31 January 2006A.Ciocio - SCTSG1 Type IV cables and PP3 Installation Type IV installation Connector in situ work Status of PP3 Testing

31 January 2006A.Ciocio - SCTSG2 Status of Type IV Installation Type IV cables are delivered in double lengths with connectors installed at the PP3 end and pulled between the UX15 cavern and the US/USA halls US side completed (October) 2044 cables + spares USA side installation started (end of October) Problematic Delivery for 2 months until production officially stopped just before xmas –Only 692 cables received in the 2 month period –Technical problem with wires insulation – Production stopped since the company could not continue with the level of 30% failure and rework

31 January 2006A.Ciocio - SCTSG3 Type IV connector When the stranded 14 AWG conductors receive their plastic coating, some strands are poorly aligned, and the conductor jacket has thin places. The jacket can split when the conductor is bent in a small radius. Options: Replace 100 Km cable Novacavi can’t figure out how to improve their production Delay Use a bigger hood – less bending Modify PP3 Delay Use shrink tube over or to replace the insulation

31 January 2006A.Ciocio - SCTSG4 Type IV Connector (cont’d) Preferred solution: strip the insulation from the four power cables completely, and replace it with heat shrink

31 January 2006A.Ciocio - SCTSG5 Type IV (cont’d) –Previous pictures show a good sample but the insulation of the HV cable and the fat power cables were squashed inside the strain relief clamp –Still working with KontaktSysteme to get a better sample before giving the green light to resume production. Hopefully next week Installation of type IV is still on hold or it might be interrupted by type ii/iii Still undefined schedule

31 January 2006A.Ciocio - SCTSG6 Connectors in situ All double harnesses installed in US15 racks are cut to 1 meter extra on the PS end and connectors are installed in situ by an external company CPE(Italy) was selected to do the job Technical appendix in EDMS and Workpackage produced –Several meetings including a one full day at CERN with CPE senior engineers to improve their methods and define all the issues (cutting to length, tooling, plan, QC) –A team of 10 came in December. –The work started 2 weeks before XMAS mostly to understand how to cut to length, make more samples, plan the big job. –6 came back on January 9 –First rack fully assembled on January 20 –Test of plug in PS backplane – all cables are cut to 2 cm contingency –Electrical test – a few connectors needed rework – OK now –3 racks are worked on in parallel –Add shrink tube on power wires (because of unlikely but possible insulation problem also on this side) –Goal: 2 racks/week completed (realistically 1.5)

31 January 2006A.Ciocio - SCTSG7 Status of PP3 PP3 units are coming but need more –First 100 units were received in October –~1000 by December –1401 units currently at CERN Testing –Shaun Roe carries on the testing and burn-in. –60 units can be tested at the time (2 PP3 crates) with the current number of test cables available – 40 more cables are under construction –24 hours with monitoring continuity on all lines, while varying the dummy load so that the Vcc and Vdd currents go to zero and the full power supply voltage is seen on the PP3. –Voltage limiter test by applying 6V to each PP3 in turn (manually) –Didier Ferrere has also tested one PP3 with a module, again simulating the situation where the module loses the clock and draws no current, while observing Vdd and Vcc with an oscilloscope. He reports no voltage spike observed. –Currently the entire chain (modules/final cables/PP3/PS) in SR1 –Shift for testing and assembly Installation –Cables are plugged in a few dummy Patch Panels during installation to be placed in the right (final) position and are tightened to horizontal bars –Cables will have to be all removed from the current position and plugged in by groups/rows when the installation of the real PP3 will occur –Ashley French and Scott Moncrieff (Melbourne) worked on assembly and installation in November/December –Estimated installation of 90 units per day (limited today by testing capability and problems) –10 PP3 subracks have been installed so far –30 subracks assembled –Problems The plastic support feet of the PCB inside the metal casing of the PP3 had been broken in some cases and the PCB was therefore moving at one end – replaced and under investigation Ground contact between magnetic shields and/or strap holder due to the screw heads protruding above the surface Solution by applying kapton strips to cover screw-heads Current Plan –Rework of remaining subracks (10) that don’t have kapton tape on screws –Produce 200 PP3s for first rack where connector hood is bigger needs more tolerance (shorter standoffs) –Installation of PP3s in racks to which type III cables arrive with highest priority –Edward (Cracow) and Vladimir (Protvino) for the next 2 weeks – need people to continue at full speed after that (Melbourne, Freiburg …)

31 January 2006A.Ciocio - SCTSG8 Testing Tester designed and provided by Ljubljana (Gregor, Erik) –3 Test boxes + 1 coming, 2 Laptops test cables Test steps (for Type IV): –Cables are tested at reception (acceptance test) –After being routed from UX15 to US(A)15 (uncut-double length) –After connectors are installed Test steps (for Type II/III) –Cables are tested at reception (only samples of delivered batches) –After installation row by row in the cable tray –Prague has produced feedthrough board for testing with PS crates Shift planner (developed by D. Robinson) works very well for planning the activities and have people to sign up –(and contact me because of unexpected changing in rate delivery/testing problems) What is needed to be able to take a shift: 1)take the safety training course (level video in B55) Level 4 for working in US15 + Oxybox (we have them) If you have an AIS LOGIN (used for EDH documents), you can follow the course from anywhere (even outside CERN) with AIS login by accessing If you have no AIS LOGIN, you need to register at the following address 2)make the access request on EDH 3)get your safety boots & helmet (or borrow them)

31 January 2006A.Ciocio - SCTSG9 Database Discussion with ID people about the equipment ID for MTF Can probably take items id’s from SCT (and Pixel) production database Still defining PS and ROD items

31 January 2006A.Ciocio - SCTSG10 LINKS Summary SCT Cables Web page – Mapping – Shifts – Safety courses –Level –Level 4: with AIS login Overall Safety and Health Procedure Document – Rack Wizard – ID installation Tuesday mornings, CRM (control room management) meetings Wednesday mornings ID/TC installation meeting December 05 TMB –