Chiho Wang ATLAS TRTDuke University Dubna, May 2005

1

Fuse Box Production

Chiho Wang/Jack Fowler

Chiho Wang ATLAS TRTDuke University Dubna, May 2005

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

Chiho Wang ATLAS TRTDuke University Dubna, May 2005

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

Chiho Wang ATLAS TRTDuke University Dubna, May 2005

4

Old Fuse Box

GND jumper

GND jumperGND jumper

HV jumper

Mounting NutsSwitched to the other half in new design

Similar jumpers also needed for new fuse box

Chiho Wang ATLAS TRTDuke University Dubna, May 2005

5

HV Granularity & Current Draws

565-1087 μA/line

999-1253 μA/line498-735 μA/line

3 lines

3 lines

5 lines

Chiho Wang ATLAS TRTDuke University Dubna, May 2005

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.

Chiho Wang ATLAS TRTDuke University Dubna, May 2005

7

Front Side Connections

Nominal Fuse Box

Connection

Pattern repeats

in 4 modules interval

(i.e. every 2 sectors)

Connectors

Chiho Wang ATLAS TRTDuke University Dubna, May 2005

8

Connections & Naming Convention

Another table to map: straws fuse HV line !

Chiho Wang ATLAS TRTDuke University Dubna, May 2005

9

Production procedures

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

At Duke

manpower permitting

Chiho Wang ATLAS TRTDuke University Dubna, May 2005

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.