100 Quadrupole Quadrant 4 Coil Prep Traveler

TD / Process Engineering Specification # 5520-TR-333675

January 29, 2007

Rev. I

f / Fermi National Accelerator Laboratory
Batavia, IL 60510
FERMI MAIN INJECTOR
116” QUADRUPOLE POTTED COIL
MAIN COIL w/TRIM COIL
INSULATION/ASSEMBLY
Reference Drawing(s):
116” Quadrupole Coil Assembly Quadrant #1 ME-388323
116” Quadrupole Coil Assembly Quadrant #2 ME-388324
116” Quadrupole Coil Assembly Quadrant #3 ME-388325
116” Quadrupole Coil Assembly Quadrant #4 ME-388326
Project # Task #: «ProjectTaskNo» / Job #: «JobNo»
Released by: «ReleasedBy» / Magnet/Device Series: «Series»
Date: «ReleasedDate» / Scan Pages:

Prepared by: B. Jensen

Title / Signature / Date
TD / Process Engineering / Bob Jensen
Bob Jensen / Designee / 1/29/07
TD / MS Production Supervisor / Dan Smith
Dan Smith / Designee / 1/31/07
TD / MS Production Engineer / Bill Robotham
Bill Robotham/ Designee / 1/30/07
TD / MS Production Physicist / Dave Harding
Dave Harding / Designee / 2/14/07

Revision Page

Revision / Step No. / Revision Description / TRR No. / Date
None / N/A / Initial Release / N/A / 6/26/02
A / 3.2 / Modify the Quad Filler. / 1501 / 9/27/02
4.1 / 2 / Combined Steps.
4.6 / 4.7 / Moved to Coil Impregnation traveler.
B / 4.4 / Only Apply Mylar to the ends of the coil. / 1518 / 11/15/02
C / 4.2 / Only apply 2 layers half lap fiberglass insulation for ground wrap. / 1621 / 3/26/04
D / CvrPge / Updated Cover Page to reflect department name change. / 1846 / 8/29/06
All / Rewrote entire traveler using WQB Coil Insulation/Assembly traveler as base line. Rev C traveler lacked clarity.
E / 3.4 / Update: Drawing for 0.005 x 0.500” changed from and end view to a top view / 1849 / 9/11/06
3.7 / Update: Use of Filler Quad G-10 pieces are not to be used and replace w/cord
3.7 / Moved: Step now is Step 3.9
3.12 / Deleted: Step to be moved to TR-333828.
3.18 / Updated: ‘with grease’ and Note to be moved to TR-333828..
3.19 / Updated: ‘onto the Ceramic Block’ removed from step now done TR-333828.
F / 4.0 / Added: Electrical Check prior to ground wrap. / 1857 / 9/15/06
6.0 / Updated: Changed parameters for Trim Coil electrical resistance measurement per DR4370
G / 4.2 / Update: Electrical Tables to remove Trim Coil Ls@1KHz limits / 1870 / 10/16/06
6.2 / Update: Electrical Tables to remove Trim Coil Ls@1KHz limits
H / 3.4 / Corrected: Typo on Dwg numbers; 333826 should be 388826 / 1877 / 11/29/06
I / 5.4 / Updated: Instructions and dwg to clarify trim coil lead routing and hookup. / 1895 / 1/29/07
5.5 / New: Step added to have Lead Person verify trim coil lead routing

Ensure appropriate memos and specific instructions are placed with the traveler before issuing the sub traveler binder to production.

1.0 General Notes

1.1 White (Lint Free) Gloves (Fermi stock 2250-1800) or Surgical Latex Gloves (Fermi stock 2250-2494) shall be worn by all personnel when handling all product parts after the parts have been prepared/cleaned.

1.2 All steps that require a sign-off shall include the Technician/Inspectors first initial and full last name.

1.3 No erasures or white out will be permitted to any documentation. All incorrectly entered data shall be corrected by placing a single line through the error, initial and date the error before adding the correct data.

1.4 All Discrepancy Reports issued shall be recorded in the left margin next to the applicable step.

1.5 Cover the coil assembly with green Herculite (Fermi stock 1740-0100) when not being serviced or assembled.

2.0 Parts Kit List

2.1 Attach the completed Parts Kit List to this traveler. Ensure that the serial number on the Parts Kit List matches the serial number of this traveler. Verify that the Parts Kit received is complete.

Process Engineering/Designee Date

3.0 Conductor Wrap Procedure

3.1 Spread the conductor apart in the coil wrapping room using approved methods.

Note: Ensure the coil is properly supported from collapsing while spread apart.

Technician(s) Date

3.2 Clean the coil conductor using approved methods to remove contaminants and is free

of burrs, nicks, etc., in the conductor.

Technician(s) Date

X 3.3 Perform a visual to ensure conductor is clean of contaminants and is free of burrs, nicks ,etc

Inspector Date

3.4 Apply one layer half-lapped 0.007” X 1” Fiberglass tape (MA-116511) conductor insulation

as per Dwg ME-388323/388324/388325/388826. During the conductor Insulation, install one strip

of 0.007” x 0.500” fiberglass tape (MA-274977) between the inside straight conductors along the length of the coil to within 1” of the radius bends on the ends using approved installation procedures.

Note: 0.500 Fiberglass tape can be place on the coil and wrapped into the conductor wrap

or place on top of the conductor wrap.

Technician(s) Date

3.5 Return the coil to original winding condition. Clamp the coil windings together using

approved methods.

Technician(s) Date

3.6 Perform a Main Coil pre-ground wrap electrical inspection.

Electrical Test / Equipment Serial Number / Limit / Actual Measurement / Pass / Fail / Out of Tolerance
Coil Resistance / 1.39 to 1.54 mW / mW
LS @ 1 KHz / 32 to 37 mH / mH
Q @ 1 KHz
LS @ 100 Hz / mH
Q @ 100 Hz
100 V Ring

Inspector Date

3.7 Record the Trim Coil Serial Number below. If you are doing either a 1M or 3M Main coil,

the Trim Coil must have a 1T in the serial number. If you are doing either a 2M or 4M Main

coil, the Trim Coil must have a 2T in the serial number.

Trim Coil Serial Number

Technician(s) Date

3.8 Install the Trim Coil onto the Main Coil with Main Coil using Sicomet (MA-274442)

or approved equivalent. Both Trim Coil Leads and Main Coil Leads must be together on

the same end. Using approved clamping methods to ensure a tight bond between the Main Coil

and the Trim Coil.

Note: Trim Coil should be aligned with the Main Coil outer edge, as shown below.

Technician(s) Date

4.1 Pre-Ground Wrap Electrical Check

4.1 Perform a Pre-Ground wrap Coil electrical inspection of the Main Coil.

Main Coil

/ Serial Number / Limit / Actual Measurement / Pass / Fail / Out of Tolerance
Resistance / 1.39 to 1.54 mW / mW
LS @ 1 KHz / 32 to 37 mH / mH
Q @ 1 KHz / For reference only
LS @ 100 Hz / For reference only / mH
Q @ 100 Hz / For reference only
Ring Test @ 100 volts
Hipot Main to Trim Coil / < 5 µA @ 500 V / µA

4.2 Measure the Trim Coil resistance with the temperature compensator turned OFF. Measure the Trim

Coil temperature (oC) and perform the below calculation to acquire a corrected resistance measurement.

Perform other measurements with the Equipment Temperature Compensator turned ON.

Note: This measurement temperature compensation process only applies to resistance for

the IQx Trim Coils.

R = R (actual measurement)[1 + 0.0039 (25oC – Temperature (initial)]

Electrical Test / Equipment Serial Number / Limit / Actual Measurement / Coil
Temperature / Calculated
Measurement / Pass / Fail
Resistance / 695 - 720 mΩ / mΩ / oC / mΩ
Ls @ 1 KHz / mH
Q @ 1 KHz / For reference Only
Ls @ 100 Hz / For reference Only / mH
Q @ 100 Hz / For reference Only
100 Volt Ring

Inspector Date

5.0 Main Coil w/Trim Coil Assembly Ground Wrap

5.1 Using Fiberglass Cord 0.125” diam (MA-292474) fill the area between the Trim Coil

Radius and the Main Coil Radius as shown below.

Technician(s) Date

5.2 Apply two layers half-lapped 0.007” X 1” Fiberglass tape (MA-116511) ground wrap onto

the main coil

Note: Approved Fiberglass Tape 0.007” x 2” wide (MD-225574) is permissible in

the straight section of the coil.

Technician(s) Date

5.3 Clean the Ceramic Block (MA-388614) with KPC 820N (Fermi stock 1920-0705) (or equivalent)

and Heavy Disposable Wipers (Fermi Stock 1660-2600 or equivalent).

Technician(s) Date

5.4 Dry Fit, Route and attach Trim Coil Leads (Outer Lead (OL)) and Inner Lead (IL)) into the Ceramic Block as shown below and as per Dwgs ME-388323 Page 2, ME-388324 Page 2,

ME-388325 Page 2, and ME-388326 Page 2. Cut and remove excess Trim Coil lead as necessary to keep Trim Coil leads as short as possible.

Note: Ensure a coating of approved grease has been applied to the clamping screws

in Ceramic Block before attaching the Trim Coil leads to the Ceramic Block.

Note: Indicate above which quadrant coil was completed by either

circling or highlighting.

Technician(s) Date

5.5 Verify Trim Coil Leads (Outer Lead (OL)) and Inner Lead (IL)) are routed to the Ceramic

Block properly.

Lead Person Date

5.6 Attach the Ceramic Block to the Main coil lead and coil insulation using Sicomet (MA-274442)

as shown below. Use approved clamping methods to ensure proper fit with no gaps between

the Ceramic Block and the Main Coil

Technician(s) Date

5.7 Apply Red Mold Release (MA-292449) to the Trim Coil Tooling Shim (MA-445349). Install Trim Coil Shim along the length of the trim coil as shown below.

Note: Ensure Trim Coil Tooling Shims DO NOT OVERLAP each other.

Technician(s) Date

5.8 Apply half-lapped 0.002” X 2”wide Tedlar (MA-116528) to the entire coil package.

Note: Ensure Tedlar has been perforated to allow epoxy to saturate the fiberglass during Impregnation.

Technician(s) Date

X 5.9 Verify that Tedlar Tape has been applied and applied correctly.

Lead Person Date

5.10 Insert copper or steel rods and secure them into the Ceramic Lead Block.

Technician(s) Date

5.11 Apply Teflon Tape 0.0035” x 2” (MA-274469) to the area around the Ceramic Block.

Note: Leave access for Electrical measurement equipment test leads.

Technician(s) Date

6.0 Post Insulation Electrical Check

6.1 Perform a Final Insulated Coil electrical inspection of the Main Coil.

Main Coil

6.2 Measure the Trim Coil resistance with the temperature compensator turned OFF. Measure the Trim

Coil temperature (oC) and perform the below calculation to acquire a corrected resistance measurement.

Perform other measurements with the Equipment Temperature Compensator turned ON.

Note: This measurement temperature compensation process only applies to resistance for

the IQx Trim Coils.

R = R (actual measurement)[1 + 0.0039 (25oC – Temperature (initial)]

Inspector Date

7.0 Production Complete

7.1 Process Engineering verify that Traveler is accurate and complete. This shall include a review of all steps to ensure that all operations have been completed and signed off. Ensure that all Discrepancy Reports, and dispositions have been reviewed by the Responsible Authority for conformance before being approved.

Comments:

Process Engineering/Designee Date

IQD 116” Quadrupole Potted Coil Insulation/Assembly

Coil Serial No. «SerialNo»-«ReworkID»

Notes: «Notes»

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