1. Service channels between Tracker and PP1
Installation order
Lessons from Cabling Mock-up
Component status
Work done by Auli, Erkki, Giulio, Hans, Jarmo, Michel, Pascal, Pauli, Sébastien, Temuri, …
TK Engineering Meeting 19 June 2007, Antti Onnela, CERN

2. Installation steps 1: Cable channels + 2: Water cooling
Tracker
STEP 1:
Install cable channel, made of 5 sections (sections 1 and 2 are one unit)
All attached to HCAL with screws
Section 1
Section 2
Section 3
STEP 2:
Install 10 mm water cooling pipe, one loop around channels “A” and “C” with its copper cooling plates (not shown here)
Copper plates attached to channel pieces with screws
Section 4
Section 5
Braze connections in PP1 and leak test water circuit
PP1

3. Installation step 3: Temperature and humidity sensors
Per PP1 sector the sensors are only in one ½ channel
In top and bottom sectors the sensors are in the special ½ channels
“Min-max against ECAL”:
1 sensor at far corner away from water cooling
1 sensor next to water cooling
Route sensor wires along 10 mm cooling pipe up to connector in PP1

4. Installation step 3: Temperature and humidity sensors
Wires from ECAL area run along the 10 mm water pipes up to the connector (Note: Per channel only “A” or “C” side, never both)
“Hot at cable entry”:
Tight packing of cables entering PP1
“Cold against ribbons”:
On the inside wall below multi-ribbon cables
Total amount of sensors per channel: 2 temp sensors at ECAL + 2 in PP1 1 humidity sensor in PP1
D-SUB connector (with humidity sensor) and pre-installed cable to racks

5. Installation step 4: Pipes
Install male Lancasher fitting + first bend piece
Measure the correct length of the copper pipe end
Remove Lancasher fitting, cut the pipe and solder them together
Install the pipe definitively
Installation step 4: Pipes
Attach the pipe to the temporary mid-support (subsequent pipes attached to previous ones)
Cut the pipe to correct length
Solder the pipe with ceramic fitting
Clamp the pipe with support block (every 2 pipes)
Leak test with Argon (every 2 pipes)

6. Installation step 5: Pipe insulation, from TK to mid-support
2 layers of 9 mm Armaflex AF insulation, with joining tape
In channels 1 and 2 must reduce insulation to allow space of cables. Where possible use 3 mm tape in addition
Insulation of individual pipes at TK end is still to be studied:
3 mm tape?
Tubular insulation?

7. Installation step 5: Pipe insulation at mid-support
Mid-path support with this element.
During pipe installation use temporary support
This support shall be slightly closer to optoribbons, to provide space for cables next to water pipe.
This support shall also be a bit further away from the pipe bend, to ease insulation joint.

8. Installation step 5: Pipe insulation from mid-support to PP1
From mid-supports to PP1 use 18 mm insulation or 2 layers of 9 mm.

9. Installation step 5: Pipe insulation in PP1
Inside PP1 use precut flat pieces, glued together
Glued junction from tubular to rectangular section at PP1 entry
Insulation of Y-section being done alreardy now!

10. Installation step 6: Heating cable in PP1
30 W/m heating cable,
length ~7 m / standard PP1,
Routed on outer surfaces of the pipe channel
connection

11. Installation step 6: Heating cable in PP1
Aluminium or plastic clamps and aluminium tape on top of the cable
Heating cable follows the Y-piece (not present in this photo)

12. Installation step 7: Barrel MS & Ctrl cables
Channel sections 1-4
Here we have installed 7 cooling pipes 40 multi-service cables
This represents the biggest channel occupancy, which is 7 cooling pipes 38 multi-service cables 6 ctrl-cables (≈ 2 MS-cables)
Channel section 5

13. Installation step 7: Barrel MS & Ctrl cables
The covers fit, tightly
Edges of covers 2 and 5 need to be slightly bent, to avoid scratching cables

14. Installation step 8: Optoribbons (after removal of nose cone)
In section 1 and 2 optoribbons are 8 or 10 side by side, from section 3 to PP1 6 ribbons side by side.
Ribbon pre-bundling work to be done in TIF

15. Installation step 8: Optoribbons
Channels for these ribbons to reach the PP1 are at these phi-locations
1 cm
All pipes, including TEC pipes, must be in place and insulated before installing optoribbons
Installation step 9: TEC cables
Last 1 cm of TK volume for TEC cables

16. Summary of installation order per PP1
Installed component + checks
Status and remaining preparations (non-exhaustive list) 1
Cable channels
Channel pieces at CERN. Need to add HCAL supports for channel 1-2, fibre supports in channels 2 & 3, pipe supports in channel 3 and pem nuts for holding copper pieces. 2
Water cooling circuit leak test
Need to produce copper plates, and procure 10 mm pipe material. Need to design and produce assembly jig, and then assemble 32 circuits. 3
Temp + humidity sensors checks?
Sensors and cable material being procured. Need to make sensor protections and cable the sensors. 4
Cooling pipes leak test
3D-design ready, except last ¼ of TEC- and specials. 2D-drawing production started. Order being placed to pipe bending company. Pieces for ceramic PP1 fittings received, vacuum-brazing to be done. 5
Pipe insulation
Armaflex AF approved in June by CERN safety. First sets of material already available and being installed in Y-pieces, the rest material being ordered. 6
PP1 heating cable functional check
Cable roll received at CERN.
Cutting to be done. Clamps to be ordered. 7
Barrel MS & Ctrl –cables functional checks
Barrel cables to be labeled with PP1 connector names and bundled by ½-channels on nose cones. 8*
Optoribbons functional checks
To be reorganized after TK cold test. Reference point (channel 1-2 junction) to be marked on TEC ribbons. Optoribbon supports to be made+installed. 9
TEC MS & Ctrl –cables
+ functional checks
Cables in production.
* After removal of the nose cone the optoribbon installation can be done in parallel with tasks 4-7.