XFEL Tuner system non-conformities Detected At saclay 2015 XFEL Tuner system non-conformities Detected At saclay WG Tuner TTC 2015 @ SLAC / Thierry Trublet – CEA Saclay

XFEL Tuner system non-conformities detected at Saclay– TTC 2015 @ SLAC Introduction In the context of the XFEL project, CEA is in charge of assembling the 100 linac cryomodules 72 cryomodules have been delivered up until now The XM100 will be delivered at the end of April 2016 CEA has contracted with ALSYOM for assembly 600 tuner systems have already been assembled XFEL Tuner system non-conformities detected at Saclay– TTC 2015 @ SLAC

Tuner Incoming inspection and preparation Tuner systems are delivered pre-assembled in plastic bags The incoming inspection is performed when the store keeper prepares the set for the work station. He partially disassembles the set XFEL Tuner system non-conformities detected at Saclay– TTC 2015 @ SLAC

Non-conformities detected during incoming inspection Part repair return discard missing Hinge axle 38   3 Piezo axle 40 1 12 Framework Circlip Ø8 2 Ball bearing Ø24 37 Tuner mechanics Silver coated screws 469 117 Pressure screw Piezo system 8 Frequency tuner drive unit normal 4 XFEL Tuner system non-conformities detected at Saclay– TTC 2015 @ SLAC

Non-Conformities repaired at Saclay Ball bearings seized => Repaired by polishing with abrasive cloth Oxidation on silver coated screws => First we used ultrasonic cleaning => Later we received an exemption to use as is Adjustment issue for bearing assembly => Repaired by polishing with abrasive cloth Circlip groove not deep enough => Returned to DESY XFEL Tuner system non-conformities detected at Saclay– TTC 2015 @ SLAC

Non-conformities Detected during Assembly One piezo axle seized => repaired at Saclay Piezos did not charge correctly (in shipment area) => used as is The result of the motor & piezo test on cavity 1 was not correct. The reset did not work for piezo 2.  Turn1 : 1.398v (piezo1) 0.921v (piezo2)  Turn2 : 3.015v (piezo1) 1.511v (piezo2)  reset : -0.011v (piezo1) -1.364v (piezo2) Piezo charged negatively (x5) => Used as is but cabling on flange reversed During LVDT(linear variable differential transformer) check, piezo 2 in Pos.6 has a negative charge instead of positive. After 1 turn : -0,765 V After 2 turns : -1,540 V XFEL Tuner system non-conformities detected at Saclay– TTC 2015 @ SLAC

Non-conformities in assembly Cable damaged during piezo system installation (replaced) Tuner mechanism parallelism defect (used as is) Motor stop issue (the motor changed direction by itself…) => The assembly procedure was changed. The problem was due to the location of the limit switch Problem at DESY: Polarization was reversed on all the piezo 2’s of XM67. => No explanation was found (between DESY/CEA/INFN) All the checks done at Saclay during assembly were OK XFEL Tuner system non-conformities detected at Saclay– TTC 2015 @ SLAC

Production des cryomodules XFEL - Journées AFF-CSS @ Aussois 2015 Commissariat à l’énergie atomique et aux énergies alternatives Centre de Saclay | 91191 Gif-sur-Yvette Cedex T. +33 (0)1 69 08 xx xx | F. +33 (0)1 69 08 99 89 Etablissement public à caractère industriel et commercial | RCS Paris B 775 685 019 DSM Irfu DIR Production des cryomodules XFEL - Journées AFF-CSS @ Aussois 2015