CERN LHC Project Document No. CH-1211 Geneva 23 LHC-DFB-ES-0005 rev 1.1 Switzerland CERN Div./Group or Supplier/Contractor Document No. AT-ACR-IC
the EDMS Document No. Large 445927 Hadron Collider project Date: 2004-02-13
Functional Specification
ELECTRICAL CONNECTIONS IN THE CRYOGENIC ELECTRICAL FEEDBOXES (DFB)
Abstract
This document defines the functionalities of the electrical connections in the cryogenic electrical feedboxes (DFB). A naming convention is defined for these interconnections. It also presents the quantity and various types of connections. Some adaptations from the standard connections have been made to fit to the busbar bundles and the specific working conditions.
Prepared by : Checked by : Approved by : Redwane MARIE Thierry GOIFFON Rob VAN WEELDEREN AT-ACR-IC Antonio PERIN [email protected] Philippe TRILHE Laurent Jean TAVIAN LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 2 of 34
History of Changes
Rev. No. Date Pages Description of Changes
0.1 2004-01-08 8 First Draft
0.2 2004-02-03 24 Second Draft
1.0 2004-06-17 35 Release of first version
1.1 2004-06-24 35 Modification of DFBM available dimensions LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 3 of 34
Table of Contents 1. REFERENCE DOCUMENTS...... 6 2. GENERALITIES ABOUT THE DFB ELECTRICAL CONNECTIONS...... 7 2.1 DEFINITIONS...... 7 2.1.1 DFB...... 7 2.1.2 INTERCONNECTION (IC)...... 7 2.1.3 SCOPE...... 7 2.2 SPECIFICITIES OF THE DFB CONNECTIONS...... 7 2.3 IMPORTANT DIMENSIONS...... 8 2.4 NAMING CONVENTION FOR THE DFB INTERCONNECTIONS...... 9 2.4.1 DFB CODE...... 10 2.4.2 INTERCONNECTION CODE...... 11 2.4.2.1 IC code for the Current Lead IC (clic)...... 11 2.4.2.2 IC code for the HCM/LCM IC...... 11 2.4.2.3 IC code for the HCM extra IC...... 11 2.4.2.4 IC code for the DFSM IC...... 12 2.4.2.5 IC code for the DFBM/magnet IC...... 12 2.4.2.6 IC code for the DFBL IC (except DFBLC IC)...... 13 2.4.2.7 IC code for the DSL IC (except DSLC)...... 13 2.4.2.8 IC code for the DFBLC/DSLC connection...... 13 2.4.2.9 IC code for the DSLC IC...... 14 2.4.2.10 IC code for the DSLC/DFBAF IC...... 14 2.4.3 SUMMARY OF IC CODES...... 15 2.4.4 CABLE REFERENCE...... 15 3. INTERCONNECTIONS BETWEEN THE CURRENT LEADS AND THE DFB BUSBARS (CLIC)...... 16 3.1 GENERALITIES...... 16 3.2 SPECIFICITIES OF THE CONNECTION...... 16 3.2.1 13 KA DIPOLAR AND QUADRUPOLAR BUSBARS (IC #11)...... 16 3.2.2 6 KA CABLES (IC #12)...... 16 3.2.3 600 A AND 120 A CABLES (IC #13, 14 & 15)...... 17 4. DFBA ELECTRICAL CONNECTIONS...... 18 4.1 CONNECTIONS BETWEEN THE DFBA LEAD MODULES (HCM/LCM)...... 18 4.1.1 GENERALITIES...... 18 4.1.2 SPECIFICITIES OF THE CONNECTION (IC #23, 24 & 25)...... 18 4.2 13KA EXTRA CONNECTION IN THE DFBAK HCM (IC #31)...... 19 4.3 600 A EXTRA CONNECTION IN DFBAF (IC #33)...... 19 4.4 ELECTRICAL CONNECTIONS BETWEEN THE DFSM AND THE LEAD MODULES. 20 4.4.1 GENERALITIES...... 20 4.4.2 SPECIFICITIES OF THE CONNECTION...... 20 4.4.2.1 13 kA dipolar and quadrupolar busbars (IC #41)...... 20 4.4.2.2 6 kA cables (IC #42)...... 21 4.4.2.3 600 A and 120 A cables (IC #43, 44 & 45)...... 21 5. DFBL AND DSL ELECTRICAL CONNECTIONS...... 22 5.1 GENERALITIES...... 22 5.2 DFBLA, DFBLB, DFBLD AND DFBLE IC...... 22 LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 4 of 34
5.2.1 IC BETWEEN THE DFBL AND THE DSL IN POINTS 1 & 5 (IC #62 & 63)...... 22 5.2.2 IC BETWEEN THE DSL AND Q5 OR Q6 IN POINTS 1 & 5...... 23 5.2.3 IC BETWEEN THE DSL AND Q4-D2 IN POINTS 1 & 5...... 23 5.3 DFBLC IC (POINT 3)...... 24 5.3.1 IC BETWEEN THE DFBLC AND THE DSLC IN POINT 3 (IC #83)...... 24 5.3.2 CONNECTIONS IN THE DSLC (IC #84 & #85)...... 24 5.3.3 IC BETWEEN THE DFBAF AND DSLC (IC #86)...... 25 6. DFBM ELECTRICAL CONNECTIONS...... 26 7. ANNEX...... 27 7.1 ANNEX 1: AMOUNT OF ELECTRICAL CONNECTIONS IN DFB...... 27 7.2 ANNEX 2: SUMMARY OF BUSBAR ROUTING...... 33 LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 5 of 34
Index of Tables
Table 1: Various dimensions and their symbol in Figure 2...... 8 Table 2: List of the DFB suffixes...... 10 Table 3: List of applicable DFB codes...... 10 Table 4: IC code for the current lead IC (CLIC)...... 11 Table 5: IC code for the HCM/LCM IC...... 11 Table 6: IC code for the HCM IC (5L6)...... 12 Table 7: IC code for the DFSM IC...... 12 Table 8: IC code for the DFBM/magnet IC...... 12 Table 9: IC code for the DFBL/DSL IC in points 1 & 5...... 13 Table 10: IC code for the DSL/DSL IC in points 1 & 5...... 13 Table 11: IC code for the DFBLC/DSLC IC...... 13 Table 12: IC code for the DSLC IC...... 14 Table 13: IC code for the DSLC/DFBAF IC...... 14 Table 14: Summary of all interconnection (IC) codes...... 15 Table 15: Current leads - 13 kA busbars connections...... 16 Table 16: Current leads - 6 kA busbars connections...... 17 Table 17: Current leads - 600 A & 120 A busbars interconnections...... 17 Table 18: HCM/LCM - 600A & 120A cold interconnections...... 18 Table 19: DFBAK HCM – 13 kA extra-connections...... 19 Table 20: DFBAF – 600 A extra-connections...... 19 Table 21: DFSM/Lead Module – 13 kA interconnections...... 20 Table 22: DFSM/Lead Module – 6 kA interconnections...... 21 Table 23: DFSM/Lead Module - 120A & 600A interconnections...... 21 Table 24: DFBL/DSL pts 1 & 5 - 120A & 6kA connections...... 22 Table 25: DSL/Q5 or Q6 pts 1 & 5 – 6 kA connections...... 23 Table 26: DSL/Q4-D2 pts 1 & 5 – 120/600 A & 6 kA connections...... 23 Table 27: DFBLC module/DSLC - 600A connections...... 24 Table 28: DSLC interconnections...... 24 Table 29: DSLC-DFBAF connection...... 25 Table 30: DFBM module/Magnet – 120A, 600A & 6kA connections...... 26 Table 31: DFBA cables and chimneys...... 27 Table 32: DFBA electrical connections...... 28 Table 33: Total number of connections for DFBAs...... 28 Table 34: DFBM electrical connections (from MC5L2 to MM5L6)...... 29 Table 35: DFBM ELECTRICAL CONNECTIONS (from MM4L6 to MJ6R8)...... 30 Table 36: Total number of connections for DFBMs...... 30 Table 37: DFBL electrical connections...... 31 Table 38: Total number of connections in DFB...... 32 LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 6 of 34
1. REFERENCE DOCUMENTS
Edms Refer. Document # Title Author # 1. LHC-DFBA-ES- Routing of Busbars and Cables inside J. Lyngaa 395123 0004 the DFBA’s 2. Connection 13 kA –High Current LHCDFBA_0049 module Main bus bars interconnections 3. LHC-LI-ES- between cryomagnets of the LHC J-P Tock 108101 0005.00 arcs 4. LHC-QBQID-ES- Resistive soldering of line N 6kA bus F. Schauf 362427 0001.00 bars in the LHC interconnections 5. LHC-QBBI-ES- Ultrasonic welding of auxiliary bus A. 31860 0001.00 bars in the LHC interconnections Jacquemod 6. Heat Loads and mass Flows in the LHC-DFB-ES-0006 R. Marie 446011 DFB 7. DFBA Layout – Cold Electrical LHCDFBA_0101 Connections 8. DFBM Layout - Cold Electrical LHCDFBM_0005 Connections 9. DFBL Layout - Cold Electrical LHCDFBL_0004 Connections 10 6000A HTS CURRENT LEADS – . LHCDFLCS0002 Interface drawing
11 600A HTS CURRENT LEADS – . LHCDFLBS0002 Interface Drawing
LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 7 of 34
2. GENERALITIES ABOUT THE DFB ELECTRICAL CONNECTIONS
2.1 DEFINITIONS
2.1.1 DFB The cryogenic electrical feed boxes (DFB) lead and support all types of bus bars as interfaces between the LHC conditions and the open air. We are concerned in three types of them: DFB for arcs (DFBA), DFB for matching sections (DFBM) and DFB for superconducting links (DFBL). A DFBA is composed [Figure 2] of a Shuffling Module (DFSM) and one or two Lead Modules (LM). These Lead Modules are the High Current Module (HCM) leading the 13kA and 6kA busbars and the Low Current Module (LCM) leading the 600A and 120A busbars and some 6kA busbars. A DFBM is composed of one module designed on the model of a LCM [6]. A DFBL is also composed of one module connected to a superconducting link (DSL) [6].
2.1.2 INTERCONNECTION (IC) The electrical connections consist in connecting two superconducting cable or busbars of the same type. This connection has to ensure some specified functionalities: the connection electrical resistance must remain lower than a specified value dealing with the cryogenic conditions (1.9 K or 4.5 K) adapting the geometrical constraints of the DFB there must be fix points for the cables on each side it must be possible to connect in the geometrical constraints of the LHC tunnel disassembling must remain possible
An interconnection (IC) is a group of electrical connections performed at the same location and concerning one type of cables. An IC includes one or several electrical connections.
2.1.3 SCOPE This document deals with the connection of busbars and superconducting cables in the DFBA, DFBL, DSL and DFBM, performed by the AT-ACR-IC section. Neither the TIG welding of the sleeves, nor the connection between the DFBA and magnets are parts of its scope.
2.2 SPECIFICITIES OF THE DFB CONNECTIONS The DFB integrates several types of bus bars. The choice of a technique for the electrical connections depends on the busbar and the design is based on the technology developed by AT-CRI for the cryomagnet interconnections: Inductive soldering for 13 kA dipolar and quadrupolar busbars [3]; Resistive soldering for 6 kA busbars [4]; Ultrasonic welding for 600 A and 120 A busbars [5].
Although the connecting technologies remain similar to the standard ones for each cable type, the tooling and supports have to be resized or redesigned to the room available in the DFB’s and to the specific busbar bundles. For each type of cable, various situations of interconnections ([Figure 2] & [7]) have to be considered. LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 8 of 34
2.3 IMPORTANT DIMENSIONS
A typical IC with one electrical connection is shown in Figure 1. The distances A to E describe the space used to perform the IC.
B A
E D
C
Figure 1: Scheme of a typical electrical connection
Table 1: Various dimensions and their symbol in Figure 2
Braizing length (cables overlap) A Needed length for tooling B Length between flanges C Flange ext. diameter D Pipe diam. E LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 9 of 34
Hi gh cu rr en t m o du le 13 kA & 6 kA le Load w s DFSM/HCM cu rr interconnect en t m 600A, 6kA, 13kA od 6kA CL- busbar ul e 6 connection kA & 60 0A Interconnects le ad 13kA CL- busbar s 13kA CL- busbar connection lyra HCM/LCM interconnect (600A only)
Configuration of DFBAO IR8 600A CL- busbar left connection
Figure 2: Example of DFBAO configuration with interconnections (CL = Current Lead)
2.4 NAMING CONVENTION FOR THE DFB INTERCONNECTIONS The DFB interconnection names are alphanumeric codes unique for each cable connection. These codes are composed of : An alphanumeric code with the DFB suffix (2 letters) and the cell number (3 characters) 2 digits corresponding to the interconnection type 2 digits coresponding to the cable reference
Cable reference [1]
Interconnection code
DFB code: 2 letters for the DFB suffix 3 characters for the DFB cell name example: AA7L1-15-03 is the connection of the 600A auxiliary cable #03 to the current lead in the DFB called DFBAA and settled in cell 7L1. LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 10 of 34
2.4.1 DFB CODE To obtain the DFB code, compatible with all types of DFB, the DFB suffix [Table 2] is completed with the cell code. Together they are the DFB code [Table 3] which is the first part of the naming convention for DFB interconnections.
Table 2: List of the DFB suffixes
DFB name DFB suffix DFBAA to DFBAP From AA to AP DFBMA to DFBMM From MA to MM DFBLA to DFBLE From LA to LE
Table 3: List of applicable DFB codes
DFBA DFBM DFBL AA7L1 MC5L2 LA7L1 AB7R1 MA4L2 LB7R1 AC7L2 MB4R2 LCJ33 AC6L2 MC5R2 LD7L5 AD6R2 MD6L3 LE7R5 AD7R2 MD6R3 AE7L3 MG6L4 AF7R3 MF5L4 AG7L4 ME5L4 AH7R4 MK5R4 AI7L5 ML5R4 AJ7R5 MG6R4 AK5L6 MM5L6 AL5R6 MM4L6 AM7L7 MM4R6 AN7R7 MM5R6 AO7L8 MH6L7 AO6L8 MH6R7 AP7R8 MC5L8 MA4L8 MB4R8 MI5R8 MJ6R8 LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 11 of 34
2.4.2 INTERCONNECTION CODE The IC code is the second part of the naming convention. It enables to identify the connection type, its location and the cable type.
2.4.2.1 IC CODE FOR THE CURRENT LEAD IC (CLIC)
Table 4: IC code for the current lead IC (CLIC)
13 kA LCC Spool piece Spool piece Cable type 13 kA quad 6 kA dip (600A) (600A) (120A) Cable code DCBD DCQDD DCQFD DCDD DCFD DCGD DCGD Current lead DFLAS DFLCS DFLBS DFLFS code IC code 11 12 13 14 15 Number of 1 1 4 4 4 or 8 Connections
2.4.2.2 IC CODE FOR THE HCM/LCM IC This interconnection concerns the auxiliary and spool piece cables and it takes place between the High Current Module (HCM) and the Low Current Module (LCM).
Table 5: IC code for the HCM/LCM IC
Cable type LCC (600A) Spool piece (600A) Spool piece (120A) Cable code LCM side DCFD DCGD DCGD Cable code HCM side DCAD DCHD IC code 23 24 25 Number of 28, 32 or 36 16 0 or 4 Connections
2.4.2.3 IC CODE FOR THE HCM EXTRA IC In some particular cases, a specific interconnection may exist only once. This happens in two cases: Due to the length of the DFBA in cell 5L6, one more connection is necessary for the main busbars [7] between the Shuffling Module (DFSM) and the High Current Module (HCM). There is a DCE (48x600A) cable crossing the DFBAF to reach the superconducting link DSLC. See below IC#86. LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 12 of 34
Table 6: IC code for the HCM IC (5L6)
Cable type 13 kA dip 13 kA quad Cable code DCBD DCQDD DCQFD IC code 31 Number of 2 2 2 Connections
2.4.2.4 IC CODE FOR THE DFSM IC Table 7: IC code for the DFSM IC
Main Main Spool Spool Thermal Cable type 13kA 13kA 6 kA piece piece Screen dip quad (600A) (120A) Cable code LM side DCBD DCQDD DCQFD DCDD DCHD - Cable code DFSM side Line M N’ N E
IC code 41 42 44 45 46
Number of 1 1 Up to 48 - Connections
2.4.2.5 IC CODE FOR THE DFBM/MAGNET IC Table 8: IC code for the DFBM/magnet IC
Lattice Cable type 6 kA (600 A or 120 A) DFBM DCDD DCFD Cable side code Magnet DCDD DCFD side IC code 52 53 Number of Up to 11 Up to 12 Connections LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 13 of 34
2.4.2.6 IC CODE FOR THE DFBL IC (EXCEPT DFBLC IC) The IC code remains the same as the connection box is identical in these cases: Interconnections between the DFBLA, DFBLB, DFBLD, DFBLE and the corresponding DSL (1 interconnection for each DFBL) Interconnections between the DSLA, DSLB, DSLD, DSLE and the magnets (3 magnets per DSL and 2 connections per magnet)
Table 9: IC code for the DFBL/DSL IC in points 1 & 5
Lattice Cable type 6 kA (120 A) In DFBL DCDD DCFD Cable code In DSL DCDD DCID In Magnet DCDD DCFD IC code 62 63 Number of 11 12 Connections
2.4.2.7 IC CODE FOR THE DSL IC (EXCEPT DSLC)
Table 10: IC code for the DSL/DSL IC in points 1 & 5
Lattice Cable type 6 kA (120 A) DFBL DCDD DCID Cable side code Magnet DCDD DCID side IC code 72 73 Number of 11 12 Connections
2.4.2.8 IC CODE FOR THE DFBLC/DSLC CONNECTION This IC code concerns the interconnection between the DFLBC and the DSLC in point 3.
Table 11: IC code for the DFBLC/DSLC IC
Lattice Cable type (600 A) Cable DFBL DCFD code DSL DCED IC code 83 Number of 44 Connections LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 14 of 34
2.4.2.9 IC CODE FOR THE DSLC IC The IC code remains the same for all the interconnections taking place in the DSLC (point 3) including the connection to DFBAF, except the connection to DFBLC (IC #83).
Table 12: IC code for the DSLC IC
Lattice Cable type (600 A) Cables code DCED
IC code 84 & 85 Number of 48 Connections
2.4.2.10 IC CODE FOR THE DSLC/DFBAF IC Table 13: IC code for the DSLC/DFBAF IC
Lattice Cable type (600 A) Cables code DCED
IC code 86 Number of 48 Connections LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 15 of 34
2.4.3 SUMMARY OF IC CODES The following table gathers all the connection details for each IC code.
Table 14: Summary of all interconnection (IC) codes
IC code IC description Cable type 11 Main (13 kA) 12 6 kA Between current leads 13 Lattice (600 A) and DFB busbars 14 Spool piece (600 A) 15 Spool piece (120 A) 23 Lattice (600 A) Between the HCM 24 Spool piece (600 A) and LCM busbars 25 Spool piece (120 A) 31 HCM (5L6 only) Main (13 kA) 41 Main (13 kA) 42 6 kA Between the HCM 44 Spool piece (600 A) and the DFSM 45 Spool piece (120 A) 46 Thermal screen (E line) 52 6 kA DFBM/Magnet 53 Lattice (120 A & 600 A) 62 Between the DFBL and the DSL 6 kA 63 In points 1 & 5 Lattice (120 A & 600 A) DSL/Plug cable to Q4 72 6 kA in points 1 & 5 Plug cable to Q4/Q4 73 6 kA in points 1 & 5 DSL/plug cable to Q5 74 6 kA in points 1 & 5 Plug cable to Q5/Q5 75 6 kA in points 1 & 5 76 DSL/Plug cable to Q6 6 kA 77 in points 1 & 5 Lattice (120 A & 600 A) 78 Plug cable to Q6/Q6 6 kA 79 in points 1 & 5 Lattice (120 A & 600 A) 83 Between DFLBC & DSLC Lattice (600 A) 84 & 85 In DSLC Lattice (600 A) 86 DSLC/DFBAF in DFBAF Lattice (600 A)
2.4.4 CABLE REFERENCE This 2 digits code is a unique cable reference from [1]. LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 16 of 34
3. INTERCONNECTIONS BETWEEN THE CURRENT LEADS AND THE DFB BUSBARS (CLIC)
3.1 GENERALITIES This kind of connections concerns all types of DFB (DFBA, DFBL & DFBM). There is one cable coming from a DFb to aech current lead but the number of current leads per chimney depends on the type of busbar [Table 4].
The connections to the current leads are not standard since some special cables were designed by AT-MEL for the current leads.
These electrical connections are usually performed before the transport of DFBs to the LHC tunnel. Though, in case of problem, it must be possible to assemble them in the tunnel, as a result the necessary tooling shall take this constraint into account.
3.2 SPECIFICITIES OF THE CONNECTION
3.2.1 13 KA DIPOLAR AND QUADRUPOLAR BUSBARS (IC #11)
Table 15: Current leads - 13 kA busbars connections
Technique Inductive soldering Brazing length 60 mm Needed length for 90 mm tooling Length between 110 mm flanges Flange ext. diameter 64 mm Pipe diameter 40/43 Cable ends from the current leads are Specificity not standard [2].
3.2.2 6 KA CABLES (IC #12) From the current lead, two flat bundles of 18 wires come to the connection zone [10]. The resistive soldering process will have to be adapted to this geometry. LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 17 of 34
Table 16: Current leads - 6 kA busbars connections
Technique Resistive soldering Solder length 50 mm Needed length for tooling 50 mm Length between flanges 80 mm Flange ext. diameter 41 mm Pipe diameter 18.1/21.3 mm
3.2.3 600 A AND 120 A CABLES (IC #13, 14 & 15) From the current lead, two flat bundles of 4 wires come to the connection zone [11]. The welding with ultrasounds process will have to be adapted to this geometry.
Table 17: Current leads - 600 A & 120 A busbars interconnections
Technique Ultrasound welding Weld length 10 mm Needed length for < 80 mm tooling Length between 80 mm flanges Flange ext. diameter 41 mm Pipe diameter 18.1/21.3 mm LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 18 of 34
4. DFBA ELECTRICAL CONNECTIONS
4.1 CONNECTIONS BETWEEN THE DFBA LEAD MODULES (HCM/LCM)
4.1.1 GENERALITIES These connections are performed in the LHC tunnel which leads to specific geometrical constraints to take into account.
Figure 3: Interconnection space between the two DFBA modules
4.1.2 SPECIFICITIES OF THE CONNECTION (IC #23, 24 & 25) This connection concerns only the 120 A and 600 A cables.
Table 18: HCM/LCM - 600A & 120A cold interconnections
Technique Welding by ultrasounds Solder length 10 mm Needed length for 300 mm tooling Length between 300 mm flanges Flange ext. diameter 135 mm Pipe diam. 50/54 mm LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 19 of 34
4.2 13KA EXTRA CONNECTION IN THE DFBAK HCM (IC #31)
IC #41 IC #31
DFSM HCM LCM 10.3 m
Figure 4: DFBAK extra-length
Because of the long distance between the DFSM and the HCM in the DFBAK, an extra connection was designed only for 13 kA busbars.
Table 19: DFBAK HCM – 13 kA extra-connections
Technique Inductive soldering Brazing length 120 mm Length between flanges 220 mm Flange ext. diameter 188 mm Pipe diameter 163.1/168.1 mm
4.3 600 A EXTRA CONNECTION IN DFBAF (IC #33)
Table 20: DFBAF – 600 A extra-connections
Technique Ultrasonic welding Solder length 10 mm Length between 300 mm flanges Flange ext. diameter 135 mm Pipe diameter 50/54 mm LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 20 of 34
4.4 ELECTRICAL CONNECTIONS BETWEEN THE DFSM AND THE LEAD MODULES
4.4.1 GENERALITIES These connections are performed before the integration in the tunnel.
Figure 5: Interconnections between the Shuffling Module and the High Current Module in a DFBA
4.4.2 SPECIFICITIES OF THE CONNECTION
4.4.2.1 13 KA DIPOLAR AND QUADRUPOLAR BUSBARS (IC #41) Table 21: DFSM/Lead Module – 13 kA interconnections
Technique Inductive soldering Brazing length 120 mm Length between flanges 220 mm Flange ext. diameter 188 mm Pipe diam. 163.1/168.3 mm LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 21 of 34
4.4.2.2 6 KA CABLES (IC #42)
Table 22: DFSM/Lead Module – 6 kA interconnections
Technique Resistive soldering Solder length 50 mm Length between 249 mm flanges Flange ext. diameter 135 mm Pipe diameter 50/54 mm
4.4.2.3 600 A AND 120 A CABLES (IC #43, 44 & 45)
Table 23: DFSM/Lead Module - 120A & 600A interconnections
Technique Ultrasonic welding Solder length 10 mm Length between 249 mm flanges Flange diameter 135 mm Pipe diameter 50/54 mm LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 22 of 34
5. DFBL AND DSL ELECTRICAL CONNECTIONS
5.1 GENERALITIES
The DFBLs electrical connections concern 6 kA, 600 A and 120 A bus bars. Each one is connected through a long superconducting link (DSL) to the magnets.
5.2 DFBLA, DFBLB, DFBLD AND DFBLE IC
5.2.1 IC BETWEEN THE DFBL AND THE DSL IN POINTS 1 & 5 (IC #62 & 63) Due to the presence of a plug and because of specific dimensional constraints, there are two identical interconnections between the DFBL and the DSL: one on each side of the plug. Furthermore, the junction is particular as the DSL pipe is connected vertically to the DFBL.
Figure 6: Schemes of DFBL & DSL IC in points 1 & 5
Table 24: DFBL/DSL pts 1 & 5 - 120A & 6kA connections
Standard: resistive soldering Technique and ultrasonic welding Solder length standard Length between flanges 450 mm (including fix points) Sleeve diameter 88.9/83.7 mm Pipe diameter 48.3/44.3 mm LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 23 of 34
5.2.2 IC BETWEEN THE DSL AND Q5 OR Q6 IN POINTS 1 & 5 Table 25: DSL/Q5 or Q6 pts 1 & 5 – 6 kA connections
Technique Standard: resistive soldering Solder length standard Needed Length between 200 mm flanges Sleeve diameter 88.9/83.7 mm Pipe diameter 33.7/29.7 mm
5.2.3 IC BETWEEN THE DSL AND Q4-D2 IN POINTS 1 & 5 Table 26: DSL/Q4-D2 pts 1 & 5 – 120/600 A & 6 kA connections
Standard: resistive soldering Technique and ultrasonic welding Solder length standard Needed Length between 400 mm flanges Sleeve diameter 88.9/83.7 mm Pipe diameter 48.3/44.3 mm LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 24 of 34
5.3 DFBLC IC (POINT 3)
5.3.1 IC BETWEEN THE DFBLC AND THE DSLC IN POINT 3 (IC #83)
Figure 7: Schemes of DFBLC & DSLC IC (point 3)
The busbar connection box is designed on the model of a DFBM connection box (see chap. 6).
Table 27: DFBLC module/DSLC - 600A connections
Standard: ultrasonic Technique welding Solder length Standard Needed length between flanges 550 mm (including fix points) Sleeve diameter 76.1/70.9 mm Pipe diameter 48.3/44.3 mm
5.3.2 CONNECTIONS IN THE DSLC (IC #84 & #85) Table 28: DSLC interconnections
Technique Standard: ultrasonic welding Solder length Standard Needed length between 550 mm flanges (including fix points) Sleeve diameter 76.1/70.9 mm Pipe diameter 48.3/44.3 mm LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 25 of 34
5.3.3 IC BETWEEN THE DFBAF AND DSLC (IC #86) Table 29: DSLC-DFBAF connection
Technique Standard: ultrasonic welding Solder length standard Needed length between 550 mm flanges Sleeve diameter 76.1/70.9 mm Pipe diameter 48.3/44.3 mm LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 26 of 34
6. DFBM ELECTRICAL CONNECTIONS
The DFBMs electrical connections concern 6 kA, 600 A and 120 A bus bars. The connections to the current leads are similar to the DFBA current leads connections (3.2).
The only module shall be designed on the model of a DFBA Low Current Module [8, 9]. At the DFBM outlet, there is one connection box for all connections [Figure 10]. A specific procedure will have to be defined though, the room available is sufficient to use the tooling developed for the DFBA connections.
Though the number of connections will change from one DFBM to another, the whole room available remains constant [Table 30] and it fits all possible situations.
Table 30: DFBM module/Magnet – 120A, 600A & 6kA connections
Standard: resistive soldering Technique and ultrasonic welding Solder length standard Length between 400 mm flanges Sleeve diameter 76.1/70.9 mm Pipe diameter 50/54 mm LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 27 of 34
7. ANNEX
7.1 ANNEX 1: AMOUNT OF ELECTRICAL CONNECTIONS IN DFB
Table 31: DFBA cables and chimneys
AC7L2 AD6R2 AO7L8 AA7L1 AB7R1 AE7L3 AF7R3 AG7L4 AH7R4 AI7L5 AJ7R5 AK5L6 AL5R6 AM7L7 AN7R7 AP7R8 DFBA IC AC6L2 AD7R2 AO6L8 13 kA dip 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 Busbars through 13 kA quad 0 0 4 4 0 0 4 4 0 0 4 4 0 0 4 4 the Lambda Plate 6 kA 12 12 12 12 0 0 12 12 12 12 9 9 0 0 12 12 600 A 42 42 62 62 48 48 62 62 42 42 62 62 48 48 62 62 13 kA 2 2 6 6 2 2 6 6 2 2 6 6 2 2 6 6 HCM 6 kA 12 12 12 12 0 0 12 12 12 12 9 9 0 0 12 12 Number of 600 A 0 0 0 0 44 0 0 0 0 0 0 0 44 44 0 0 Current Leads 6 kA 0 0 3 3 0 0 0 0 0 0 3 0 LCM 600 A 28 28 48 48 48 48 28 28 48 48 48 48 120 A 0 0 8 4 4 4 0 0 4 4 4 4 13 kA 2 2 6 6 2 2 6 6 2 2 6 6 2 2 6 6 HCM 6 kA 12 12 12 12 0 0 12 12 12 12 9 9 0 0 12 12 600 A 0 0 0 0 44 48 0 0 0 0 0 0 44 44 0 0 Number of 6 kA 0 0 3 3 0 0 0 0 0 0 3 0 Cables 600 A 28 28 48 48 48 48 28 28 48 48 48 48 LCM Spare 600 A 0 0 0 0 4 4 0 0 4 4 0 0 (no CL!) 120 A 0 0 8 4 4 4 0 0 4 4 4 4 HCM 14 14 18 18 13 2 18 18 14 14 15 15 13 13 18 18 Number of LCM 7 7 16 16 0 0 14 14 7 7 14 14 0 0 16 13 Chimneys Total 21 21 34 34 13 2 32 32 21 21 29 29 13 13 34 31 LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 28 of 34
Table 32: DFBA electrical connections
AC7L2 AD6R2 AO7L8 AA7L1 AB7R1 AE7L3 AF7R3 AG7L4 AH7R4 AI7L5 AJ7R5 AK5L6 AL5R6 AM7L7 AN7R7 AP7R8 DFBA IC AC6L2 AD7R2 AO6L8 13kA 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 13kA 4 0 0 4 4 0 0 4 4 0 0 4 4 0 0 4 4 Current 6kA 12 12 15 15 0 0 12 12 12 12 9 9 0 0 15 12 Leads 600A 28 28 48 48 44 0 48 48 28 28 48 48 44 44 48 48 120A 0 0 8 4 0 0 4 4 0 0 4 4 0 0 4 4 13kA 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 Number 13kA 4 0 0 4 4 0 0 4 4 0 0 4 4 0 0 4 4 of IC SM/ 6kA 12 12 12 12 0 0 12 12 12 12 9 9 0 0 12 12 LM 600A 0 0 16 16 0 0 16 16 0 0 16 16 0 0 16 16 120A 0 0 4 4 0 0 4 4 0 0 4 4 0 0 4 4 HCM/ 120A 0 0 4 4 0 0 4 4 0 0 4 4 0 0 4 4 LCM 600A 28 28 48 48 44 0 52 52 28 28 52 52 44 44 48 48 Special 13kA 0 0 0 0 0 0 0 0 0 0 6 0 0 0 0 0 13kA 4 4 12 12 4 4 12 12 4 4 18 12 4 4 12 12 Total Number of Connections 6kA 24 24 27 27 0 0 24 24 24 24 18 18 0 0 27 24 per DFBA 600/120A 56 56 128 124 88 0 128 128 56 56 128 128 88 88 124 124
Table 33: Total number of connections for DFBAs
13k 134 Total Number of DFBA 6k 285 Connections 600/120 1500 LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 29 of 34
Table 34: DFBM electrical connections (from MC5L2 to MM5L6)
DFBM Electrical Connections MC5L2 MA4L2 MB4R2 MC5R2 MD6L3 MD6R3 MG6L4 MF5L4 ME5L4 MK5R4 ML5R4 MG6R4 MM5L6 6 kA 3 5 5 3 0 0 3 5 2 2 5 3 3 Number of Current Leads = 600 A 0 0 0 0 4 4 0 0 2 2 0 0 0 Number of Cables 120 A 12 12 12 12 0 0 0 0 0 0 0 0 12 Number of Chimneys 5 7 7 5 1 1 3 5 3 3 5 3 5 6 kA 3 5 5 3 0 0 3 5 2 2 5 3 3 Current 600 A 0 0 0 0 4 4 0 0 2 2 0 0 0 Leads 120 A 12 12 12 12 0 0 0 0 0 0 0 0 12 Number of 6 kA 3 5 5 3 0 0 3 5 2 2 5 3 3 DFBM/ Q6 Connections 600 A 0 0 0 0 4 4 0 0 2 2 0 0 0 Or Q4 120 A 12 12 12 12 0 0 0 0 0 0 0 0 0 6 kA 6 10 10 6 0 0 6 10 4 4 10 6 6 Total 600/120 A 24 24 24 24 8 8 0 0 4 4 0 0 0
Table 35: DFBM ELECTRICAL CONNECTIONS (from MM4L6 to MJ6R8) LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 30 of 34
DFBM Electrical Connections MM4L6 MM4R6 MM5R6 MH6L7 MH6R7 MC5L8 MA4L8 MB4R8 MI5R8 MJ6R8 6 kA 3 3 3 0 0 3 5 5 3 3 Number of Current Leads = Number of 600 A 0 0 0 4 4 0 0 0 0 0 Cables 120 A 0 0 0 0 0 12 12 12 12 0 Number of Chimneys 3 3 3 1 1 5 7 7 5 3 6 kA 3 3 3 0 0 3 5 5 3 3 Current Leads 600 A 0 0 0 4 4 0 0 0 0 0 120 A 0 0 0 0 0 12 12 12 12 0 6 kA 3 3 3 0 0 3 5 5 3 3 Number of Connections DFBM/ Q6 600 A 0 0 0 4 4 0 0 0 0 0 Or Q4 120 A 0 0 0 0 0 12 12 12 12 0 6 kA 6 6 6 0 0 6 10 10 6 6 Total 600/120 A 0 0 0 8 8 24 24 24 24 0
DFBL Table 36: Total Electrical Connections number of DFBLA DFBLB DFBLC DFBLD DFBLE connections for DFBMs Location RR13 RR17 UJ33 RR53 RR57 Number of Current Leads Total6 Number kA of 11 6 kA 11 134 0 11 11 = 600 A 0 0 44 0 0 DFBM 600/120 A 232 Number of Cables Connections120 A 12 12 0 12 12 Number of Chimneys 13 13 11 13 13 Table 37: DFBL 6 kA 11 11 0 11 11 electrical To Current connections 600 A 0 0 44 0 0 Leads 120 A 12 12 0 12 12 6 kA & 4 kA 11 11 0 11 11 DFBL/DSL 600 A 0 0 44 0 0 120 A 12 12 0 12 12 Number of DSL/Q6 (2 times) 6 kA 3 3 0 3 3 Electrical DSL/Q5 (2 times) 6 kA 3 3 0 3 3 Connections 6 kA & 4 kA 5 5 0 5 5 DSL/Q4 & D2 (2 times) 120 A 12 12 0 12 12 DSL/DSL (2 times) 600 A 0 0 48 0 0 DSL/DFBAF 600 A 0 0 48 0 0 Total all 6 kA & 4 kA 44 44 0 44 44 176 Total IC 600/120 A 48 48 228 48 48 420 LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 31 of 34
Table 38: Total number of connections in DFB
Total of DFB Electrical Connections 13 kA 134 6 kA 595 600/120 A 2152 LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 32 of 34
7.2 ANNEX 2: SUMMARY OF BUSBAR ROUTING
Connection to current leads
DFSM/HCM connection
Figure 8: 13 kA and 6 kA busbar routing LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 33 of 34
Figure 9: 600 A & 120 A busbar routing LHC Project Document No. LHC-DFB-ES-0005 rev 1.1 Page 34 of 34
Figure 10: DFBM busbar connection