EMCal ALICE modules stacking / assembly

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1 EMCal ALICE modules stacking / assembly User s Manual / Tutorial Manoel Dialinas updated The EMCal module

30 mm) below the table, and start to rise them up.

2 Put assembly fixture dust clean, and all surfaces degreased. 1. Check guide rods system (guiding rods Ø 1.30 mm) below the table, and start to rise them up. Before to start assembly of first module on each module assembly tooling, mount at bottom a frontplate and a backplate at bottom and check that distance should be mm +0, mm.

2. Mount the two Ø6 locating pins on the center block, for the FrontPlate, on the assembly tooling. 3. Mount assembly shoes (lateral stops) on the table 4.

3 2. Mount the two Ø6 locating pins on the center block, for the FrontPlate, on the assembly tooling. 3. Mount assembly shoes (lateral stops) on the table 4. Front plate : drawing 26K200_H, locate Phi and Eta sides, check outer sizes (mainly width in Phi direction) and thickness of the edge for strap, 5. Compression Plate : locate Phi and Eta sides, check outer sizes (drawing 26K202_E) Put a flat stainless steel washer (OD /-0.1mm) at the bottom of the Belleville Washers, put graphitized grease on this washer. 6. Back Plate : drawing 26K201_G, locate Phi and Eta sides, check geometrical dimensions (mainly width in Phi direction), check that the 5 M6x1 screws for set up of Belleville Washers turn free in threaded holes. 7. Strap : drawing 26K203_C, check overall thickness of straps is < 3.15 mm, including welds 8. Module assembly begins with the placement of the frontplate. Care should be taken that the frontplate is squarely seated on the base plate and fully down of the locating pins. The assembly shoes are then brought up to the front plate and tapped securely in place as they are bolted to the steel plate : this is important in order to perform module s width within design tolerances (overall width in phi must be < 120 mm) Rise up the guiding rods in order to locate accurately the first BondPaper sheet.

Prepare different blocks of scintillators A and B with right

4 9. Check height of 4 towers of 77 scintillators. If total height is different at corners, make decision to shim. Prepare different blocks of scintillators A and B with right orientation (mark line on outer side). A and B scintillator tiles are not interchangeable.

.. Rise up progressively guiding rods for each

5 9. Start stacking. Put one Bond paper first (drawing 26K206_B), then Scintillator (drawing 26K205_A), then Bond Paper, then lead tile, and so on... Rise up progressively guiding rods for each layer. One operator for handling lead and bond paper, one other for handling scintillator

during stacking. 11. Put flat washers with graphitized grease the 5 Ø 10.

6 10. Stack 77 layers, finish with a Bond Paper. After the last layer of BondPaper is put in place, the stack should be a few mm higher than the last aluminium block, this depends on the flatness of the Pb plates during stacking. 11. Put flat washers with graphitized grease the 5 Ø 10.1 mm holes of Compression Plate, then 5 sets (one set = 5 stacks of 3 washers) of Belleville washers (ref. Schnorr ). Orientation of BW sets : highest set has small diameter at the top. Mount brass Belleville Washers plunger on the Belleville washers stacks, when integrated plunger pins are not used. 12. Mount Compression Plate on stacked module, using the guides rods for alignment.

7 13. Mount load cells block and steel crossbeam on vertical rods, and apply progressively a precompression load of 9.5 bar (total load 5350 N = 545 kgf = 1210 lbs) during minutes (typically lunch time or tea time) in order to remove the large flatness defaults of lead tiles. The module should creep roughly 2-5 mm when load is applied at very first time, then 1-2 mm more during the minutes precompression time. 14. Dismount load cells block and steel crossbeam. Check height of module, at each corner. Shim if necessary in order to have same height at 4 corners, and in order to have a compressionplate - backplate gap of mm. Shimming is achieved with aluminium sheets, 0.5 mm, 1 mm, 2 mm and 3 mm thick. 15. Put the 5 M6 integrated plunger pins into backplate with threaded part set just at level of bottom side. Mount BackPlate on the compression plate, check Phi and Eta sides before mounting.

16. Mount load cells block on Back Plate, mount

backplate for alignment, tight the 4 M6 screws

18. The steel crossbeam is bolted to the

8 16. Mount load cells block on Back Plate, mount Ø6 mm dowel pins through load cells block and backplate for alignment, tight the 4 M6 screws in order to fasten load cells block to BlackPlate. 17. Put steel crossbeam on the vertical large rods 18. The steel crossbeam is bolted to the loadcells block and then bolted to the vertical large rods. Check top, bottom, left and right sides of stacked module. 19. Mount the pneumatic pistons head on the module assembly tooling.

9 20. Set pressure at high value (9.5 bar, loadcell 1070 N = 109 kgf = 242 lbs) in order to achieve the compression load that will remove the remaining flatness defaults of tiles and sheets. When gap no more changes or change less than 0.01 mm within half a day, or when gap starts to fluctuate with temperature, the compression time is finished. Typically, for a total load of 5350 N = 1200 lbs, compression time is within hours long, depending of initial flatness of lead tiles and quality of bondpaper. Total creeping of module during this compression time should be within mm. It is recommended to record the gap during the compression time and to edit the curve g = f(t) as shown below. This helps to know when compression time is finished (flat curve). Variation gap N7 Gap variation (mm) 0,4 0,35 0,3 0,25 0,2 0,15 0,1 0, Time (hours) Variation gap N49 Variation (mm) 0,4 0,35 0,3 0,25 0,2 0,15 0,1 0, Temps (h)

21. Mount black paper shroud on 4 lateral sides of the module.

Mount straps, low flange first, check that there is a correct

10 21. Mount black paper shroud on 4 lateral sides of the module. Check width of module in phi direction. 22. Mount straps, low flange first, check that there is a correct contact between edges of flanges and edges of Front Plate and Back Plate, then insert the 24 M2.5 screws without tighting them, just in order to make sure that inner side of strapflanges are in contact with edges of Front Plate and Back Plate.

11 23. Put a low load, 107 N = 11 kgf = 24 lbs for each loadcell, in order to stretch the straps, check that inner side of strapflange are still in contact with edges of Front Plate and Back Plate.

24. Tight the 24 M2.5 screws with a torque of 0.9 N.m 25. load for the postcompression time (relaxation, stabilisation time). Set load at 450 N = 45.9 kgf = 101 lbs for each load cell.

12 24. Tight the 24 M2.5 screws with a torque of 0.9 N.m 25. load for the postcompression time (relaxation, stabilisation time). Set load at 450 N = 45.9 kgf = 101 lbs for each load cell. Check that temperature is < 22 C during this time. 26. Move down guiding rods. 27. Remove crossbeam from Assembly Tooling in order to be able to move the module. Move module to compression place for stabilization-relaxation of the module. Compression area has to be temperature controlled (< 21 C) at this time.

28. Check width in phi direction (should be <120.00 mm). 29. If not correct, discuss situation in order to know what to do (move back to assembly tooling for dismount-remount or store it?). 30.

13 28. Check width in phi direction (should be < mm). 29. If not correct, discuss situation in order to know what to do (move back to assembly tooling for dismount-remount or store it?). 30. Compression time is finished when load cell indication is quite stable (when it no more decreases). After 24 hours post-compression (stabilization, relaxation), let decrease the compression load down to its nominal value : N = kgf = lbs for each loadcell. Check and record temperature that have to be lower than 22 C, because there is a relationship between module height and temperature : If ΔT 1 C ΔL strap 5.1 µ If ΔT 1 C ΔL module =11.3 µ If temperature in L3 is higher than temperature in assembly area by 1 C, increase of module length will be 11.3 µ, as increase of strap length will be only 5.1 µ, compression load will rise. At the opposite, if temperature in L3 is lower than temperature in assembly area compression load inside module will decrease. 31. Put Loctite glue (n 243) on threads of M6 plunger screws, put them in their threaded holes. Then tight plunger M6 screws for Belleville washers progressively (process by 1/4 turn on each M6 plunger screw, total 1.3 turns for 1.3 mm range) in order to transfer progressively load from cells to Belleville Washers. After 1.3 turns load cells indication should be zero (0), the compression load in module is transferred to Belleville Washers, load cells are no more loaded. In other words when we have a 375 N load on Belleville Washers, that means that we have a torque of 0.5 m.n on the M6 plunger pins (this operation may be done with a torquemeter). Check gap between Back Plate and Compression Plate. Note this value. After transfer of load from screws to Belleville Washers, the module is ready for stripmodule assembly or it may be stored at any temperature (within 0 40 C).

14 32. Remove load cells from compressed module, they can now be used for next module. 33. Put 24 Ø6 locating pins on the StripModule assembly tooling. These pins allow the 120 mm pitch of modules in the StripModule with an accuracy of ± 0.02 mm. 34. Move module to Strip Module assembly table, 35. Locate Module using the Ø6 locating pins and Ø6 holes at the bottom of the Front Plate.

15 36. Put optic fibers in each module.

16 37. When a module has its optic fibers it can be mounted on the stripmodule assembly tooling. 38. Mount 4 M5 studs (drawing 26K212_A) on Back Plate, use loctite glue (n 290) to secure studs in Back Plate,

Locate at best position with the setup devices, using studs and

17 39. Put black silicon rubber RTV 133 on base of strongback as an optic seal. 40. Put StrongBack on lift tables. Locate at best position with the setup devices, using studs and Bundle Fiber terminators as references. 41. Move down slowly StrongBack until contact with BackPlates.

42. Mount and tight the M5 nuts for studs

18 42. Mount and tight the M5 nuts for studs with a torque of 4.0 N.m (use a torquemeter for this operation). It is recommended to secure the nuts with loctite Mount preampl Fiber Manifold, drawing 26K307_B. It has to be glued to strongback with an epoxy glue.

19 44. Mount the APDs For the shaft ring, use Rotor Clip MSH-12SS or Smalley VSM-12-S16. These rings should be made from an amagnetic material (austenitic steel or cupro-beryllium alloy).

45. Close all holes (centering holes, guiding rods holes) with black paper on Front Plate, in order to avoid light enter in the module. 46. Put shims between modules, nominal thickness 0.

20 45. Close all holes (centering holes, guiding rods holes) with black paper on Front Plate, in order to avoid light enter in the module. 46. Put shims between modules, nominal thickness 0.07 mm : in fact thickness of shim has to be adjusted to effective width of module. These shims should be located at best at flange strap position at top and bottom of modules. 47. Put 2mm nominal thickness shims between end part of StripModule and walls of SuperModuleCrate in order to prevent any deflection of modules for 9:20 and 10:00 locations in ALICE.

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