |
+----------------------------------------------+------+------+---------+
| 12v Low Voltage Regulator (filtered)         | 51   |      | P=layer |
| (ANALOG)                                     |      |      |         |
+----------------------------------------------+------+------+---------+
| Transfer Laser driver cable                  | 52   |      | P=l     |
|                                              |      |      | ocation |
+----------------------------------------------+------+------+---------+
| AGILENT- T sensor Interface cable            | 53   |      | P=layer |
+----------------------------------------------+------+------+---------+
| AGILENT Data Acquisition Unit                | 54   |      | P=layer |
+----------------------------------------------+------+------+---------+
| Ethernet-Serial Port HUB                     | 55   |      | P=layer |
+----------------------------------------------+------+------+---------+
| T sensor Interface Unit                      | 56   |      | P=layer |
+----------------------------------------------+------+------+---------+
| Laser driver Unit                            | 57   |      | P=layer |
+----------------------------------------------+------+------+---------+
| Inner MAB DCOPS sensor                       | 58   |      | P=pathN |
+----------------------------------------------+------+------+---------+
| Inner MAB DCOPS sensor mount                 | 59   |      | P=pathN |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+
|                                              |      |      |         |
+----------------------------------------------+------+------+---------+

3.  DETAIL CODE

To describe special conditions, geometry reflections, mirror
configurations on certain elements etc; we allow special code positions.
This code may include

> a pointer to alignment or the pointer can be included in the serial
> number.

  --------------- -------------------------------------------------------
  Code            Special Conditions

  000             None

  -NM             Z minus Endcap assignment

  mNM             Mirror configuration of MN (item)

  NMx             Special geometry or position for standard NM (item)

                  

                  

                  

                  

                  

                  

                  
  --------------- -------------------------------------------------------

> All of the Barcode data shall be entered into a database configuration
> which can
>
> be merged with the general CMS Endcap database, other Muon alignment
> subsystems, and the general CMS database in development. One simple
> database
>
> package will be used by all sites in a given alignment subsystem; for
> consistency and merging. An alignment pointer filter can be used to
> isolate the subsystem entries and information in a larger database.
> Tracking can be performed by filtering on production center.

**4. Quality Control of System Parts**

Qualification criteria about the technical requirements for system parts
are

Included in the Requests for Quotation and the Purchase orders issued to
vendors for

each item. Vendor Quality Control obligations on parts before shipping
are given. In

many cases, these requirements will include ASTM, ANSI, ISO, and MIL
standard specifications.

> We describe the tests to be performed at a specified Production center
> upon delivery.