PMT HV Base Board Test Description (draft)kitamura/hvdocs/FT/Base/doc/9400-0028... · 10 25 LEVEL 2/LEAD DATE PRODUCT ASSURANCE DATE PROJECT APPROVAL DATE 11 26 12 27 ... 3. PMT HV

REVISIONS LTR. ECN DESCRIPTION DATE APPROVED

A NA Original release May 9, 2005 CONTROLLED DIST. LIST

1 16 ANTARCTIC ASTRONOMY AND ASTROPHYSICS 2 17 RESEARCH INSTITUTE 3 18 THE UNIVERSITY OF WISCONSIN - MADISON, WISCONSIN 4 19 TITLE

5 20 ICECUBE 6 21 DOM PMT HIGH VOLTAGE POWER SUPPLY BASE BOARD 7 22 PRODUCTION TEST REQUIREMENTS AND PROCEDURE 8 23 ORIGINATOR DATE ENGINEER DATE CHECKER DATE

9 24

10 25 LEVEL 2/LEAD DATE PRODUCT ASSURANCE DATE PROJECT APPROVAL DATE

11 26

12 27 FILENAME PROJECT NO.

13 28 9400-0028-TEST.050509.pdf 9000

14 29 DRAWING NO. SCALE SIZE SHEET

15 30 9400-0028-TEST NA A Page 1 of 20

DOM PMT HV Base Board Functional Test Setup and Procedure Page 2 of 20 Document # 9400-0028-TEST Rev: A

9400-0028-TEST.050509.doc

Antarctic Astronomy and Astrophysics Research Institute The University of Wisconsin-Madison

IceCube DOM PMT High-Voltage Power Supply Base Board Production Test Requirements and Procedure Rev: A May 9, 2005

Originator IceCube Document #

9400-0028-TEST

Engineer Filename

9400-0028-TEST.050509.pdf

QA

Approval


9400-0028-TEST.050509.doc

Revisions

Ltr. Description Date Approved A Original release May 9, 2005


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Contents

REVISIONS 3

CONTENTS 4

1. GENERAL 5

1.1 SCOPE 5 1.2 PURPOSE OF THE TESTS 5 1.3 RESPONSIBILITY 5 1.4 APPLICABLE DOCUMENTS 5

2. THE FLYING PROBE TEST 7

2.1 OBJECTIVE 7 2.2 PROBE ACCESS POINTS 7 2.3 TEST SPECIFICATION 8

3. ENVIRONMENTAL STRESS AND SCREENING (ESS) 10

3.1 MINIMUM REQUIREMENTS 10

4. RF MEASUREMENT WITH A NETWORK ANALYZER 11

4.1 OBJECTIVE 11 4.2 SETUP 11 4.3 CALIBRATION 12 4.4 TEST SPECIFICATION 13

5. HIGH VOLTAGE TEST WITH THE HIPOT TESTER 14

5.1 OBJECTIVE 14 5.2 SETUP AND TEST CONDITIONS 14

APPENDIX A FLYING PROBE TOLERANCE DATA 15

APPENDIX B THE RF MEASUREMENT SOFTWARE 16

APPENDIX C HIPOT TESTER SPECIFICATION 20


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1. General

1.1 Scope

The intended user of this document is the vendor of the DOM PMT High-Voltage Supply Base Board (“HV Base Board”). The tests outlined in this document are required and must be executed on each of the HV Base Board prior to shipping to IceCube.

The focus of this document is the requirements associated with the tests, and not the complete description of test implementation. Description of the procedures is minimal in this document. It is up to the responsible party to define the tests in a manner suitable for execution (See 1.3 ). Responsibility

1.2 Purpose of the Tests

The required tests with respect to the HV Base Board manufacturing process flow is as shown in Fig . ure 1

The Flying Probe Test is conducted before and after the ESS in order to verify the correct installation and electrical integrity of the components.

Environmental Stress Screening (ESS) is performed in conjunction with Flying Probe Tests to screen early-life failures (infant mortality).

The RF Impedance Test is used to detect anomalies in the critical low-voltage signal chain that is not accessible by the Flying Probe.

The Hi-Pot Test is used to screen out faulty high-voltage components (capacitors in particular).

1.3 Responsibility

1. Vender shall define the Flying Probe test within the framework outlined in this document.

2. Vender shall define the Environmental Stress Screening within the framework outlined in this document in collaboration with IceCube. The ESS protocols require IceCube’s approval.

3. IceCube is responsible for defining and implementing the RF Impedance Test.

4. IceCube is responsible for defining the Hi-Pot test.

5. Vender shall disposition failed units according to its own Non-Conforming Material (NCM) system.

1.4 Applicable Documents

1. DOM PMT High Voltage Power Supply Base Board Specification Control Drawing, 9400-0028-SCD

2. PMT HV Base Board Schematic Diagram, 9400-0028-SCH.040517.pdf

3. PMT HV Base Board Parts List, 9400-0028-PRT.041110.pdf

4. PMT HV Base Board Assembly Drawing, 9400-0028-DWG.050202.pdf


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5. PMT HV Base Board Conformal Coating Requirements, 9400-0028-DWG3.050201.pdf

6. Unidata file for HV Base Board Rev C (base_revc.uni, 5/28/2004, 6:47PM) (used for programming the Flying Probe instrument).

Figure 1 HV Base Board Process Flow


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2. The Flying Probe Test

2.1 Objective

By probing only the accessible pads on the board:

o Verify the presence of correct components at correct locations according to the board design documents.

o Detect open and shorts in the circuit.

2.2 Probe Access Points

The pads accessible for the probes are shown in and . All other pads are conformally coated and thus electrically insulated.

Table 1

Table 1 Nodes accessible for the Flying Probe Test

Figure 2

To avoid undesirable indentation (or asperity which may become a corona discharge point) on the solder pads, only the PMT mounting pads and two additional pads, HV+ and HV-, where the HV cable from the HV Generator are attached, are allowed to be probed.

Node name Silkscreen marking PMT_K K

PMT_DY1 D1 PMT_F2 F2 PMT_F1 F1 PMT_F3 F3

PMT_DY2 D2 PMT_DY3 D3 PMT_DY4 D4 PMT_DY5 D5 PMT_DY6 D6 PMT_DY7 D7 PMT_DY8 D8 PMT_DY9 D9

PMT_DY10 D10 PMT_P P

HV+ HV+ HV- HV-


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Figure 2 Probe-accessible pads are marked with a red square

2.3 Test Specification

Table 2 Flying Probe Test Pass/Fail Criteria

Pilot Tester Reading (MΩ) Node 1 Node 2 Parameter Nominal*(MΩ) Min Max PMT_K HV- R17 (FB1) 0.1 0.098 0.102

PMT_DY1 PMT_F2 (continuity) 0 0 0 PMT_F2 PMT_F1 R2 1.87 1.8 1.9 PMT_F1 PMT_F3 (continuity) 0 0 0 PMT_F3 PMT_DY2 R3A + R3B 10.46 13.3 13.8

PMT_DY2 PMT_DY3 R4A + R4B 15.36 19.3 20.1 PMT_DY3 PMT_DY4 R5A + R5B 10.22 13.0 13.5 PMT_DY4 PMT_DY5 R6//C1 5.11 6.8 7.1 PMT_DY5 PMT_DY6 R7//C2 3.09 4.3 4.5 PMT_DY6 PMT_DY7 R8//C3 3.74 5.1 5.3 PMT_DY7 PMT_DY8 R9//C4 + R13 4.64 6.2 6.5 PMT_DY8 PMT_DY9 R10//C5 +

R13 + R14 6.81 8.8 9.2

PMT_DY9 PMT_DY10 (R11A + R11B)//C6 + R14 + R15

9.28 11.9 12.3

PMT_DY10 PMT_P R12//C7 + R15 + R16

7.50 9.6 10.1

*Nominal DC resistance

The pass/fail criteria for the Flying Probe Tester reading between pairs of nodes are shown in the table above.


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Note that the table is created based on the actual measurement of a test article on a given Plying Probe Tester, and is applicable only to the tests performed at EMS in CY2004 and 2005. Although given in mega-ohms, the Pilot Tester readings are not to be interpreted as the measurement of the component values.


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3. Environmental Stress and Screening (ESS)

3.1 Minimum Requirements

The following requirements apply to the HV Base Board assembly.

o Minimum of 5 thermal cycles, where one thermal cycle is defined to be a temperature excursion of +20 ºC→ −40 ºC →+20 ºC.

o +20 ºC to −40 ºC temperature range.

o Ramp rate of between 2 and 5 ºC per minute.

o Dwell time of a minimum of 60 minutes at each temperature extreme.


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4. RF Measurement with a Network Analyzer

4.1 Objective

This is a one-port measurement at the connector attached to the end of the pulse-output cable K2.

o Test the integrity of the toroid (K1)

o Test the presence of R16 in correct value.

o Test the continuity of the cable/connector assembly (K2)

4.2 Setup

Figure 3 RF Measurement Setup

Hardware Setup

The setup consists of the HP3589A Network Analyzer with the S-Parameter unit HP35689A; the PC for controlling the Network Analyzer; and, the test bed (not shown) on which the PCB panel containing two UUTs is placed during the test.

The PC controls the Network Analyzer through the GPIB port using a National Instruments GPIB-to-USB adapter GPIB-USB-B.

The connector J2, located on the top side of the test bed, is where the cable plugs are connected one at a time for testing the individual UUTs. The connector adapter contains a rf-transformer (Mini Circuits T2-1-KK81) for matching the impedance to the input port of the Network Analyzer (50Ω).


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Network Analyzer Setup

1. Configure the Network Analyzer as follows:

o Measurement type = VSWR (voltage standing wave ratio)

o Frequency Range = 75 to 150MHz

o Sweep = 1Hz

o Averaging = 10 sweeps

2. Calibrate the normalized reflection coefficient while J2 is open.

3. Place a reference sample (a known good board) on the test bed and connect the cable to J2.

4. Measure the VSWR and save the curve data as “D1”.

5. Define function “F3” as F3 = log (VSWR / D1).

6. Display F3 in linear scale with the following settings:

o Scale = 0.5 Units / div

o Reference level = 0

o Reference position = 0 %

7. Save the instrument’s state.

Software

See the test program documentation in Appendix B.

Operating Procedure

1. Run the main test script RunTest.bat.

2. Enter the Operator name and UUT serial number according to the prompt.

3. Connect the cable plug to J2.

4. Start measurement by ‘pressing any key’.

5. Exit <Ctrl-C> or go to step 2 by ‘pressing any key’.

4.3 Calibration

See Steps 2 – 4 of the Network Analyzer setup in the previous section.

The reference sample is a known good board, selected and designated by IceCube.


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4.4 Test Specification

See the table below. The unit passes the test if and only if the entire plot of

F3 = log(VSWR/D1)

over the test frequency is within the test limit.

Table 3 Test limits for F3 = log(VSWR / D1)

Test Frequency 75-150 MHz (swept) Parameters to be verified K1, R16

Nominal value F3 0 Min pass limit F3mix −0.5 Max pass limit F3max +0.5


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5. High Voltage Test with the HiPot Tester

5.1 Objective

Test the integrity of the capacitors under a high-voltage load.

5.2 Setup and Test Conditions

The HiPot test specification is constrained by the HiPot tester’s accuracy and programmability allowing only five pre-set test conditions. Accordingly, five most critical node pairs have been selected for the test.

The HV Base Boards are tested in the panelized form on a bed-of-nails fixture equipped with a rotary switch that allows the operator to sequentially execute the preset tests.

The test voltages correspond to the situation where a total voltage of 2.5kV is applied across HV+ and HV-.

Table 4 HiPot Test Parameters and Pass/Fail Limits

Node Pair Applied voltage*

Normal current max**

Failure current

max Preset

(+) (-)

Target component

(V) (mA) (mA)

1 PMT_P PMT_DY10 C7 140 0.0205 0.03 2 PMT_DY10 PMT_DY9 C6 180 0.0212 0.03 3 PMT_DY9 PMT_DY8 C5 130 0.0210 0.03 4 PMT_DY8 PMT_DY6 C3, C4 160 0.0210 0.03 5 PMT_DY6 PMT_DY4 C1, C2 160 0.0214 0.03

All Presets Operating mode DC Dielectric withstand test mode Ramp up time 5.0 sec Ramp down time 5.0 sec Dwell time 10.0 sec

* Corresponds to a total of 2.5kV applied between HV+ and HV-.

**Assume 2% accuracy for resistors and ±(2% of setting +5V) applied voltage setting.


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Appendix A Flying Probe Tolerance Data Because of the high resistance values on the PMT HV Base Board, running the Flying Probe tester required non-standard tuning of the probe current and voltage. The following table, provided by the EMS, demonstrates that all the flying-probe tester (“Pilot Tester”) is finally capable of measuring the resistance and capacitance to within the tolerance indicated (%) using only the probe access points marked in Figure 1.

Table A1 UW-Madison HV Base Pilot Test Summary

Test Type Components

Tested Meas. Value

Meas. Tol. (%)

Resistance R1A_G 52500000 Ohm 5 Resistance R2 1870000 Ohm 5 Resistance R3A_B 10460000 Ohm 5 Resistance R4A_B 15360000 Ohm 5 Resistance R5A_B 10220000 Ohm 5 Resistance R6 5110000 Ohm 5 Resistance R7 3090000 Ohm 5 Resistance R8 3740000 Ohm 5 Resistance R9_R13 4640000 Ohm 5 Resistance R10_R13_R14 6810000 Ohm 5 Resistance R11A_B_R14_R15 9280000 Ohm 5 Resistance R12_R15_R16_K1 7500000 Ohm 5 Resistance R18_R16 100000 Ohm 5 Resistance R17_FB1 100000 Ohm 5 Capacitance C1 3.3 nF 15 Capacitance C2 4.7 nF 15 Capacitance C3 4.7 nF 15 Capacitance C4_R13 4.7 nF 15 Capacitance C5_R13_R14 10 nF 15 Capacitance C6_R14_R15 10 nF 15 Capacitance C7_R15_R16 22 nF 15 Untested = R16, K1, K2 (cable)


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Appendix B The RF Measurement Software

B1. Contents of RunTest.bat @echo off prompt = [IceCube] :start cls color f1 type blank date /t time /t echo -------------------------------------- echo IceCube type blank echo High Voltage Base Board type blank echo RF Impedance Test type blank echo Press [ctrl-C] to terminate echo -------------------------------------- type blank :start echo Please connect the cable and ... type blank pause c:\python23\python SNentry.pyw ..\TestDat\logbook1.dat > thisuut.txt type blank echo Running test ... type thisuut.txt wait 30 gpib_write "DISP:LIMIT:STAT ON" wait 5 REM gpib_read "DISP:LIMIT:RES?" temp.txt gpib_read "DISP:LIMIT:RES?" result.txt wait 1 gpib_write "DISP:LIMIT:STAT OFF" echo ....Done type blank echo Test Result type blank echo [] echo [] echo _[]_ echo \\// echo \/ type blank c:\python23\python timestamp.pyw thisuut.txt result.txt ..\TestDat\logbook1.dat type blank type blank pause type blank goto start


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B2. Program Execution Environment Windows XP

National Instruments GPIB driver for GPIB-USB-B adapter

Python 2.3

B3. Brief Description of the Files Referenced in RunTest.bat

SNentry.pyw Graphical user interface allowing the operator to enter the UUT serial number. The UUT value received from the GUI is passed on the command line argument.

timestamp.pyw Makes an entry into logbook1.dat by concatenating thisuut.txt, result.txt, and the timestamp of the test finish time.

logbook1.dat Log file created by SNentry.pyw, containing the UUT serial number, the Pass/Fail result, and the time stamp.

thisuut.txt Temporary text file containing the serial number of the UUT being tested.

result.txt Temporary text file containing the pass/fail result of the UUT being tested.

gpib_write.exe Sends the string passed on the command line to the GPIB port at address 11 (dec).

gpib_read.exe Sends the first argument to the GPIB port at address 11 (dec) and writes the value read from the port to the second argument.


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B4. Contents of SNentry.pyw from Tkinter import * import sys import os class SNEntry: def __init__(self): self.root = Tk() self.root.title('PMT HV Base Board Test') self.root.protocol('WM_DELETE_WINDOW', self.root.bell) try: f = open(sys.argv[1], 'rt') d = f.readlines() f.close() d = d[len(d)-1].split() d = d[len(d)-2] d = d.lstrip('SN') d = str(int(d)+1) except: d = '001' self.data = d self.ent = None def makeform(self): def __fetch(*event): self.data = self.ent.get() self.root.destroy() #return row = Frame(self.root) row.pack() Label(row, width=20, text='Serial Number:').pack(side=LEFT, expand=NO,

fill=X) sn_ent = Entry(row) sn_ent.config(width=10) sn_ent.delete(0, END) sn_ent.insert(0, self.data) sn_ent.pack(expand=NO) self.ent = sn_ent self.root.bind('<Return>', __fetch) Button(self.root, text='OK', command=__fetch).pack(side=BOTTOM) def run(self): self.makeform() self.root.grab_set() self.root.focus_set() self.root.wait_window() self.root.mainloop() def get_data(self): return self.data if __name__=='__main__': if len(sys.argv)<>2: exit('usage: SNentry.pyw loogbook.dat') SN = SNEntry() SN.run() print SN.get_data()


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B5. Contents of timestamp.pyw import time import sys if len(sys.argv)<>4: print 'usage: timestamp sn_file pass_fail_file out_file' exit(0) try: sn_file = open(sys.argv[1], 'rt') except: exit('FileError') try: pass_fail = open(sys.argv[2], 'rt') except: exit('FileError') try: out_file = open(sys.argv[3], 'at') except: exit('FileError') sn = sn_file.readlines() sn_file.close() pf = pass_fail.readlines() pass_fail.close() outstr = "'"+time.asctime()+"'\tSN"+sn[0].rstrip('\n')+'\t'+pf[0].rstrip('\n') out_file.write(outstr+'\n') out_file.close() print outstr


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Appendix C HiPot Tester Specification

Table C1 Partial specification of the HiPot tester

Model name Associated Research #3570D

Voltage setting 0 - 6kV in 10 volt steps

Accuracy: ±(2% of setting +5V)

Dwell time setting 0.2 – 999.9 sec in steps of 0.1 sec

Ramp time setting

0.1 – 999.9 sec in steps of 0.1 sec

Failure setting High limit: 0.02 – 5.00 mA in 0.01 mA steps

Low limit: 0.00 – 5.00 mA in 0.01 mA steps

Accuracy: ± (2% of setting + 0.02 mA)

Programmability 5 presets, no remote control