CUTTING THE BRAID TO LENGTH AND MOUNTING OF...

LHC Project Document No.

LHC-DCA-AP-0001 CERN Div./Group or Supplier/Contractor Document No.

AT/MEL/EM, HNINP

EDMS Document No.

592324

Date: 2005-05-18

the Large Hadron Collider project

CERN CH-1211 Geneva 23 Switzerland

Assembly Procedure

CUTTING THE BRAID TO LENGTH AND MOUNTING OF THE RESTRICTION FLANGE

ON A LINE-N CABLE SEGMENT Q7 SIDE

Abstract This document describes the procedure for cutting the braid to length and mounting of the restriction flange a 42-wire Line-N cable segment Q7 side.

Prepared by :

Montse Felip Slawomir Olek Olivier Desebe

Checked by :

Davide Bozzini Jean Philippe Tock

Approved by:

Davide Bozzini Boguslaw Prochal

Alain Poncet Stephan Russenschuck


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History of Changes

Rev. No. Date Pages Description of Changes

08.11.2004

19.02.2007

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43

First draft

Second draft prepared by Montse Felip


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Table of Contents

1. INTRODUCTION.......................................................................................4 2. INITIAL PREPARATION ...........................................................................4 3. RELATED DOCUMENTATION.....................................................................5 4. CONCLUSIONS.......................................................................................32 5. REFERENCES..........................................................................................32 6. ANNEX A: TOOLING, COMPONENTS AND CONSUMABLE MATERIAL........33 7. ANNEX B: DETAILS OF PREPARATION OF THE HEAD-END OF THE LINE-N CABLE SEGMENT EQUIPPED WITH THE CONDUCTING PLUG ......................43


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1. INTRODUCTION

This document describes the procedure for cutting the braid to length and mounting of the restriction flange a 42-wire Line-N cable segment Q7 side.

2. INITIAL PREPARATION

Before starting to cut the stainless steel braid and mounting the restriction plug on a new cable of a reel, an electrical insulation test of all conductors shall be carried out: the stainless steel braid, the central former and all conductors except one shall be connected to ground. This first measurement is used as reference for later electrical qualifications of manufactured segments. A voltage of 2 kV shall be applied to the free conductor and the leakage current is measured. Limit for the leakage current of each individual wire must not be above 4 µA per km. All conductors shall be tested by changing the electrical connections in turn (conductor under test at +2 kV, everything else connected to mass).

In the case that an error occurs during the plug manufacturing or if an electrical of mechanical fault is detected after its assembly the plug will be cut off and only 0.5 m of cable will be lost. Only if the plug has passed successfully the electrical tests, the cable is measured and then cut to the proper length.


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3. DETAILED ASSEMBLY PROCEDURE

Step Description Reference/picture/drawing

1 From the dipole-Q7 side:

Pull the cables a distance of 275mm as shown.

2 From the Q7-DFBA side:

Mark the position 7mm from the extremity of the flange with a felt pen on the stainless steel braid.

This reference shows the position where the restriction plug will be located.

3 Mark a line at a distance of 2 cm

from the reference position.

This line shows where will be cut the stainless steel braid.


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4 From the Q7-DFBA side (working place):

Pull the cables (top and bottom) a distance of 10 cm.

Important: Pull out on both lines (600A and 6kA) equally.

5 From the Dipole-Q7 side:

Push the cables to make step 4 easier.

This pictures shows all the

references after pulling 10 cm.

6 Mark a line at a distance of 45 cm

from the 2 cm position.

This is where the cable bundle will be cut.

Put self-adhesive paper tape round the stainless steel braid at this position


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7 Cut the complete cable bundle on the 45 cm line which was marked in step 6.

8 Use a saw to do this operation


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9 Put the nut No 1(table 6.2, No 16) on the cable.

Put the stainless steel ring (table 6.2, No 18) on the polyethylene tube with a cone (table 6.2, No 14). Put the polyethylene tube with a cone on the cable

Put the nut No 2 (table 6.2, No 17) on the cable.

Pass a cord through the nut No 1

10 Tie the cord to the cables or

frame in order not to loose the nut assembly in the magnet tube.


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11 Carefully remove the stainless steel braid from the end of the cable over about 4 cm. Take care to avoid unrolling the polyester bedding tape. Use Stanley knife (table 6.1, No 10).

Secure the polyester bedding tape with the self-adhesive paper tape on the end of the cable.

12 Firmly secure the stainless steel

braid near the flange, with self-adhesive paper tape as shown.

To simplify cutting the braid, expand it by pushing it back from the end of the cable by a few centimetres.

Fix it with self-adhesive paper tape.

13 Cut off the stainless steel braid

along the marked line. Use sharp pliers (table 6.1, No 8) to ensure a clean cut.


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14 Remove the long loose part of the stainless steel braid.

15 Image just after to cut the

stainless steel braid


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16 Mark the extremity of the stainless steel braid on the polyester tape (position A).

17 Carefully push back the stainless steel braid about 10 cm from the reference line and fix it with self-adhesive paper tape.

Be careful to avoid damaging the end of the braid

18 Mark a line at a distance of 3 mm

from position A.

This will be the position of the Kapton® -self adhesive tape and of the Kapton® foil.


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19 Carefully push back the stainless steel braid about 10 cm from the reference line and fix it with self-adhesive paper tape.

Be careful to avoid damaging the end of the braid.

20 Shift the stainless steel braid 3 cm right. Be carefully to avoid devastation of the end of the stainless steel braid. Fasten the polyester tape with Kapton® self-adhesive tape at position B.


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21 Remove the self-adhesive paper tape from the end of the cable.


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22 Unwrap the polyester tape and cut it away just before the layer of Kapton® self-adhesive tape. Use scissors, (tab. 6.1, No 16).


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23 Unwrap and remove the Kapton® tape from the outer layer of insulated superconducting wires. Use scissors, (tab. 6.1, No 16).

Be very careful not to damage the insulation of the wires.

24 Prepare the Kapton® foil (table

6.2, No 19).

Attach 2 pieces of Kapton® self-adhesive tape to one end.


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25 Fix Kapton® foil (table 6.2, No 19) to the polyester bedding tape using Kapton self adhesive tape (tab. 6.2, No 13).

Roll the Kapton foil very tightly round the cable.

26 Fix it using Kapton self adhesive

tape.


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27 Move the stainless steel braid over the layers of Kapton® foil.

The end of the braid should be at about 5 mm from the end of the Kapton® foil.

Fix the braid with self-adhesive paper tape.

28 Mark position C at a distance of 5

mm from the end of the Kapton foil.

This will be the position of the thermal shrink sleeve.

29 Slide the thermal shrink sleeve A (table 6.2, No 9), over the stainless steel braid.

Remove the self-adhesive tape securing the stainless steel braid.

Slide back the thermal shrink sleeve until it is lined up with position C.


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Step Description Reference/picture/drawing 30 Heat up the thermal shrink sleeve

with the hot-air gun and make it shrink to fit. Set temperature regulation knob to position 6. Heat from distance of about 5 cm during 30 seconds.

Make sure that the sleeve is aligned with position C before heating.

31 Remove the self-adhesive paper

tape from the stainless steel braid, near the flange.


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Step Description Reference/picture/drawing 32 Put the flange (table 6.2, No 2)

on the cable.

Screw the nut No2 (tab. 6.2, No 17) into the flange.

While holding the flange with the special tool, tighten the nut using the dynamometric key No 32 (tab. 6.1, No 18).

Torque to be applied 80 Nm.

Special Tool


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Step Description Reference/picture/drawing 33 Remove the string attached to nut

No1.

Slide the stainless steel ring with the polyethylene tube into nut No2 on the flange.

Slide nut No1 over the cable and polyethylene tube and screw it into nut No2.

Ensure that the two tapped holes on the flange are in the horizontal plane.

Again, holding the flange with the special tool, tighten nut N01musing the dynamometric key.

34 Torque to be applied 100 Nm

35 The image shows the two tools

used for the steps 33 and 34.


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Step Description Reference/picture/drawing 36 Fix the flange to the tube.

Screws: stainless steel hexagonal head M

37 The two tapped holes shown

should be in the horizontal plane.


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38 Unwind and straighten the wires of the cable. The bending radius should not be smaller than 45°.

39 Slide the numbered labels on to

all the wires according the numbers printed on the Kapton® insulation. Position is at 10 cm from the wire extremity.

A trick to read the number on the Kapton® insulation:

- Find the two lines

- Read the number from the above the line to the line


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The image shows how to slide the labels with wire numbers on all wires.

40 Cut the multistrand Cu former at

the distance of 35 mm from the edge of shrinking sleeve A. Use front cutting pliers (tab. 6.1, No 6).


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41 Put sleeve C, length 15 mm (ZHTM-5/2.5) on the end of multistrand Cu former. Use tweezers, (tab. 6.1, No 7).

42 Heat up thermal shrinking sleeve

C. Sleeve should stick out 5 mm over the end of the multistrand Cu former (for details see annex C). Immediately proceed to the next step of the procedure.

43 Form the end of the sleeve C

using pliers (tab. 6.1, No 15) as is shown at the picture.


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44 Final image after Heat up thermal shrinking sleeve C.

45 Slide the labels with wire

numbers on all wires according to numbers printed on the Kapton insulation. Position is at 10 cm from the wire extremity.

46 Heat up the labels with numbers

of wires.

The sleeves must not be fully shrunk as they will be moved later.


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47 Cut the wires.Use cutting pliers (table 6.1, No.8)

48 Remove the Kapton insulation from all wire ends over a length of 15 mm using the stripping tool (table 6.1, No 12)

49 Make the continuity test and the high voltage test, if necessary (MEL).


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50 Fix the auxiliary support plate (tab. 6.2, No 4) to the connection board (table 6.2, No 3).

Fix the auxiliary support plate and the connection board to the support, (tab. 6.1, No 17). Use screwdriver (tab. 6.1, No 3) and screw M6 x 12.

Mount the connection board to the flange. Use hexagonal socket head screw M6x12 and hexagonal key No 5.

51 Separate the cables from the top

(about 8-10 cables).

Start with the cables from the bottom

52 Find the correct wiring diagram

for the interconnections being done (Fig. 6.10).


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53 Make cabling of the connection board. Put protective sleeves (table 6.2, No12) on all wires and put the wires into the corresponding slots according to the interconnection board layout (for details see [1-9]). Be aware of succession of slots on board. Operator situated in front of the board shall verify that the cable is on his left side. The volume of the bundle shall be limited in space.

54 Install the rear part of the

connection board to keep in place the bundle of wires.


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55 Install the rear part of the connection board to keep in place the bundle of wires.

56 Slide the labels to their position.

57 Slide the labels to their final

position of 30 mm from the end of wires.


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58 Cut the wires at a length of 55 mm for the top row and 70 for the bottom row. Length is measured from position E. Use cutting pliers (table 6.1, No. 8).

59 Remove the Kapton insulation from all wire ends over a length of 15 mm using the stripping tool (table 6.1, No 12).


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60 Slide the labels to their final position of 30 mm from the end of wires.

61 Soldering the wires from A to the

wires from B.

A

B


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4. CONCLUSIONS

Mounting of the plug is a part of whole activity of manufacturing of the Line-N cable segments (for details see [10]). During manufacturing and the qualification tests of the segments ELQA SEG SW software will be used for supervising the process of the production (see [11]).

5. REFERENCES

[1] R. Solaz Cerdan “Slot assignment algorithm for the Electrical Interconnection Boards in the Line-N of the LHC Machine

[2] R. Solaz Cerdan “Line-N sector 1-2 boards”








[10] D. Bozzini, R. Herzog, R. Solaz Cerdan, „Line-N flexible cables from raw material to installation”

[11] L. Furman “SW for LINE-N segments preparation/manufacturing (ELQA seg sw v.1.0)”


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6. ANNEX A: TOOLING, COMPONENTS AND CONSUMABLE MATERIAL

Table 6.1 lists all the tools required for the assembly procedure. In Table 2.2 the components needed for manufacturing of the one plug and consumable materials are summarised.

Table 6.1 Tooling

No Required tooling Description CERN SCEM

1 Hot-air gun Hot-air gun to make heat-shrinking sleeves shrink.

34.95.35.100.0

2 Wire stripper Tool for removing 15 mm of insulation at the extremities of wires.

34.95.62.090.2

3 Screwdriver Flat head screwdriver No 4 34.74.10.040.5

4 Set of hexagonal keys No 3, 4 and 5 34.72.75.302.4

5 Side cutting pliers Used for cutting of the superconducting ø 1,6 mm wires

34.76.45.120.9

6 Front cutting pliers Used for cutting of the auxiliary thinned copper line

34.95.64.160.7

7 Tweezers Length 150 mm 34.76.10.100.8

8 Scissors for cutting the Kevlar fibre

Scissors used for cutting of the stainless steel braid. Catalogue Radiospares code: 400-6080

9 Universal pliers Type Facom No 187-16 CPY 34.76.55.160.6

10 Stanley knife 34.78.54.099.6

11 Ball-and-socket joint vices

Used to hold the cable during various stages.

34.95.92.200.9

12 Holder for keeping the cable in vice

Cubic holder made of plastic with cylindrical hole, diameter 17 mm. Used before dressing of shield grid (see fig.7.6).

13 Tube Tube used for marking the length on the stainless steel braid of the cable (see fig.

14 Rear part of the connection board

Drawing LHCDCA__0002.

15 Flat pliers 34.76.15.160.6

16 Scissors 34.94.22.130.7

17 Polyethylene custom made support

See fig. 7.9.

18 Torque key No 30 Torque range 20-100 Nm.

19 Torque key No 32 Torque range 20-100 Nm.


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Table 6.2 Consumable materials

No Required material Description Quantity CERN SCEM

1 Line-N superconducting 42-wire cable

Fig.7.2. About 54 m. Length depends on type of cable, (location in the LHC).

2 Flange of the conducting plug

Fig. 7.4. 1 piece

3 Connection board Fig.7.1., drawing LHCDCA__0003

1 piece

4 Auxiliary support plate Used for fixing board during wiring (see fig.7.8).

1 piece

5 Hexagon socket head cap screw M4 × 10

Made of stainless steel Cr.Ni.18.12.Mo. Used for fixing the auxiliary plate to the connection board.

1 piece 47.62.71.154.8

6 Self-adhesive crepe paper tape

19 mm wide About 1m 04.95.45.219.8

7 Labels for the wires Used for labelling of wires. Numbers from 1 to 42.

42 pieces

8 Labels for the cable Used for labelling the cable segment on the both extremities

2 pieces

9 Thermal shrink sleeve A 24-8, length 25 mm , with glue inside

1 piece Catalogue Radiospares, No 157-3903

10 Thermal shrink sleeve B ZHTM-34/17-0, 100 mm

1 piece 04.86.62.155.0

11 Thermal shrink sleeve C ZHTM-5/2,5 15mm 1 piece 04.86.62.110.3

12 Brown insulating glass-cloth tubing 600V, D 2 mm

Protective sleeve used during wiring of board

42 pieces 04.86.51.208.3

13 Self-adhesive Kapton tape

Width 19 mm 1 piece 04.94.70.100.3

14 Polyethylene tube See fig.

15 Hexagonal stainless steel screw M6x12

Used for fixing the auxiliary support plate to the flange


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No Required material Description Quantity CERN SCEM

16 Nut No 1 Raccord inox a4 3/4" special

1 piece 41.40.31.499.0

17 Nut No 2 Lot ecrou bagues inox

1 piece 41.40.31.599.7

18 Stainless steel ring No 1 See fig 7.6. 1 piece

19 Kapton® foil 0.125 mm Kapton® foil. Size of the foil: 80 x 105 x 0,125 mm (for the cable made by Outokumpu®), 80 x 160 x 0,125 mm (for cable made by Vacuum Shmelzen®).

1 piece


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Fig.6.1. Connection board


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Fig.6.2. Cross section of the 42-wire superconducting cable (ø 17.0 mm – cable

made by Vacuum Schmelzen, ø 17.3 mm – cable made by Outokumpu)

Fig. 6.3.Polyethylene custom made tube with the cone.


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Fig. 6.4. Flange of the conducting plug.


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Dimensions: ØA = 21,10 mm, ØB = 17,60 mm, ØC = 18,95 mm, A=100,00 mm, B=10,00mm Fig. 6.5. Tube used for marking measured length on the circumference of the stainless steel braid of the cable


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Fig. 6.6. Stainless steel ring No 1.

Quantity: 2 pieces.

Material: plastic

Fig. 6.7. Holder used for keeping the cable in the vice.


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Fig. 6.8. Auxiliary support plate

Fig. 6.9. Support with fixed connection board used during cabling of the board.


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Fig. 6.10. Wiring diagram


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7. ANNEX B: DETAILS OF PREPARATION OF THE HEAD-END OF THE LINE-N CABLE SEGMENT EQUIPPED WITH THE CONDUCTING PLUG

Fig. 7.1. Preparation of the head-end of the Line-N cable segment equipped with theconducting plug.

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