SOW: SR BPM flexible jumper cables

Release Date: Mar 30 2026 2:36:44 PM PDT

Document Number: AL-1881-8085 Revision: B

Document Status: Released

Document Type: PROJECT MANAGEMENT

Category Code: AL7002

ALS-U - GENERAL

PROJECT MANAGEMENT

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AL-1881-8085 Rev. B Doc. Status: Released Page 2 of 16

Advanced Light Source Upgrade Project Lawrence Berkeley National Laboratory

All officially released LBNL documents are watermarked and contain LBNL Document

Control Center release information in the lower-left corner of the document's pages.

Printed hard copies of this document are for reference only.

Table of Contents

Revision History

Approvals

Abbreviations and Acronyms

1 Introduction

1.1 Project Overview

1.2 Description and Requirements

1.3 Roles and Responsibilities

2 Scope of Work

3 Deliverables and Schedule

3.1 Deliverables

3.2 Schedule

3.3 First article

3.4 Production

The production shall not commence until LBNL approval of the first article has been granted.

The expected hold period is 12 weeks to allow LBNL to perform installation and inspection. .. 8

The cable length and quantity of the production batch will be established based on the evaluation results of the first article during the Hold Point

All production units shall undergo 100% testing in accordance with Section 8.3

3.5 Verification summary

4 Management

4.1 Reporting/Communication requirements

4.2 Documentation requirements

4.3 Reviews

4.4 Hold points and what’s required

5 Engineering

5.1 General engineering requirements

5.1.1 The supplier shall provide/supply/manufacture/fabricate

6 Fabrication (as applicable)

6.1.1 Build per LBL-xxx process, industry spec., etc

6.1.2 Special production instructions

7 Shipping, Handling, and Storage

7.1 Packaging

8 Quality Assurance ci al ly R el ea se d

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8.1 Quality reporting requirements

8.1.1 Subcontractor Quality program

8.1.2 Deviation requests

8.1.3 Nonconformance reports

8.2 Work Instructions

8.3 Factory Inspection and Test Plan

8.4 ACL upon receipt at LBL

9 Applicable Documents

10 References

Appendix A: Verification Table

(To be completed by delivery date)

Appendix B:

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REVISION HISTORY

Rev. CM Number Description of Change A Initial Release B Update the procurement option for production batch

APPROVALS

The following individual(s) shall approve this document:

Approver Project Role Changchun Sun CAM Alessandro Ratti Electrical System Lead Jiani Niu Q&A Manager Windchill Approved / Concurred By jianiniu,aratti

ABBREVIATIONS AND ACRONYMS

ALS Advanced Light Source ALS-U Advanced Light Source Upgrade LBNL Lawrence Berkeley National Laboratory University The Regents of the University of California ci al ly R el ea se d

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1 INTRODUCTION

1.1 Project Overview

ALS-U is an upgrade project to the LBNL Advanced Light Source (ALS). The ALS will be upgraded with a Multibend Achromat (MBA) lattice design to provide a soft x-ray source with orders of magnitude increase in brightness and coherence.

This SOW defines the procurement of critical Beam Position Monitor (BPM) jumper cable assemblies required for the upgraded Storage Ring (SR). These coaxial cables are essential for transmitting high-frequency signals from BPM pickups with minimal loss and distortion, ensuring accurate beam position measurement.

1.2 Description and Requirements

The purpose of this SOW is to define the requirements for the supplier to manufacture, test, and deliver a total of about 1,068 high-frequency, flexible LMR195 coaxial cable assemblies with straight angle SMA(M) connectors for the ALS-U Storage Ring BPM system. This BPM jumper cable assembly must meet the following project-specific requirements:

• Precisely controlled impedance (50 ohms) and phase matching (+-10 picosecond) to support BPM measurement accuracy

• Low insertion loss at required operating frequencies 0.05 – 18 GHz to maintain signal integrity (S21 > 0.94 and +- 0.0015 at 500MHz)

• Straight SMA(M) connectors on both ends

• Mechanical flexible and dimensional tolerances compatible with limited space constraints

1.3 Roles and Responsibilities

• University Procurement Representative: See subcontract for details.

• University Technical Representative: See subcontract for details.

• Supplier Project Manager: The selected subcontractor shall identify a single point of contact to interface directly with the LBNL Technical Representative for all technical, programmatic, and schedule matters.

2 SCOPE OF WORK

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The supplier shall manufacture, assemble, test, label, document, and deliver the LMR-

195FR cable assemblies with SMA(M) straight connector as specified herein and in the attached Applicable Documents. The scope includes:

• Production of three cable assembly types with different lengths (phase-matched to ±10 ps).

• Sourcing and use of LMR-195 FR flexible coaxial cable conforming to industry standards.

• Sourcing and use of straight SMA(M) connectors at both ends, rated for the required frequency range.

• Heated shrink tubing applied to both ends to provide strain relief and environmental protection.

• A color coded permanent label sleeve shall be installed on both ends, positioned

50 mm away from the end of the heated shrink tubing. The label shall contain the assembly Part Number and a unique serial number (e.g., LMR195-2.0FT-R-

0001).

• Performing 100% production testing per the attached Acceptance Criteria List

(ACL).

• Providing all required test and inspection results together with final cable delivery.

Item Name Marker 1 Marker 2 Length (FT)

LMR195-2.0FT

LMR195-2.0FT-C-xxxx

Same as label 1 2.0 +- 10 ps

LMR195-2.5FT LMR195-2.5FT-C-xxxx Same as label 1 2.5 +- 10 ps

LMR195-3.5FT LMR195-3.5FT-C-xxxx Same as label 1 3.5 +- 10ps

LMR195-(Length)FT LMR195-(Length)FT-C-xxxx Same as label 1 3.5 +- 10ps ci al ly R el ea se d

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Note: Labels should have black text printed on color-coded heat shrink sleeves:

Blue, Red, Green, and White, represented by the letters “B,” “R,” “G,” and “W” respectively. Each label’s format is Item-C-XXXX, where C is the color code and

XXXX is the serial number, starting at 0001 and incrementing sequentially for each color. Each item shall be supplied in four colors, with equal quantity for each color.

3 DELIVERABLES AND SCHEDULE

Item No.

Item Name Qty Delivery Schedule

1 LMR195-2.0FT 60 First article, within 8 weeks ARO or sooner

LMR195-2.5FT 16 First article, within 8 weeks ARO or sooner

LMR195-3.5FT 8 First article, within 8 weeks ARO or sooner

4 LMR195-(Length)FT (Option)

984 Production, within 8 weeks upon the first article approval

Note: The quantity listed in the table for each item represents the total number of cables, which are divided into four color-coded groups: Blue (B), Red (R), Green (G), and White (W). Each color group must contain the same number of cables. To determine the quantity for each color, divide the total number of cables by four.

3.1 Deliverables

The primary deliverables consist of 1,068 cable assemblies that have been tested and accepted. Deliveries will be made in two separate batches. Supporting deliverables include test results and shipping documentation.

3.2 Schedule

• Line Items 1, 2 and 3 shall be delivered within 8 weeks ARO or sooner as the first article delivery

• Line Item 4 corresponds to Production batch. The scope will be selected from the

Option Table below based on the installation and testing results from the Hold

Point. The total quantity for the selected options shall be 984 units. The selected options shall be delivered within eight (8) weeks following completion and approval of Hold Point.

• Hold Point (expected to be 12 weeks) is established at completion of the first article delivery in accordance with Section 4.4.

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Option Table for Production Batch

Options Length Qty

1.5Ft – 2.0FT

0-100 101-200 201-300 301-400 401-500 500+

2.0FT – 2.5Ft

0-100 101-200 201-300 301-400 401-500 500+

2.5Ft – 3.0FT

0-100 101-200 201-300 301-400 401-500 500+

3.0FT- 3.5FT

0-100 101-200 201-300 301-400 401-500 500+

3.5FT-4.0FT

0-100 101-200 201-300 301-400 401-500 500+

3.3 First article

The first article is required for the production order. The supplier shall inspect and test all unit of each part number against all requirements of this SOW. The first article and associated test results shall be delivered to LBNL for review. The first article must be approved in writing by the LBNL Technical and QA representatives before the final production proceeds.

3.4 Production

The production shall not commence until LBNL approval of the first article has been granted. The expected hold period is 12 weeks to allow LBNL to perform installation and inspection.

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The cable length and quantity of the production batch will be established based on the evaluation results of the first article during the Hold Point.

All production units shall undergo 100% testing in accordance with Section 8.3.

3.5 Verification summary

At the time of delivery, the supplier shall follow the instructions in Appendix A; print and complete the table with the correct information. Attachments may be added if needed for further explanations.

4 MANAGEMENT

4.1 Reporting/Communication requirements

• Submission & Review: Test results shall be delivered to LBNL, followed by a review meeting if discrepancies are found.

• Regular Updates: Monthly email updates from the supplier's Project Manager to the LBNL Technical Representative, summarizing progress against schedule and highlighting any issues.

• Final Delivery Notification: Immediate notification upon shipment, with tracking information and electronic copies of shipping documents.

4.2 Documentation requirements

Upon subcontract award, a Windchill Project portal will be established by LBNL and access provided to the subcontractor. Windchill will be used as the repository for all documentation, QA data, certificates of conformance, test results, models, and drawings.

An electronic copy of all required documentation as noted in this document is required and shall be transmitted to LBNL via the designated Windchill portal. LBNL document

AL-1265-6612: ALS-U BUILD TO SPECIFICATION CAD MODEL AND DRAWING

REQUIREMENTS, identifies the acceptable file formats and requirements for the final drawings and CAD models.

Acceptable document formats include .docx, .xlsx, and other editable Office file formats or as noted in this document.

4.3 Reviews

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The first batch production review is required. The LBNL Technical Representative will review the submitted first batch documentation and provide written approval or comments.

The LBNL technical representative will work with the sub-contractor to establish an appropriate timeline and location for all reviews. Reviews may be conducted at either the subcontractor’s or the LBNL site or via web/video conference tools. External, non-

LBNL reviewers may be included at LBNL’s discretion.

4.4 Hold points and what’s required

Written approval from LBNL is required to proceed beyond any identified hold points.

Hold Point: Production Release

• Location: After the first article delivery completion, prior to the final production.

• Period: LBNL is expected to require up to 12 weeks to inspect and test the first article

• Requirement: Written approval from the LBNL Technical Representative with selected cable length and quantity

5 ENGINEERING

5.1 General engineering requirements

Document Number

Title

Vendor specified Vendor specified

Vendor shall supply a detailed engineering specification and document for cable and connector assembly for review before the production

5.1.1 The supplier shall provide/supply/manufacture/fabricate

The cable assemblies as described in this SOW and the attached Applicable Documents.

6 FABRICATION (AS APPLICABLE)

6.1.1 Build per LBL-xxx process, industry spec., etc.

• Cable assemblies shall be built per vendor internal standards.

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• Bulk cable shall be procured and shall conform to standard RF cable requirement.

• Cable connector shall be procured and shall conform to the standard SMA connector

6.1.2 Special production instructions

• Labeling: Each assembly shall have two permanent color coded heat shrink label, located at 50 mm from the end the heated shrink tubing. The label shall contain the assembly Item Number and a unique serial number.

• Material: supplier specified.

• Length: Assemblies shall be measured and verified center line to center line.

7 SHIPPING, HANDLING, AND STORAGE

7.1 Packaging

Standard packaging is acceptable. Assemblies must be packaged to prevent physical damage, connector crushing, or bending beyond the cable's minimum bend radius during transit.

8 QUALITY ASSURANCE

8.1 Quality reporting requirements

8.1.1 Subcontractor Quality program

The subcontractor shall complete the ALS-U Supplier Quality Evaluation Survey (AL-

1208-0209).

The subcontractor shall maintain and apply an effective QA program for the design, manufacture, testing of all systems and equipment provided

Post-award surveys may be required and shall be supported.

The supplier's quality program is referenced in their Quote and Terms and Conditions

8.1.2 Deviation requests

Any deviations from the dictating LBNL documents must be requested by the subcontractor and approved by LBNL prior to implementation. LBNL will provide a ci al ly R el ea se d

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Deviation requests apply to requests to modify processes or documented drawings.

Deviation requests DO NOT apply to hardware that is built and does not conform to the specification.

Any proposed deviation from this SOW or its Applicable Documents requires a written request and LBNL's written approval prior to implementation.

8.1.3 Nonconformance reports

A nonconformance report provides a summary for products or procedures which do not conform to the defined requirements. Nonconformances may be determined and reported by either the subcontractor or LBNL staff. LBNL will provide a standard nonconformance report form however, a subcontractor’s existing or internal document may be utilized with LBNL approval. Nonconformance reports are to be submitted to

LBNL within 3 business days of the identification.

Nonconformance reports apply to hardware that is built and does not conform to the specification(s). LBNL will provide a written disposition establishing a path forward for each nonconformance. No operations may be performed on the nonconforming item without LBNL’s written disposition or approval to proceed.

Any unit failing the tests in the ACL (Section 8.3) shall be documented on a

Nonconformance Report (NCR). NCRs shall be submitted to LBNL within 3 business days of identification. No disposition (rework, scrap, use-as-is) shall be executed without LBNL's written approval.

8.2 Work Instructions

The supplier shall use their own work instructions for assembly and testing, provided they meet the requirements herein.

8.3 Factory Inspection and Test Plan

The supplier shall perform and document 100% testing of every cable assembly per the following sequence, as detailed in table:

• Visual/Label Inspection: Verify correct labeling.

• Length Verification: Measure using TDR.

• S21 (Insertion Loss) Measurement: Measure using VNA across 0.05-18 GHz.

• Connector/Termination Quality: Verify using TDR for impedance integrity ci al ly R el ea se d

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ITE

M

NO.

CHARACTERISTIC OR

TEST TO BE

CONDUCTED, VERIFIED

or WITNESSED

VERIFYING

ENTITY

VERIFICATION

REPORT/ INSPECTION

DATA

1.

Visual inspection:

Check if the cables are correctly labeled and match specifications

Check there is no damage to the cable

Vendor

2.

Measure the length with TDR.

The length shall be within +-10 ps

Vendor

3.

Measure S21 coefficient with

VNA. Shall be >= 0.94 and +-

0.0015 at 500 MHz

Vendor

4.

Verify connector type. Measure connector and termination quality with TDR. Shall be no fault

Vendor

The subcontractor shall provide an Inspection and Test Plan which shall be submitted to the LBNL technical representative for written approval by ALS-U Quality Assurance prior to its required use.

This Inspection and Test Plan shall consist of a plan in the subcontractor’s format listing components, subassemblies, and assemblies; identifying inspections and tests planned for the verification of quality; and identifying documentation/planning for recording the results.

8.4 ACL upon receipt at LBL

The ACL (AL-1887-9968) will be used by LBNL to evaluate and accept all deliverables.

9 APPLICABLE DOCUMENTS

This section identifies applicable documents that are considered to be a part of this document. All information contained in an applicable document shall be valid to the full extent, unless specifically noted within this document. Applicable documents shall be obtained from the LBNL Document Control Center (DCC).

Document Number

Title

AL-1887-9968 SR BPM Flexible Jumper Cable Acceptance Criteria List (ACL).

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10 REFERENCES

Documents listed in this section are considered reference documents that can be used to better describe, clarify intent, or provide information where the information was obtained from.

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APPENDIX A: VERIFICATION TABLE

(To be completed by delivery date)

This appendix summarizes the final set of subcontractor deliverables which are due to LBNL in addition to the other deliverables listed in section 3 above. It is the lab’s expectation that as a final action, the subcontractor will print out this page, and complete the “Complete? (Y/N)” column as part of the completed delivery package. For any “N” (no) response, an explanation in the comments section below shall be provided as to why that deliverable is not complete. It is then up to LBNL to accept the deliverable as is through a waiver, or work with the subcontractor for completion of the task before acceptance of the final delivery.

Item Section Item Complete?

(Y/N)

1 5.1 Engineering specification and document

2 8.3 Test report of each cable x N/A

All Government Furnished Property (GFP) and/or materials purchased by LBNL for this project have been returned to and received by LBNL

Comments:

Attachments:

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APPENDIX B:

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