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

2. 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 SLAC

3. 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 SLAC

4. 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 SLAC

5. 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 SLAC

6. 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 : v (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 SLAC

7. 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 SLAC

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