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/ Author(s) / DateJeffrey Tice
David Kiehl
Tom Nieland / REVISED
8-11-2014
SLAC LCLS II TTF3 Coupler
Build Number 5
Particle Physics & Astrophysics
Document Title
TTF3 Coupler Assembly Process
Cold Part Serial Numbers / Warm Part Serial Numbers / CPC Assembly Serial Numbers / Operators / Dates
CP3C95 / CP3H84 / #5 / TN/DK / 9-29-14
CP3C96 / CP3H101
1. Change History Log
Revision / Effective Date / Description of Changes1 / 08-04-2009 / Capacitor / Waveguide Install Sequence
2 / 08-06-2009 / Made Cleaning Process A Separate Document
3 / 08-25-2009 / Added Acronym section
4 / 08-27-2009 / Moved Parts List To A Bill Of Materials
5 / 09-08-2009 / Torque Guidelines For Vacuum Components
6 / 09-15-2009 / Data Sheet
2. Contents
1. Change History Log 1 .
2. Contents 1.
DATA SHEET (BUILD SUMMARY)...... 3
3. Scope………………………………………………………………………………………………………6
4. Applicable Documents 6
5. Acronyms…………………………………………………………………………………………6
6. Receiving TTF3 Couplers……………………………………………………………………..…7
7. TTF3 Coupler Cleaning Process…………………………………………………………………7
8. Coupler Processing Cavity Assembly SA-390-006-58…………………………………………….8
9. Cleaning of Cold Parts & Cold Transitions………………………………………………………9
10. Assembly of Cold Parts to CPC…………………………………………………………………..9
11. Cold Pumping Group Assembly to CPC Assembly……………………………………………..11
12. Cleaning of Warm Part………………………………………………………………………….12
13. Assembly of Warm Parts………………………………………………………………………...12
14. Leak Test of Couplers……………………………………………………………………………15
15. Moving Couplers from Clean room to ESB……………………………………………………15
16. End Station B Oven Bake Out………………………………………………………….……….17
17. Assembly of Wave Guide Housing to Coupler Assembly……………………………………..18
18. R.F. Cold Test / Test Results……………………………………………………………………21
19. Install R.F. Blankets, fiber optic sensor and TC's……………………………………………..22
20.. R.F. Test………………………………………………………………………………………...23
21. Post Test Inspection For Arcing……………………………….……………………………….24
22. Disassembly and inspection of the couplers for shipping………………………………………25
/ Author(s) / DateJeffrey Tice
David Kiehl
Tom Nieland / REVISED
09-01-2010
SLAC ILC TTF3 Coupler
Build Number
Particle Physics & Astrophysics
Document Title
TTF3 Coupler Data Sheet
BUILD NUMBER:
CPC:
CPC P/N: / SA-375-450-18-1CPC Upper Weldment S/N: / 5
CPC Lower Weldment S/N: / 5
CPC Assembly Date: / 9-29-14
RF IN WARM PART:
WARM PART P/N: / RDESY2988356A000WARM PART COUPLER PORT I: / CP3H84
WARM PART Assembly Date: / 9-30-14
Helium Leak Test:
Ion Pump Vacuum Reading PRE-BAKE OUT:
Ion Pump Vacuum Reading POST-BAKE OUT:
Ion Pump Vacuum Reading Post R.F. Test
CAPACITOR S/N:
WAVEGUIDE S/N:
RF IN COLD PART:
COLD PART COUPLER PORT I: / CP3C95
COLD PART Assembly Date: / 9-29-14
Helium Leak Test: / 5.0 x 10-10
Ion Pump Vacuum Reading PRE-BAKE OUT:
Ion Pump Vacuum Reading POST-BAKE OUT :
Ion Pump Vacuum Reading Post R.F. Test
RF OUT COLD PART:
COLD PART P/N: / SA-375-600-01COLD PART COUPLER PORT II: / CP3C96
COLD PART Assembly Date: / 9-29-14
Helium Leak Test: / 5.0 x 10-10
Ion Pump Vacuum Reading PRE-BAKE OUT:
Ion Pump Vacuum Reading POST-BAKE OUT:
Ion Pump Vacuum Reading Post R.F. Test
RF OUT WARM PART:
WARM PART P/N: / RDESY2988356A000WARM PART COUPLER PORT II: / CP3H101
WARM PART Assembly Date: / 9-30-14
Helium Leak Test: / 4.5 X10-10
Ion Pump Vacuum Reading PRE-BAKE OUT:
Ion Pump Vacuum Reading POST-BAKE OUT:
Ion Pump Vacuum Reading Post R.F. Test
CAPACITOR S/N:
WAVEGUIDE S/N:
BAKE OUT:
NITROGEN PURGE FOR 18 HOURS AT 40 SCFH:BAKE OUT STARTED @ 100C (212F)
DATE/TIME:
TEMPERTURE INCREASE TO 150C (310F) DATE/TIME:
BAKE OUT END DATE/TIME:
COLD TEST:
START DATE/TIME:END DATE/TIME:
RESULTS
RF PROCESSING:
START DATE/TIME:END DATE/TIME:
NC REPORTS:
NONESHIPPING TO FERMI:
SENT DATE/TIME:FED EX NUMBER:
RECEIVED DATE/TIME:
SLAC SHIPPER NUMBER
3.0 Scope
This document describes the assembly of the TTF3 Coupler and its assemblies. It captures all assembly requirements associated with assembly of the TTF3 Coupler.
4. Applicable Documents
[1] TESLA-COU-TTF3-ASSEM, “List of Preparation and Assembly Operations for Two TTF3 Couplers on their Test Bench” 16-05-2005
SLAC TTF3 Coupler Cleaning Process
Bill Of Materials
Torque Guidelines For Vacuum Components
5. Acronyms
B.O.M. Bill Of Materials
C. Centigrade / Celsius
CF Con Flat
C.P.C. Coupler Processing Cavity
E.S.B. End Station B (R.F. Test Facility)
F. Fahrenheit
MM. Millimeter
O.D. Outer Diameter
O.F.H.C. Oxygen Free H----- Copper
N.C. Non Conformance
NPT National Pipe Thread
Continued Next Page
P/N. Part Number
P.S. Power Supply
P.S.A. Pressure Sensitive Adhesive
P.T.F.E. Polytetrafluoroethylene, (Pipe Thread Teflon Tape)
R.F. Radio Frequency
R.T.V. Room Temperature Vulcanizing
S/N. Serial Number
SS. Stainless Steel
T/C Thermo Couple
T.B.D. To Be Determined
U.H.V. Ultra High Vacuum
U.P.W. Ultra Pure Water
6. Receiving TTF3 Couplers
Use clean room gloves when handling all parts. Parts are received at Bldg. 33. Move crates to a clean area to inventory against the Bill Of Materials. Note any missing parts and any additional parts required for build up. Visually inspect parts for any damage and cleanliness. Put all parts that do not go through the metrology inspection into clean room bins and move to Bldg. 6 clean room for cleaning. Any parts that will not be cleaned immediately will be stored in the nitrogen purge cabinets at bldg. 6. The warm parts and cold parts will remain at bldg. 33 clean room for additional metrology inspection. After metrology inspection is complete, place parts in clean room bins and transport to bldg. 6 for cleaning.
7.0 TTF3 Coupler Cleaning Process
Refer to TTF3 Coupler Cleaning Process Document.
8.0 Coupler Processing Cavity Assembly SA-390-006-58
8.1 Assembly of CPC is done by placing bottom flange (PF-390-006-65) on CPC assembly stand with cavity facing up.
8.2 Visually inspect knife edges for a clean and sharp interface. Edge should be free of nicks and deformities.
8.3 Using class 10 alcohol wipe, clean and visually inspect copper gasket (part # MDC 191022) for any nicks and deformities. Place gasket onto gland of CPC
8.4 Install cleaned dust covers caps over 3 flanges and install nitrogen purge blank off to Vacuum Port II of item 1 top flange weldment.
8.5 Connect nitrogen purge and start flowing, mate top flange weldment item 1 (SA-390-006-59) onto bottom flange (PF-390-006-65) making sure copper gasket does not move during mating process.
8.6 With nitrogen purge flowing, assemble finger tight in mounting ear locations per SA-390-006-58, using hardware the two hole dog ears go to Coupler Port II end. See figure 1 for reference.
Figure 1 (CPC assembly SA-390-006-58)
8.7 With nitrogen purge flowing, install remaining fasteners finger tight into CPC assembly per SA-390-006-58
8.8 With nitrogen purge flowing, install CPC into the coupler integration stand.
8.9 With nitrogen purge flowing, torque hardware. 3/8-24 to 40 ft.-lbs., ¼ - 20 to 12 ft.-lbs.
8.10 With nitrogen purge flowing, Invert coupler integration stand. Torque all CPC hardware as needed to final torque at this time.
8.11 If you are not installing the cold part of the coupler at this time then cover all open ports on the CPC. Then remove the nitrogen purge and cap the purge port.
9 Cleaning of Cold Parts & Cold Transitions
See SLAC TTF3 Cleaning Process
10.0 Assembly of Cold Parts to CPC
10.1 Blow with filtered ionized nitrogen (P= 4 bars or 60 psi) on each cold parts:
Note: In each position of each part, the count must be below 10 particles of 0.3 microns per cubic foot (i.e. per minute) If, after 5 minutes of blowing, there are still greater then 10 particles, the parts goes back to cleaning process.
10.2 Place CPC (SA-390-006-58) from class 100 storage area into the class 10 work bench area. Carefully remove dust covers from cold coupler ports (8 holed ports viewed at 12 and 6 clocked).
10.3 Place CPC (SA-390-006-58) from class 100 storage area into the class 10 work bench area. Carefully remove dust covers from cold coupler ports I & II Do a particle count at each port.
10.4 Install 6mm X 40mm nitronic 60 studs & nuts into Coupler Ports I & II.
10.5 Invert stand to normal configuration
10.6 Install aluminum vacuum gasket onto cold part assembly. Make sure gasket it is free of nicks & scratches for a proper vacuum seal.
10.7 Delicately place cold part into position on Coupler Port I flange. Make sure the e pick-up port of the cold part is facing toward the outside edge of the CPC per photo above.
10.8 Install all (8) Nitronic 60 6mm nuts onto cold part and tighten in a torque pattern
Note cold part serial number here: __CP3C95______
10.9 Install aluminum gasket onto coupler port II flange. Make sure gasket it is free of nicks & scratches for a proper vacuum seal.
10.11 Delicately place cold part from support stand onto Coupler Port II flange. Make sure the e pick-up port of the cold part is facing towards the outer edge of CPC per photo above.
10.12 Install all (8) Nitronic 60 6mm nuts onto cold part and tighten in a torque pattern
Note cold part serial number here:______CP3C96______
10.13 Examine the knife edge on the E-Pickup Port of each cold part. Verify gasket surface is free of nicks & scratches for a proper vacuum seal.
10.14 Examine the knife edge on the E-Pickup to be installed on each cold part. Verify gasket surface is free of nicks & scratches for a proper vacuum seal.
10.15 Examine the copper seal for each E – Pickup. Verify gasket surface is free of nicks & scratches for a proper vacuum seal.
10.16 While maintaining a nitrogen purge place a clean copper gasket on one of the ports and install E- Pickup on cold part with Hexagonal Bolt w/ Duo-Nut fastener kits. Then repeat the same process for the second E-Pickup port.
10.17 Inspect knife edge of VAC Port I. Inspect and install VAT gate Valve in the open position. If pump assembly is not going to be installed at this time, then inspect knife edges and install a blank off.
11.0 Cold Pumping Group Assembly to CPC Assembly
11.1 Connect nitrogen purge to VCR fitting on Vac Port II. (Remove blank off if installed) Do a particle count @ Vac Port I.
11.2 Inspect the knife edges on VAT Valve and the copper gasket for scratches on the sealing surfaces.
11.2 Connect a nitrogen purge to the cold section Ion Pump assembly. remove blank off from assembly, the end that will be mating to the CPC and inspect knife edge for nicks or scratches.
11.3 Do a particle count on the pump assembly. If assembly meets particle requirements, then disconnect nitrogen purge from the Ion Pump and install assembly onto vacuum port I while a nitrogen purge is connected and flowing @Vac Port II.
12.0 Cleaning of Warm Part
Refer to TTF3 Coupler Cleaning Process Document.
13.0 Assembly of Warm Parts
Install purge port on the vacuum 2.75” vacuum port. Set purge at 3 psi. Use all Nitronic 60 hardware.
Warm Coupler S/N Port I __CP3H84__Warm Coupler S/N Port IICP3H101___
13.1 Install Nitronic 60 antenna screw in to warm part center coax.
13.2 Place CF100 copper gasket onto Cold part CF flange.
13.3 Blow off cold parts with Nitrogen. Do a particle count on the ceramic copper cavity of the warm part.
13.4 Position warm part over the cold part, insert the antenna screw with the allen wrench. Verify alignment is correct with respect to CF16 port alignment. (per diagram on page 11) Thread antenna screw into hole of the cold part until flush, then back off half a turn.
13.2 Install all 8 mm bolts to hand tight only. Then tighten antenna screw.
13.3 Mount support plates to warm part and to the coupler stand.
13.4 Verify the cold part bellows protectors are tight, Use torque support tool when tightening the 8 mm to counter act the torque force when tightening hardware. With torque support tool in the proper position, tighten the 8mm Nitronic 60 bolts (CF100 Flange) on Warm part. See Photo of torque tool below.
13.5
13.6 Install springs to RF Antenna. Mount the RF springs on tuning rods (bend last spring end 90 from existing configuration on both ends then place one end into the other for fastening). Test of inserting the rods into warm parts to make sure that the springs don’t move.
13.7 Install copper gaskets to top of warm part, then install tuning rod. Be sure to turn tuning rod 90 degrees for insertion of tuning pin at coax end. Hole alignment is done by pushing down on tuning rod and moving slowly to align through holes. Torque to just over hand tight using 10mm socket.
13.8 Before Proceeding Verify Proper Antenna Rod Engagement
13.9 Install e-pickups on warm parts (one blank-offs on the top port opposite of bottom e-pickup) e-pickup on the top and bottom ports of warms parts are inline vertically with each other.
Note: All CF16 ports may not be mated at a metal to metal. (copper gasket may be visible).
13.8 Do a particle count on both Ion Pump Assemblies for the warm Parts
13.9 With a nitrogen purge flowing Install Ion Pump Assemblies to both warm parts per orientation in sketch below.
13.10 Install Ion Pump Support Rods to the coupler stand
Coupler Port # I Pump Assembly Coupler Port # II Pump Assembly
Coupler Configuration: