SST electrical cable qualification

1
SST electrical cable qualification

• Simone Paoletti
• CERN, 11 July 2006

2
Routing of the Power in the SST

• PSUs will be placed on balconies in the
  experimental cavern (UXC), 10m (direct) distance
  from the beams crossing point. From there
• 35m of cables will be needed to reach the patch
  panel 1 (PP1)
• A Cu cable is to be used in this region, in order
  to have better performances
• 6m of cables will be needed to reach the tracker
  internal structures from PP1.
• An Al cable is to be used in this region, in
  order to keep low the material budget.

Power cables will be used also to route signals
from T and H probes inside the tracker
Cu Cable - COST and PERFORMANCE -
Al Cable - MATERIAL BUDGET -
3
short (? 6m) cables
4
long (? 30 m) cables
5
Quality Control

• All cables are checked upon reception before
  being used for the experiment
• LIC, PLCC, TIB/TID short cables ? automatic test
  setup checking connections, isolation and
  capacitance
• TEC/TOB short cables ? Lyon box checking
  connections and isolation.
• Each cable is checked at production by the
  connectorising firm
• QC checks for PLCC and LIC after connectorisation
  were agreed with us.
• For the LIC cables additional QC tests are
  performed by the cable producing firm, before
  connectorisation, as specified in the tender.
• Standard qualification tests on all produced
  spools
• Sampling destructive tests

6
The LIC cable
7
The LIC cable

• Two versions
• v1 for TIB/TID
• v3 for TEC/TOB
• the connectorisation of he two versions is
  compatible (TEC/TOB may use LIC_v1 and
  vice-versa)

• All relevant documentation (design, tests,
  safety) is on EDMS https//edms.cern.ch/
• First steps of PRR passed
• the LIC cable was approved for safety
• we are allowed to buy the cables
• still missing cable lengths definition inside CMS
  cabling database

LIC V1
LIC V3
8
(No Transcript)
9
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10
LIC QC before connectorisation

• The LIC is produced by Elettronica Conduttori
  (Volpiano, TO)
• Each production lot is certified by the firm
  according to contract and to CERN-required
  specifications
• IEC 60317-0-1, IEC 60317/51, CEI 20-11, CEI
  20-35, IEC 60332-1, 73/23/CEE, 93/68/CEE,
  2002/95/CEE, TECH SPEC. LIC V1, LIC V3
• The manufacturer performs the following isolation
  tests, on each spool, before cutting to
  individual lengths
• 3000 Vcc (between twisted pairs)
• 2000 Vcc (twisted versus shield braid)
• 3000 Vcc (twisted versus enamelled)
• 250 Vcc (enamelled vs enamelled)
• 250 Vcc (enamelled vs shield braid)
• The certified working voltages are
• 30 V for the enamelled wires (LV lines)
• 600 V for the twisted pairs (HV, LV senses and
  T,H probes)

11
Production lot certificate
12
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13
Electrical test results
14
LIC QC destructive tests

• Additional destructive tests are performed on
  each production lot, on a sample basis, in order
  to spot possible mechanical problems
• These tests are not addressing any weakness
  specific of the LIC cable, but were required as a
  safety measure, since the LIC cable design is new
  (use of enamel wire).
• Traction
• 820 N / 60 s
• U bends
• 200 cycles (Rbend 75 mm) 5 cycles (Rbend 20
  mm)
• Crushing
• 150 kg on 80 mm length
• The electrical properties of the cable samples
  are measured after the destructive tests and have
  to be good within large safety margins

15
Traction test
16
Crush test
17
Bending test
18
Bending radius

• The LIC is certified for Rbend 8cm
• Rule of thumb (average manufacturer) Rbend
  10 x ø
• The QC procedure was agreed with the manufacturer
  in order to allow us to lower Rbend in a few
  difficult installation points
• Once bent below 8 cm, any further movement of the
  cable is strongly discouraged
• We have to keep Rbend as large as we can during
  the installation
• It is a single-pose cable
• the characteristics and costs of movement cables
  are different (cost higher by factor 3)
• we can re-use this cable a limited number of
  times, provided it is adequately handled and
  never bent below 8 cm
• some bad handlings which can damage the cable
  (from my personal experience)
• drop from height while fastened at the bottom
• wrong re-winding into drum

19
Outer jacket

• The jacket material is ECCOH 3140 LS0H polyolefin
  compound
• satisfies CERN IS23 safety rules (fire and
  radiation resistance)
• similar compound (Megolon S-304) used in previous
  LIC preproduction
• polyolefin compounds used by several
  sub-detectors
• The jacket is 1mm thick
• adequate to the cable dimensions
• constraints
• occupancy on cable trays
• bending radius
• power consumption

20
Connectorisation

• Connectorisation technique for enamel wires
  developed
• bath in tin/lead at 390C
• initial technical problems due to the constrained
  dimensions in PP1 solved
• molding technique developed using polyurethane
  (Rampfs RAKO-PUR)

insertion key
21
Connectorisation schemes
22
Tests performed after connectorisation

• Continuity and isolation tests performed at the
  firm using a programmable tester machine
• SCHAFFNER ELECTROTEST TEST SYSTEM W427
• More refined tests (using the same instrument)
  performed at CERN upon cable reception
• four point R measurement allows to monitor the
  quality of connections
• capacitance measurements ensure the correct
  twisted pair assignments

23
Test performed by firm
24
Test performed at CERN
SCHAFFNER ELECTROTEST TEST SYSTEM
W427 ------------------------------------------ P
rogramma di test LIC versione 3 (35 metri) Nome
del file LIC_V3-35mt Data/ora
06/06/2006 15.00.55 Seriale 213 Test
APERTI Parameter R8.500 Ohm I200.0mA
Tmin2.000ms Tmax2.000ms Test CORTI
Parameter R100.0kOhm U20.00V Tmin5.000ms
Tmax5.000ms Test HV-DC Parameter R1.500GOhm
U1000V Tempo salita1000V/Ms Tmin500.0ms
Tmax200.0ms
Test CORTI ---------- R100.0kOhm U20.00V
Tmin5.000ms Tmax5.000ms NCL
S gt100.00MOhm NCL
R
32.00MOhm NCL
B 6.106MOhm NCL
P 61.54MOhm
NCL X
gt100.00MOhm NCL
Y gt100.00MOhm NCL
V
gt100.00MOhm NCL
W 100.00MOhm NCL
T gt100.00MOhm
NCL U
gt100.00MOhm NCL
N gt100.00MOhm NCL
O
gt100.00MOhm NCL
L gt100.00MOhm NCL
M gt100.00MOhm
NCL J
gt100.00MOhm NCL
K gt100.00MOhm NCL
H
gt100.00MOhm NCL
I 100.00MOhm NCL
F gt100.00MOhm
NCL G
gt100.00MOhm NCL
D gt100.00MOhm NCL
E
gt100.00MOhm NCL
A gt100.00MOhm NCL
C 100.00MOhm
NCL FM36-CASE
gt100.00MOhm NCL
FM36-31 11.59MOhm NCL
FM36-30
100.00MOhm NCL
FM36-27 gt100.00MOhm NCL
FM36-12 gt100.00MOhm
NCL FM36-9
100.00MOhm NCL
FM36-10 gt100.00MOhm NCL
FM36-8
gt100.00MOhm NCL
FM36-4 100.00MOhm
tests against shorts (20V)
25
Test APERTI Parameter R8.500 Ohm I200.0mA
Tmin2.000ms Tmax2.000ms Conn. J
FM36-2 4.770 Ohm 7
T2- Conn. K FM36-1
4.775 Ohm 8 T2 Conn. U
FM36-3 4.770 Ohm 9
T3 Conn. C FM36-6
4.750 Ohm 10 Vbias4 Conn. O
FM36-5 4.745 Ohm 11
Vbias1 Conn. H FM36-7
4.845 Ohm 12 Vbias7 Conn. G
FM36-11 4.712 Ohm 13
Vbrtn1 Conn. A FM36-14
4.772 Ohm 14 Vbias5 Conn. I
FM36-13 4.850 Ohm 15
Vbias2 Conn. N FM36-15
4.825 Ohm 16 Vbias8 Conn. Y
FM36-20 4.715 Ohm 17
Sense250- Conn. X FM36-19
4.760 Ohm 18 Sense250 Conn.
V FM36-22 4.735 Ohm
19 Sense125- Conn. W
FM36-21 4.717 Ohm 20
Sense125 Conn. L FM36-24
4.932 Ohm 21 T1- Conn. M
FM36-23 4.695 Ohm 22
T1 Conn. F FM36-26
4.727 Ohm 23 Vbrtn2 Conn. T
FM36-25 4.762 Ohm 24
T3- Conn. E FM36-28
4.797 Ohm 25 Vbias3 Conn. D
FM36-29 5.313 Ohm 26
Vbias6 Test APERTI Parameter R600.0mOhm
I200.0mA Tmin2.000ms Tmax2.000ms Conn.
FM36-CASE FM36-case 385.5mOhm
29 Case Conn. FM36-16
FM36-17 389.1mOhm 30 Drain2 Conn.
FM36-16 FM36-18
422.9mOhm 30 Drain2 Conn. FM36-16
FM36-31 557.0mOhm 30
Drain2 Conn. FM36-16 FM36-32
582.4mOhm 30 Drain2 Test APERTI
Parameter R60.00mOhm I200.0mA Tmin2.000ms
Tmax2.000ms Conn. B
FM36-A1 47.91mOhm 35 GND Test
APERTI Parameter R80.00mOhm I200.0mA
Tmin2.000ms Tmax2.000ms Conn. S
FM36-A2 64.94mOhm 37
V250 Test APERTI Parameter R170.0mOhm
I200.0mA Tmin2.000ms Tmax2.000ms Conn.
R FM36-A3 161.9mOhm
39 V125 Test APERTI Parameter R300.0mOhm
I200.0mA Tmin2.000ms Tmax2.000ms Conn.
P FM36-A4 231.9mOhm
41 Drain1
continuity tests (tw pairs)
drains
LVs
26
isolation tests (1000V) one vs all others
DC-NCA J
17.91GOhm 47 T2- DC-NCA
K 14.58GOhm 48 T2 DC-NCA
U
99.34GOhm 49 T3 DC-NCA
C 17.21GOhm 50
Vbias4 DC-NCA O
14.28GOhm 51 Vbias1 DC-NCA
H 129.6GOhm 52
Vbias7 DC-NCA G
159.9GOhm 53 Vbrtn1 DC-NCA
A 24.26GOhm 54
Vbias5 DC-NCA I
20.46GOhm 55 Vbias2 DC-NCA
N 7.883GOhm 56
Vbias8 DC-NCA Y
16.13GOhm 57 Sense250- DC-NCA
X 12.66GOhm 58
Sense250 DC-NCA V
15.16GOhm 59 Sense125- DC-NCA
W 12.02GOhm
60 Sense125 DC-NCA L
11.72GOhm 61 T1- DC-NCA
M 9.986GOhm
62 T1 DC-NCA F
22.39GOhm 63 Vbrtn2 DC-NCA
T 18.43GOhm 64
T3- DC-NCA E
155.6GOhm 65 Vbias3 DC-NCA
D 130.0GOhm 66
Vbias6 Test HV-DC Parameter R10.00MOhm
U200.0V Tempo salita500V/s Tmin1.000 s
Tmax200.0ms DC-NCA B
419.7MOhm 69 GND DC-NCA
S 511.4MOhm 70
V250 DC-NCA R
1.430GOhm 71 V125 Test HV-DC
Parameter R1.500GOhm U1000V Tempo
salita1000V/Ms Tmin500.0ms Tmax200.0ms DC-NCA
FM36-4
20.38GOhm 74 Empty DC-NCA
FM36-8 22.76GOhm 75
Empty DC-NCA FM36-9
21.65GOhm 76 Empty DC-NCA
FM36-10 22.09GOhm 77
Empty DC-NCA FM36-12
22.74GOhm 78 Empty DC-NCA
FM36-27 22.18GOhm 79
Empty DC-NCA FM36-30
22.18GOhm 80 Empty

• C-Twist T01/T-01 FM36-23 FM36-24
  3.029nF 84
• C-Twist T02/T-02 FM36-1 FM36-2
  2.890nF 85
• C-Twist T03/T-03 FM36-3 FM36-25
  3.327nF 86
• C-Twist Vbias1/Vbias4 FM36-5 FM36-6
  3.256nF 87
• C-Twist Vbias2/Vbias3 FM36-13 FM36-28
  3.417nF 88
• C-Twist Vbias5/Vbias6 FM36-14 FM36-29
  3.313nF 89
• C-Twist Vbias7/Vbias8 FM36-7 FM36-15
  3.393nF 90
• C-Twist Vbrtn1/Vbrtn2 FM36-11 FM36-26
  3.190nF 91
• C-Twist S250/S250- FM36-19 FM36-20
  3.593nF 93
• C-Twist S125/S125- FM36-21 FM36-22
  3.464nF 94
• C-Twist Drain1/GND FM36-A4 FM36-A1
  60.03nF 96
• C-Twist Drain2/GND FM36-31 FM36-A1
  28.08nF 97
• Risultato del Test
• -------------------------------------
• Test APERTI B U O N O
• Test CORTI B U O N O

27
First LIC_V1 sample
28
first 35m LIC prod. deliveries
Summer !
29
Experience with LIC cables

• LIC cable prototypes have been used to power our
  detectors with our PS system since more than
  three years
• Around 270 LIC cables are in use
• 2003/2004 prototypes
• 2005 pre-production
• 2006 first deliveries
• Their performance is good
• several of them installed a lot of times and
  survived bad handlings
• test beams
• Louvain irradiation tests
• PSU test setup
• Few problems reported so far
• regarding damage of outer jacket (de-coloring,
  perforation or peeling)
• Proper handling procedure, according to the cable
  specs, has to be adopted and trained manpower has
  to handle the cables
• never bend below nominal bending radius
• never pull over sharp edges
• use some specific (slippery) product to
  de-install the cable
• If not, we dont have cables for TIF ! (or for
  CMS !)

30
Experience with connectors

• One weakness of the FM36W4 (pp1) connectorisation
  spotted after first prototypes
• occasional contact of LVs, now solved
• Pins may occasionally get pushed inside the
  bajonet connector
• its not a damage they can be simply
  repositioned with tweezers
• Occasional difficulty in plugging the cable into
  the PSU back-boards
• limited experience with this kind of problems
  too few and incomplete problem reports
• from personal experience its better to follow
  the natural torsion of the cable. Do not try to
  exercise too much force in de-torsion
• the thicker 40A pins may get distorted
• not a damage the pins get back into position
  when the torsion force is released
• General rule of thumb
• do not exaggerate with the force applied in
  connecting the cables
• never try to force the connectors guide

insertion key
31
Power long control cables
32
The PLCCs

• 20 PLCC_TIB/TID 20 PLCC_TOB prototypes produced
  in 2005
• currently used in integration setups and MTCC
• production with final connectors just started
• PLCC_TIB/TID the first one to be produced
• Electrical tests (same kind as for LIC) performed
  both by connectorising firm and at CERN, upon
  reception

33
2020 PLCC test production
PLCC_TIB/TID
PLCC_TIB/TID
(151 Rconn. expected)
(92 Rconn. expected)
34
Short cables
35
TIB/TID cables

• Electrically tested (opens and shorts) at the
  connectorising firm (ADAPT)
• Tested upon reception at CERN with the usual
  cable testing machine.

36
typical CAB60 test
SCHAFFNER ELECTROTEST TEST SYSTEM
W427 ------------------------------------------ Pr
ogramma di test CAB 60 Nome del file
CAB_60 Data/ora 10/05/2006
14.26.14 Seriale 249-560 Test APERTI
Parameter R1.500 Ohm I200.0mA Tmin2.000ms
Tmax2.000ms Test CORTI Parameter R100.0kOhm
U20.00V Tmin5.000ms Tmax5.000ms Test HV-DC
Parameter R1.500GOhm U1000V Tempo
salita1000V/Ms Tmin500.0ms Tmax20.00ms Test
CORTI ---------- R100.0kOhm U20.00V
Tmin5.000ms Tmax5.000ms NCL
FM36-CASE gt100.00MOhm NCL
FM36-01
gt100.00MOhm NCL
FM36-02 gt100.00MOhm NCL
FM36-A2 gt100.00MOhm
NCL FM36-A3
gt100.00MOhm Conn. FM36-19
FM13-05 1.095 Ohm 7
Sense250 Conn. FM36-20 FM13-04
1.205 Ohm 8 Sense250- Conn.
FM36-21 FM13-10 1.007 Ohm
9 Sense125 Conn. FM36-22
FM13-09 1.028 Ohm 10
Sense125- Conn. FM36-05 FM13-01
1.083 Ohm 11 Vbias1 Conn.
FM36-28 FM13-02 1.092 Ohm
12 Vbias2 Conn. FM36-07
FM13-07 1.066 Ohm 13 Vbias3 Conn.
FM36-29 FM13-06 1.092
Ohm 14 Vbias4 Conn. FM36-11
FM13-08 1.044 Ohm 15 VbRTN1 Conn.
FM36-26 FM13-03 1.074
Ohm 16 VbRTN2
continuity tests (cut at R 1.5 W)
isolation tests (1000 V)
37
Test APERTI Parameter R800.0mOhm I200.0mA
Tmin2.000ms Tmax2.000ms Conn.
FM36-CASE FM36-case 368.9mOhm
19 CASE-FM36 Conn. FM36-16
FM36-17 385.9mOhm 20 Drain2 Conn.
FM36-16 FM36-18
386.9mOhm 20 Drain2 Conn. FM36-16
FM36-31 636.5mOhm 20
Drain2 Conn. FM36-16 FM36-32
642.0mOhm 20 Drain2 Conn.
FM36-16 FM13-CASE 570.1mOhm
20 Drain2 Conn. FM36-16
FM13-case 566.8mOhm 20 Drain2 Test
APERTI Parameter R100.0mOhm I200.0mA
Tmin2.000ms Tmax2.000ms Conn. FM36-A4
FM13-CASE 74.84mOhm 24
Drain1 Conn. FM36-A3 FM13-A3
84.08mOhm 25 V125 Test APERTI
Parameter R60.00mOhm I200.0mA Tmin2.000ms
Tmax2.000ms Conn. FM36-A2
FM13-A2 51.13mOhm 27 V250 Test
APERTI Parameter R40.00mOhm I200.0mA
Tmin2.000ms Tmax2.000ms Conn. FM36-A1
FM13-A1 32.78mOhm 29
GND DC-NCA FM36-19
103.2GOhm 33 Sense250
80 mW expected
53 mW expected
33 mW expected
38

• DC-NCA FM36-20
  23.26GOhm 34 Sense250-
• DC-NCA FM36-21
  25.16GOhm 35 Sense125
• DC-NCA FM36-22
  93.02GOhm 36 Sense125-
• DC-NCA FM36-05
  85.11GOhm 37 Vbias1
• DC-NCA FM36-28
  gt4000GOhm 38 Vbias2
• DC-NCA FM36-07
  21.51GOhm 39 Vbias3
• DC-NCA FM36-29
  26.89GOhm 40 Vbias4
• DC-NCA FM36-11
  85.11GOhm 41 VbRTN1
• DC-NCA FM36-26
  85.11GOhm 42 VbRTN2
• DC-NCA FM36-01
  13.26GOhm 43 Empty
• DC-NCA FM36-02
  186.0GOhm 44 Empty
• DC-NCA FM36-03
  85.11GOhm 45 Empty
• DC-NCA FM36-04
  85.11GOhm 46 Empty
• DC-NCA FM36-06
  164.9GOhm 47 Empty
• DC-NCA FM36-08
  10.06GOhm 48 Empty
• DC-NCA FM36-09
  9.662GOhm 49 Empty
• DC-NCA FM36-10
  82.05GOhm 50 Empty
• DC-NCA FM36-12
  85.11GOhm 51 Empty
• DC-NCA FM36-13
  85.11GOhm 52 Empty

isolation tests
39
TEC/TOB cables

• CAB60, CAB48, CAB36 and ctrl-pwr-s1

• The cable material is qualified at Habia visual
  inspection, mechanical and geometrical checks,
  resistance measurements
• The cables are tested at ADAPT
• mechanical and geometrical checks
• pin-to-pin continuity test and short check
• hv test at 1KV (absorbed current and insulation
  among HV wires)
• visual inspection and electrical tests (Lyon test
  box) at CERN
• pin-to-pin continuity test and short check
• hv test at 600V (absorbed current and insulation
  among HV wires)

(information from G. Magazzu)
40
Data base

• Each cable used in CMS has to appear in the
  cabling database
• start point
• end point
• ID
• Each cable is labeled by firm after
  connectorisation
• type, date, length, serial number
• We intend to store general cable information
  (production date, length, some of test results)
  in our construction database
• part of the structure already defined
• Cannot glue multiple labels on the same cable
• the IDs assigned by the cabling database have to
  match those of the construction database, and
  possibly resemble the serial number assigned by
  the firm.
• Two-D labels will be used for short cables
• We have to think carefully to which labels, and
  where, should be stuck on long (LIC and PLCC)
  cables.

41
Further installation issues

• Do we check cables once they are installed in P5
  ?
• topic still under discussion
• short cables no way, I guess
• long cables
• electrical tests with cable tester from the
  balcony (short pairs of cables at PP1)
• test complete LV and HV chain after the cable is
  plugged into the PSU, using a test box in PP1
• we may benefit from the monitoring provided by
  the PP1 interconnect board
• is the installation scenario allowing to use
  powered racks ?
• Can we repair cables after installation ?
• PP1 forget it
• balcony it might be possible (depends on kind of
  damage)
• Cable spares
• we can foresee producing some spares
• we are heavily limited by space on cable trays
• have still to define the final cable distribution
• hope to place one or two spares per PP1
• at least PLCC spare