CABLE HARNESSES 12
No SCEM 04.70.07.010.0
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/ Logistics GroupMaterial Management Section
TECHNICAL APPENDIX
N° 585
Date : 29 October 2004
HARNESS CABLE II/III+CONNECTORS
N° SCEM 04.70.07.010.0
Ref. LG/mm
CABLE HARNESSES 12
No SCEM 04.70.07.010.0
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C O N T E N T S
1 GENERAL 2
1.1 SCOPE 2
1.2 CLASSIFICATION 2
2 APPLICABLE DOCUMENTS 3
3 CABLE HARNESS CONSTRUCTION 3
3.1 CABLES 4
3.1.1 MPPBF1 : 4
3.1.2 MPP2 : 5
3.2 CONNECTORS 6
3.2.1 Type II to PP1 (end inside the experiment detector) 6
3.2.2 Type III to PP3 (end outside the experiment detector) 6
3.3 SPLICING 7
3.3.1 Materials (heat shrinkable tubes): 7
3.3.2 Splicing procedure : 8
3.4 TESTING 9
3.5 MARKING 9
3.6 PACKAGING 9
4 QUALITY CONTROL 9
4.1 GENERAL 9
4.2 INSPECTION STAGES 10
4.2.1 Qualification inspection 10
4.2.2 Quality conformance inspection 10
4.2.3 Packing inspection 11
1 GENERAL
1.1 SCOPE
This specification concerns the realisation of cable harnesses, including cutting cables to specified lengths, supply and mounting of connectors, realisation of splicing connections, electrical and mechanical tests and marking.
1.2 CLASSIFICATION
All standardized cables at CERN have an internal reference known as the SCEM number.
SCEM / Designation04.70.07.010.0 / HARNESS CABLE II/III+CONNECTOR
2 APPLICABLE DOCUMENTS
This specification makes reference to the following publications :
CERN/FC/1814-II (1975) General conditions of CERN contracts
CERN/IS41 (1995) The Use of Plastic and other Non-Metallic
Materials at CERN with respect to Fire Safety
and Radiation Resistance
IEC 60189-1 (1992) Low frequency cables and wires with PVC
insulation and PVC sheath
Part 1: General test and measuring methods
IEC 60811 Common test methods for insulating and sheathing materials of electric cables
IEC 60885 Electrical test methods for electric cables
IEC 60885-1 (1987) Part 1 : Electrical tests for cables, cords and wires for voltages up to and including
450/750 V
3 CABLE HARNESS CONSTRUCTION
The cable harness is a composite system made of two cables assembled together with a splicing connection and defined connectors on both ends.
MPBF1 is a thin flexible cable that is intended to be installed inside the experiment detector, where space and radiation doses are critical. For this reason AWG20 wires are insulated with polyimide tape KAPTON 100 HN. The other wires are insulated with SILTEM STM 1500. The splicing connection and MPP2 part of the cable harness will be installed outside the detector
3.1 MPPBF1
Pos 1 / Quad of insulated wires
o 2 wires of AWG20
o 2 wires of AWG28 / Yellow, Red
Black, Green
Pos 2 / Quad of insulated wires
o 2 wires of AWG20
o 2 wires of AWG28 / Black, Green
Yellow, Red
Pos 3 / Twisted pair of AWG28 / Brown, Natural
Pos 4 / Twisted triple of AWG28 / Green, Natural, Brown
Pos 5 / Twisted triple of AWG28 / Blue, Green, Orange
Pos 6 / Drain wire of AWG24, non insulated / n.a.
Pos 7 / Shield of aluminium polyester tape in contact with the drain wire / n.a.
Pos 8 / Outer jacket / Red
Construction details :
4x AWG 20
Conductor : AWG 20, 19x0,20 mm tinned copper
Conductor diameter 1.0mm
Insulation : Polyimide tape KAPTON 100 HN
Nominal diameter 1.10 mm
2x(3x28)+4x28 AWG 50 V
Conductor : AWG 28, 7x0,127 mm tinned copper
Conductor diameter 0.39mm
Insulation : SILTEM STM 1500, nominal thickness 0,13 mm
Nominal diameter 0.64mm
2x 28 AWG 500 V
Conductor : AWG 28, 7x0,127 mm tinned copper
Conductor diameter 0.39 mm
Insulation : SILTEM STM 1500, nominal thickness 0,20 mm
Nominal diameter 0.79 mm
Overall Shield
Polyester tape 0,023 mm + Al/polyester tape 9/12 micron with tinned copper drain wire 7x0,20 mm in contact with Al. Nominal diameter 4.55 mm
Outer sheath
LSHF compound Megolon S304 , nominal thickness 0.4 mm
Colour red RAL 3000
Nominal diameter 5.40 mm (5.50mm max)
Electrical and physical characteristics
Electrical resistance at 20°
§ AWG 20 < 33.33 Ohm/km
§ AWG 28 < 222.22 Ohm/km
Test voltage 50V wires:
§ Conductors/conductors : 1kVac - 1min
§ Conductors/shield : 0,75 kVac -1min
Test voltage 500V wires :
§ Conductors/conductors : 1,5 kV ac - 1min
§ Conductors/shield: 1 kV ac - 1min
Other characteristics
Weight : 52.6 kg/km
Bending radius static : 45 mm
Working temperature range static : from -20 to +80°C
3.2 MPP2 :
Pos 1 / Quad of insulated wireso 2 wires of 1.0mm2
o 2 wires of 0.14mm2 / Blue, Red
White, Green
Pos 2 / Quad of insulated wires
o 2 wires of 1.0mm2
o 2 wires of 0.14mm2 / Grey/Black, Grey/Red
White/Brown, White/Blue
Pos 3 / Twisted pair of 2 wires of 0.14mm2 / White/Grey, White/Violet
Pos 4 / Twisted triple of 3 wires of 0.14mm2 / White/Black, White/Red, White/Green
Pos 5 / Twisted triple of 3 wires of 0.14mm2 / Yellow, Brown, Black
Pos 6 / Drain wire of 0.75mm2, non insulated / n.a.
Pos 7 / Flame retarding polyester-glass-fibre-polyester-tape / n.a.
Pos 8 / Shield of aluminium polyester tape in contact with the drain wire / n.a.
Pos 9 / Outer jacket / Grey
Construction details :
4x 1mm2
Conductor : 1 mm2, 19x0,25 mm tinned copper
Conductor diameter 1.25mm
Insulation : High density polyethylene, nominal thickness 0,375 mm
Nominal diameter 2.00mm
2x(3x0,14)+4x0.14 mm2 50 V
Conductor : 0.14 mm2, 7x0,16 mm tinned copper
Conductor diameter 0.48mm
Insulation : Hight density polyethylene, nominal thickness 0,25 mm
Nominal diameter 1.00mm
2x0.14 mm2 500 V
Conductor : 0.14 mm2, 7x0,16 mm tinned copper
Conductor diameter 0.48mm
Insulation : Low density polyethylene, nominal thickness 0,375 mm
Nominal diameter 1.25mm
Overall Shield
Polyester tape 0,023 mm + glass fibre tape + Al/polyester tape 25/23 micron with tinned copper drain wire 19x0,25 mm in contact with Al. Nominal diameter 7.60mm
Outer sheath
LSHF compound, nominal thickness 0.4 mm
Colour grey RAL 7035
Nominal diameter 10.40 mm
Electrical and physical characteristics
Electrical resistance at 20°
§ 1mm2 < 21.5 Ohm/km
§ 0.14mm2 < 142.86 Ohm/km
Test voltage 50V wires:
§ Conductors/conductors : 1kVac - 1min
§ Conductors/shield : 0,75 kVac -1min
Test voltage 500V wires :
§ Conductors/conductors : 1,5 kV ac - 1min
§ Conductors/shield: 1 kV ac - 1min
Other characteristics
Weight : 151.5 kg/km
Bending radius static : 65 mm
Working temperature range static : from -30 to +80°C
3.3 CONNECTORS
The harnesses will be fitted with following connectors :
3.3.1 Type II to PP1 (end inside the experiment detector)
o 20-position, double-row, right angle connector from JST (or equivalent if 100% identical and interchangeable) as signal, HV, shield & control line connector, composed of :
§ Housing part number : JST # SHDR-20V-S-B (1 mm pitch, double row, 20 circuit housing)
§ Header part number : JST # SM20B-SRDS-G-TF (1 mm pitch, double row, side entry, 20 circuits, shrouded header)
§ Crimp pins part number : JST # SSH-003GA-P0.2 (crimp pins for SHDR housing)
JST SM20B SRDS G TF1
2 / ILEDa (VCSEL) / Pos 4 / Green
3 / ClockSel / Pos 4 / Brown
4 / PinBias / Pos 5 / Green
5 / Reset / Pos 4 / Natural
6 / Temp1 / Pos 5 / Blue
7 / VddSense / Pos 1 / Black
8 / VddRet Sense / Pos 1 / Green
9 / VccSense / Pos 2 / Yellow
10 / VccRet Sense / Pos 2 / Red
11 / Drain / Pos 6 / n.a
12 / Temp2 / Pos 5 / Orange
13
14 / HV ret / Pos 3 / Brown
15
16
17
18
19 / HV / Pos 3 / Natural
20
o Right angle connector from FCI (or equivalent if 100% identical and interchangeable) as power line connector, composed of:
§ Housing part number : FCI # 65239-002
§ Header part number : FCI # 76383-302
§ Crimp pins part number : FCI # 76347-311
FCI 65239-002pin / pin / Line / wire group / color
2 / VccRet / Pos 2 / Black
1 / Vcc / Pos 2 / Green
4 / VddRet / Pos 1 / Yellow
3 / Vdd / Pos 1 / Red
3.3.2 Type III to PP3 (end outside the experiment detector)
o Combination of D-sub/mixed layout connector from CONEC (or equivalent if 100% identical and interchangeable). The connector is composed of :
§ Housing part number : CONEC # 3017W5PBK99A1OX (plug)
§ Header part number : CONEC # 131C11019X (plugs 4x: A1, A2, A3, A4) and CONEC # 132J14019X (socket: A5)
§ Crimp pins part number : CONEC # 13nC11019X (A1-A2-A3-A4) and CONEC # 13nJ11019X (location A5)
Combination of D-sub/mixed layout connector from CONEC
Type III (PP3 end)CONEC 17W5
pin / pin / Line / wire group / colour
A1 / Vdd / Pos 1 / Red
A2 / VddRet / Pos 1 / Blue
1 / VddSense / Pos 1 / White
7 / ClockSel / Pos 4 / White/Black
2 / Reset / Pos 4 / White/Red
8 / VCSEL / Pos 4 / White/Green
3 / VddRet Sense / Pos 1 / Green
9 / PinBias / Pos 5 / Yellow
4 / Temp2 / Pos 5 / Brown
10 / Temp1 / Pos 5 / Black
5 / VccSense / Pos 2 / White/Blue
11 / VccRet Sense / Pos 2 / White/Brown
6 / Drain / Pos 6 / n.a
12 / HV ret / Pos 3 / White/Violet
A3 / Vcc / Pos 2 / Grey/Red
A4 / VccRet / Pos 2 / Grey/Black
A5 / HV / Pos 3 / White/Grey
The state of the art rules shall be applied to ensure the electrical continuity, insulation resistance and dielectric strength. The insulation resistance and dielectric strength of the original cables and connectors must be guaranteed, referring to IEC 60189-1 sub clauses 5.2 and 5.3
3.4 SPLICING
The splicing connections shall be made between MPP2 cables and MPPF1 cable. These cables are supplied by CERN.
The overall diameter of the spliced section must not exceed 170% of cable section.
The splice should withstand a pull force of 100N without breaking single wires.
The insulation resistance and dielectric strength of the original cables must be guaranteed, referring to IEC 60189-1 sub clauses 5.2 and 5.3.
The splice joint shall add less than 10% to the total resistance of the cable harness.
3.4.1 Materials (heat shrinkable tubes):
The nominal radial thickness of the insulation shall be adapted to the required operating voltage (see sub-clause 3.2)
Since the installed cable harnesses will be exposed to ionizing radiation, it is important to keep the electrical and mechanical characteristics of the insulating material up to the expected accumulated dose of 200Gy.
The heat shrinkable tubes shall fulfil the CERN safety instruction IS41
3.4.2 Splicing procedure :
A) Strip the cables from the side where the insulation can be unwrapped easily, being careful not to tear it.
B) Thread the heat shrinkable sheath over the cable grey type III and over the red cable type II.
C) Unroll the shielding foil and place it behind the cables without cutting it.
D) Unroll and cut the paper tissue of the grey cable type III.
E) Cut the strings of the grey cable type III beginning at the edge of the shielding and thread the heat shrinkable sleeves in well defined way and then strip them until the plating is completely exposed. Thread an additional special heat shrinkable sheath over the HT strings.
F) Connect the two cables according to the colour reference table by cutting the red cable type II to the desired length and then pull the sleeves back.
G) Roll the two insulation foils together and solder the two ends together.
H) Wrap the two insulation foils around the strings starting with the red cable type II and scotch tape it.
I) Pull the heat shrinkable sheaths back, the assembly is done.
splice connection / Type II / Type IIIMPPBF1 / MPP2
Line / wire group / color / wire group / color
Vdd / AWG20 / Pos 1 / Red / Pos 1 / Red
VddRet / AWG20 / Pos 1 / Yellow / Pos 1 / Blue
VddSense / Pos 1 / White / Pos 1 / White
ClockSel / Pos 4 / Violet / Pos 4 / White/Black
Reset / Pos 4 / Red / Pos 4 / White/Red
VCSEL / Pos 4 / Dark blue / Pos 4 / White/Green
VddRet Sense / Pos 1 / Green / Pos 1 / Green
PinBias / Pos 5 / Yellow / Pos 5 / Yellow
Temp2 / Pos 5 / Brown / Pos 5 / Brown
Temp1 / Pos 5 / Black / Pos 5 / Black
VccSense / Pos 2 / Blue / Pos 2 / White/Blue
VccRet Sense / Pos 2 / Natural / Pos 2 / White/Brown
Drain / Pos 6 / n.a / Pos 6 / n.a
HV ret / Pos 3 / Pink / Pos 3 / White/Violet
Vcc / AWG20 / Pos 2 / Green / Pos 2 / Grey/Red
VccRet / AWG20 / Pos 2 / Black / Pos 2 / Grey/Black
HV / Pos 3 / Orange / Pos 3 / White/Grey
3.5 TESTING
Each cable harness shall be 100% tested prior to shipping:
o Insulation and dielectric strength
o Linear resistance
o Electrical continuity
o External dimensions
o Pull force test
A complete test report, according to DIN 50049 - 3.2C, shall be written for each cable harness. A copy of the test report shall be included in the packaging.
3.6 MARKING
Each cable harness end shall be labelled with unique labels supplied by CERN:
The labels A1 and A2 shall bear the same reference.
The cable harness number shall be referred in the individual test report.
3.7 PACKAGING
Each patch cable shall be individually packed. The packing must assure an effective protection against the wear and tear transport and handling damage. In order to facilitate the installation on site, cable harness shall be packed in a way that give easy access to the connector type II (end of MPPBF1) part as this shall be installed first.