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Fuse Box Production Chiho Wang/Jack Fowler

Fuse Box Production Chiho Wang/Jack Fowler. Fuse Box Assembly. 1 fuse box “set” supplies HV to 1 “stack” of 3 modules. 32 + 3 (10% spare) = 35 “sets” of fuse boxes to be made. Each fuse box “set” consists of 6 fuse boxes: 2 of each module type 22 HV coax cables:

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Fuse Box Production Chiho Wang/Jack Fowler

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  1. Fuse Box Production Chiho Wang/Jack Fowler

  2. Fuse Box Assembly • 1 fuse box “set” supplies HV to 1 “stack” of 3 modules. • 32 + 3 (10% spare) = 35 “sets” of fuse boxes to be made. • Each fuse box “set” consists of • 6 fuse boxes: 2 of each module type • 22 HV coax cables: • 6 for type 1 : 3 HV lines / box • 6 for type 2 : 3 HV lines / box • 10 for type 3 : 5 HV lines / box • 1 HV connector: 51-pin: • 22 HV + 22 ground + 2 interlock + 1 case ground + 4 empty

  3. What to assemble in the fuse box • Circuit boards = 2 per fuse box • Spring contacts = (# fuses) + (4 ground contacts/box) • Filter circuits: • 1 per HV line = 2 x 1kΩ Resistors + 1 x 870pF Capacitor • Mounting nuts (Ultem) = 2 per fuse box • Fuses: (contain extra fuses due to symmetry) • Type 1: 44 fuses/module (22/box), 42 in use. • Type 2: 68 fuses/module (34/box), 65 in use. • Type 3: 104 fuses/module (52/box), 100 in use • Total (for 35 sets) = 7560 + spare • Jumpers • 1 ground jumper between halves. • 1 HV jumper between halves, for type 2 and type 3 only • HV cables

  4. Old Fuse Box GND jumper GND jumper GND jumper HV jumper Mounting Nuts Switched to the other half in new design Similar jumpers also needed for new fuse box

  5. HV Granularity & Current Draws 498-735 μA/line 999-1253 μA/line 565-1087 μA/line 3lines 3lines 5lines

  6. Implementation • For each type of module: • 1 type of fuse box • 1 length of cable • Applies to (4 HV Kapton positions) x (4 connector locations). • Neighboring modules are supplied from opposite ends • Odd # modules from side A (back side) • Even # modules from side C (front side) • The HV cable is made long enough to swing to neighboring modules in case switching side is necessary.

  7. Front Side Connections Nominal Fuse Box Connection Connectors Pattern repeats in 4 modules interval (i.e. every 2 sectors)

  8. Connections & Naming Convention Another table to map: straws  fuse  HV line !

  9. Mark/label fuse box Glue circuit board to fuse box Use high temperature RTV. Along the front edge of ckt to prevent flux from flowing under circuit board. Place components on ckt board and oven solder them. Spring contacts + filter resistors + filter capacitors. Spring contacts are clamped in place in soldering process. Clean fuse box Glue mounting nuts Tape together 2 halves of fuse boxes Solder fuses by hand In case of resistor substitute may use oven soldering. Clean fuse box(?) Solder HV cable by hand Solder jumper wires by hand Clean fuse box Spot glue HV cable & jumper wires for strain relief Bake/dry fuse box right before coating Coat fuses & wires with conformal coating Label HV cables Cut HV cable to length and attach connector Production procedures At Duke manpower permitting

  10. Parts Status • G10 boxes: 16 modules/type in hand, ~ end of May • Circuit boards: in hand • Spring pins: in hand, need cutting, bending • Filter resistors + capacitors: in hand • Mounting nuts: ½ in hand, ½ to be made • Fuses: under production • (Substitute resistors: ordered) • HV Cable: available from Herve. • HV Connectors: in hand • Ultem screws: in hand • Mounting brackets: quoted, placing order.

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