Fuse Box Layout Dukhep-2004-12-13 Duke Atlas Group 1. Overview In the barrel TRT, high voltage is connected to the module through an external connector assembly called "fuse box" which includes filter circuits, fuses and spring contacts for connection to the HV kapton on the module. A module has 2 HV kaptons on each end to receive high voltage from the fuse boxes. In the installation only one end of the HV kaptons are connected to "real" fuse boxes. The other end of the HV kaptons are connected to "dummy" fuse boxes made of empty FR-4 cases only for HV protection. Real and dummy fuse boxes alternate for neighboring modules. In practice, even number modules on BSS receive HV from the C (front) side and odd number modules receive HV from the A (back) side. However, if the HV kapton developed problem one has the option to switch neighboring fuse boxes / dummy fuse boxes and change the HV feed direction. Figure 1 is an illustration of the fuse box circuit. Fuse Box 1K Space Frame 820pF Straws 820pF Space Frame HV Coax cable 820pF 1K 1K Electronics Tension Plate GND Tension Plate GND Electronics 820pF 1K GND Shield HV Trace HV Kapton 4.7K Module 4.7K Fuse Figure 1 In addition to the fuse box construction, the connection for PPB1 in the experiment must be added at the opposite end of the HV coax cable from the fuse boxes. In construction, each type of module has only one design of fuse box made to fit all 4 possible positions of the HV kapton. With HV cables attached, the symmetry 1
of the fuse box becomes rotational rather than mirror image. The 6 fuse boxes for a stack of 3 modules are grouped to form one "fuse box set" and share one HV connector that plugs into PPB1. For the entire barrel, there are 32 identical fuse box sets, 16 in the front side (Side C) and 16 in the back side (Side A). 2. Design Considerations The fuse boxes will be designed in order to provide high voltage to the barrel modules. Nominal voltage is 1450 V but the boxes will be tested to 2 kv. Also the leakage current has to be minimized. This is to be less than 50 na per HV trace. The boxes and their components are expected to last for the life of the Atlas experiment. This is expected to be 10 years. The HV granularity will be determined based on the following constraint. Each HV coax cable will be connected to a dedicated HV power supply. The current limit for these power supplies is 1.5 ma. So this sets the limit for the number of HV islands that can be connected to one cable. Addendum A shows the current of each of the HV islands at nominal operating conditions. These current values were established by simulation. Below is a table that summarizes the current for each of the HV coax cables. The cable designations and locations are covered later in this report. Module Type Side A Cable Side C Cable Total Current (µa) # HV islands connected M1C1-Px M1A1-Px 1086.83 9 M1C3-Px M1A2-Px 564.78 6 M1C2-Px M1A3-Px 761.03 6 1 M1D1-Px M1B1-Px 961.91 9 M1D2-Px M1B2-Px 580.77 6 M1D3-Px M1B3-Px 830.87 6 M2C1-Px M2A1-Px 1019.34 10 M2C2-Px M2A2-Px 1249.65 12 M2C3-Px M2A3-Px 999.35 10 2 M2D1-Px M2B1-Px 1252.87 12 M2D2-Px M2B2-Px 1141.03 11 M2D3-Px M2B3-Px 1020.38 10 M3C2-Px M3A1-Px 704.17 10 M3C1-Px M3A2-Px 497.42 10 M3C4-Px M3A3-Px 712.99 10 M3C3-Px M3A4-Px 497.93 10 M3C5-Px M3A5-Px 576.49 10 3 M3D2-Px M3B1-Px 735.33 10 M3D1-Px M3B2-Px 534.72 10 M3D4-Px M3B3-Px 730.67 10 M3D3-Px M3B4-Px 519.91 10 2
The number of straws per HV island is normally 8. There are 7 islands in type 1 and 7 islands in type 3 with only 7. The maximum current on any of the HV power supplies is 1.3 ma, for the groupings of HV islands listed above. 3. Production The production of the fuse box will be performed at Duke University. Below you will see a detailed list of the production steps. The quality control and tests steps are shown in italics. 1. Attach & glue circuit board in FR-4 casing with high temperature glue 2. Place filter capacitors, resistors and spring contacts in fuse box 3. Apply solder flux (EFD's # 62RMA-A) and heat in oven to solder. 4. Solder fuses (by hand): a. Cut fuse legs to length b. Tin legs with solder (rosin RA flux, Newark part # 35C0605) c. Solder fuse into fuse box at spring contact and the circuit trace d. Check fuse resistance (continuity) from circuit board trace to spring contact 5. Solder HV coax cable into fuse box 6. Check HV connections: a. Continuity test: apply 100V from end of HV coax cable and check voltage at spring contact b. HV stability: apply 2000V from end of Hv coax cable and check for HV trip. 7. Glue HV coax cable to fuse box for strain relief (AY103) 8. Clean fuse box: a. In ultra-sound cleaner with "Flux-Off Aqueous", from ITW Chemtronics, 5 min b. Rinse twice with distilled water. c. In ultra-sound cleaner with distilled water, 5 min. d. Allow fuse boxes to dry. 9. Check fuse resistance circuit board trace to spring contact 10. Bake in oven for > 3 hours at < 50C-55C 11. Coat the components with Hysol (toluene diluted 50-50) within 1 hour after baking. Take care not to coat the contacts. 12. Final test: a. Visual inspection b. Ground connections from end of HV coax cable to fuse box circuit board trace c. HV connections: apply 100V from end of HV coax cable and measure voltage at fuse box spring contact d. HV stability: apply 2000V from end of HV coax cable and look for HV trip 13. Apply color coded heat shrink to the HV coax cables to mark the cables. This is to simplify the cable connection into the pin socket connector for PPB1. 3
14. Apply small sections of clear polyester heat shrink at approximately 10 cm intervals along the bundle of HV coax cables. 15. Cut HV coax cables to length specified. 16. Strip HV coax cables to appropriate lengths for pin connectors. Inspect the ends for damage to the ground wires 17. Crimp HV coax cable to the pin connector. 18. Apply heat shrink to the connection. 19. Apply urethane coating to the connection. 20. Install the pin connectors into the connector housing per the schematic. 21. Connect the housing to the HV test box. 22. Apply HV and test for breakdown. Figure 2 shows the three different types of fuse boxes in their completed state. Figure 2 4. Labeling Conventions The labeling for the fuse boxes and HV coax cables must be very accurate. The channels must be mapped from the HV traces on the modules to the separate pins on the HV connector at PPB1. Figure 3 shows a view of the C side of the barrel modules. On this end of the detector the HV will be fed to the modules to the even labeled positions. So here we have the labeling for the fuse boxes. Starting at position 2 because this is the even side and rotating in a counter clockwise (CCW) direction for increasing positions. The fuse box designation will be as follows: M(Module type)(a or B depending which kapton is being connected)- P(position number on the detector). The A side kapton is the leading edge of the module in the CCW and the B side kapton is the trailing edge. 4
Figure 3 C side layout of fuse boxes and cables to PPB1 For the A side of the detector (shown in Figure 4) the naming convention will be similar. It will start at position 1 and increase in a clockwise (CW) direction. The fuse box designation will be as follows: M(Module type)(c or D depending which kapton is being connected)-p(position number on the detector). The C side kapton is the leading edge of the module in the CW and the D side kapton is the trailing edge. Figure 4 - Shows the name designations for the fuse boxes 5
For each of the half sectors shown in Figure 4 there are 22 HV coax cables from the fuse box to the connector at PPB1. Three from each of the type 1, three from each of the type 2 and 5 each from the type 3 fuse boxes. The naming convention for these cables will be similar to that of the fuse boxes. These are shown in Figure 5. A digit will be added to the end of the primary string. An example is M1A3-Px, where the 3 is the cable number shown in the diagram of Figure 5. The C and D connectors are used on the A side of the detector and the A and B connectors are used on the C side of the detector. Each of these cables will be connected to different traces inside the fuse boxes. These traces are connected to different HV islands on the barrel modules. On the other end, these cables are connected to pins inserted into the HV connector at PPB1. Figure 6 shows the pin out locations of the cables in the HV connector. 6
Figure 5 7
Figure 6 Addendum B will show tables with the relationships between the HV islands on the modules, the HV coax cable and the pin outs on the connector at PPB1. 8
Addendum A Current Draw Type 1 Connector Side A M1C-Px / Side C M1A-Px Side A M1D-Px / Side C M1B-Px Outer Inner Inner Outer From short side of module HV island current HV island current HV island current HV island current 1.00 8 86.56 1 65.60 2.00 6 86.56 7 86.56 2 86.56 3 86.56 3.00 16 79.36 5 86.56 4 86.56 9 78.02 4.00 15 78.90 13 78.90 11 78.90 10 78.90 5.00 22 126.46 23 137.12 12 78.90 20 135.84 6.00 24 106.93 19 135.84 18 135.84 7.00 14 78.90 21 135.84 17 145.24 8.00 29 148.09 30 148.09 37 136.72 28 146.10 9.00 31 148.09 38 136.72 36 119.11 27 146.53 10.00 32 131.75 39 136.72 35 122.10 26 146.92 11.00 40 136.72 41 140.31 34 117.21 25 126.37 12.00 42 117.48 33 119.71 Type 2 Connector Side A M2D-Px / Side C M2B-Px Side A M2C-Px / Side C M2A-Px From short side of module HV island current HV island current HV island current HV island current 1 1 125.06 10 125.06 9 123.57 2 3 125.06 2 125.06 8 125.06 7 125.06 3 11 114.90 4 125.06 6 125.06 16 114.90 4 5 125.06 12 114.90 20 114.90 19 114.90 5 14 114.90 13 114.90 18 114.90 17 114.37 6 21 106.11 24 106.11 15 114.90 27 108.01 7 23 106.11 22 106.11 28 106.11 30 106.11 8 36 96.74 25 106.11 29 106.11 26 106.92 9 34 98.52 35 98.52 37 101.47 39 101.47 10 32 98.52 33 98.52 40 98.52 41 98.52 11 31 98.52 48 91.69 42 98.52 38 96.63 12 47 91.69 46 91.26 49 92.18 60 85.62 13 45 91.69 59 85.20 50 91.69 53 91.69 14 44 91.69 58 85.62 51 91.69 52 91.69 15 43 91.69 57 85.62 61 86.21 62 85.62 16 56 85.62 55 85.62 63 85.62 64 85.62 17 54 86.21 65 85.62 9
Type 3 Connector Side A M3C-Px / Side C M3A-Px Side A M3D-Px / Side C M3B-Px From short side of module HV island current HV island current HV island current HV island current 1.00 8 78.85 10 78.85 1 78.00 3 78.85 2.00 11 78.85 9 78.85 5 78.85 2 78.85 3.00 12 78.85 20 73.18 4 78.85 7 78.85 4.00 22 72.74 23 72.74 6 78.85 17 72.74 5.00 21 72.74 24 72.74 14 72.74 13 72.06 6.00 31 68.33 34 67.71 15 72.74 16 72.74 7.00 35 67.71 33 67.71 18 72.74 19 72.74 8.00 36 67.71 32 68.94 27 67.71 30 68.42 9.00 43 64.81 54 60.61 25 67.12 26 67.71 10.00 44 62.39 46 62.83 28 67.71 29 67.71 11.00 45 62.83 47 62.83 42 65.30 41 64.07 12.00 48 62.83 55 58.01 40 63.29 37 62.30 13.00 56 58.34 68 48.43 38 63.57 39 63.43 14.00 57 58.34 69 48.21 53 60.61 52 59.92 15.00 60 58.34 58 58.34 49 59.92 50 60.01 16.00 59 51.27 82 52.31 51 60.20 61 56.13 17.00 81 52.31 72 48.08 66 56.13 65 56.13 18.00 71 47.61 70 47.61 63 56.13 62 56.13 19.00 83 52.31 84 51.11 64 56.13 67 49.28 20.00 85 51.96 73 54.20 78 52.31 77 52.31 21.00 94 48.43 93 48.43 74 52.31 75 52.31 22.00 95 48.43 86 51.00 76 52.31 79 52.31 23.00 97 48.30 96 48.43 80 52.31 87 48.43 24.00 98 48.43 99 47.82 90 48.43 88 48.43 25.00 100 48.89 92 48.43 89 48.43 91 48.43 10
Addendum B Cable Mapping Fuse Box Connector Type 1 Side A Cable Labels M1C-Px M1D-Px From cable entrance Cable # HV Group Cable # HV Group Cable # HV Group Cable # HV Group 1.00 M1C2-Px 42 M1D2-Px 1 2.00 M1C2-Px 40 M1C1-Px 41 M1D1-Px 2 M1D2-Px 3 3.00 M1C2-Px 32 M1C1-Px 39 M1D1-Px 4 M1D2-Px 9 4.00 M1C2-Px 31 M1C1-Px 38 M1D1-Px 11 M1D2-Px 10 5.00 M1C2-Px 29 M1C1-Px 30 M1D1-Px 12 M1D2-Px 20 6.00 M1C2-Px 14 M1C1-Px 21 M1D1-Px 19 M1D2-Px 18 7.00 M1C3-Px 24 M1D3-Px 17 8.00 M1C3-Px 22 M1C1-Px 23 M1D1-Px 37 M1D3-Px 28 9.00 M1C3-Px 15 M1C1-Px 13 M1D1-Px 36 M1D3-Px 27 10.00 M1C3-Px 16 M1C1-Px 5 M1D1-Px 35 M1D3-Px 26 11.00 M1C3-Px 6 M1C1-Px 7 M1D1-Px 34 M1D3-Px 25 12.00 M1C3-Px 8 M1D3-Px 33 Fuse Box Connector Type 1 Side C Cable Labels M1A-Px M1B-Px From cable entrance Cable # HV Group Cable # HV Group Cable # HV Group Cable # HV Group 1.00 M1A2-Px 8 M1B2-Px 33 2.00 M1A2-Px 6 M1A1-Px 7 M1B1-Px 34 M1B2-Px 25 3.00 M1A2-Px 16 M1A1-Px 5 M1B1-Px 35 M1B2-Px 26 4.00 M1A2-Px 15 M1A1-Px 13 M1B1-Px 36 M1B2-Px 27 5.00 M1A2-Px 22 M1A1-Px 23 M1B1-Px 37 M1B2-Px 28 6.00 M1A2-Px 24 M1B2-Px 17 7.00 M1A3-Px 14 M1A1-Px 21 M1B1-Px 19 M1B3-Px 18 8.00 M1A3-Px 29 M1A1-Px 30 M1B1-Px 12 M1B3-Px 20 9.00 M1A3-Px 31 M1A1-Px 38 M1B1-Px 11 M1B3-Px 10 10.00 M1A3-Px 32 M1A1-Px 39 M1B1-Px 4 M1B3-Px 9 11.00 M1A3-Px 40 M1A1-Px 41 M1B1-Px 2 M1B3-Px 3 12.00 M1A3-Px 42 M1B3-Px 1 11
Fuse Box Connector Type 2 Side A Cable Labels M2C-Px M2D-Px From cable entrance Cable # HV Group Cable # HV Group Cable # HV Group Cable # HV Group 1 M2C1-Px 65 M2D2-Px 1 2 M2C2-Px 64 M2C1-Px 63 M2D1-Px 2 M2D2-Px 3 3 M2C2-Px 62 M2C1-Px 61 M2D1-Px 4 M2D2-Px 11 4 M2C2-Px 52 M2C1-Px 51 M2D1-Px 12 M2D2-Px 5 5 M2C2-Px 53 M2C1-Px 50 M2D1-Px 13 M2D2-Px 14 6 M2C2-Px 60 M2C1-Px 49 M2D1-Px 24 M2D2-Px 21 7 M2C3-Px 38 M2C3-Px 42 M2D3-Px 22 M2D3-Px 23 8 M2C3-Px 41 M2C3-Px 40 M2D3-Px 25 M2D3-Px 36 9 M2C3-Px 39 M2C3-Px 37 M2D3-Px 35 M2D3-Px 34 10 M2C3-Px 26 M2C3-Px 29 M2D3-Px 33 M2D3-Px 32 11 M2C3-Px 30 M2C3-Px 28 M2D3-Px 48 M2D3-Px 31 12 M2C2-Px 27 M2C1-Px 15 M2D1-Px 46 M2D2-Px 47 13 M2C2-Px 17 M2C1-Px 18 M2D1-Px 59 M2D2-Px 45 14 M2C2-Px 19 M2C1-Px 20 M2D1-Px 58 M2D2-Px 44 15 M2C2-Px 16 M2C1-Px 6 M2D1-Px 57 M2D2-Px 43 16 M2C2-Px 7 M2C1-Px 8 M2D1-Px 55 M2D2-Px 56 17 M2C2-Px 9 M2C1-Px 10 M2D2-Px 54 Fuse Box Connector Type 2 Side C Cable Labels M2A-Px M2B-Px From cable entrance Cable # HV Group Cable # HV Group Cable # HV Group Cable # HV Group 1 M2A2-Px 9 M2A1-Px 10 M2B2-Px 54 2 M2A2-Px 7 M2A1-Px 8 M2B1-Px 55 M2B2-Px 56 3 M2A2-Px 16 M2A1-Px 6 M2B1-Px 57 M2B2-Px 43 4 M2A2-Px 19 M2A1-Px 20 M2B1-Px 58 M2B2-Px 44 5 M2A2-Px 17 M2A1-Px 18 M2B1-Px 59 M2B2-Px 45 6 M2A2-Px 27 M2A1-Px 15 M2B1-Px 46 M2B2-Px 47 7 M2A3-Px 30 M2A3-Px 28 M2B3-Px 48 M2B3-Px 31 8 M2A3-Px 26 M2A3-Px 29 M2B3-Px 33 M2B3-Px 32 9 M2A3-Px 39 M2A3-Px 37 M2B3-Px 35 M2B3-Px 34 10 M2A3-Px 41 M2A3-Px 40 M2B3-Px 25 M2B3-Px 36 11 M2A3-Px 38 M2A3-Px 42 M2B3-Px 22 M2B3-Px 23 12 M2A2-Px 60 M2A1-Px 49 M2B1-Px 24 M2B2-Px 21 13 M2A2-Px 53 M2A1-Px 50 M2B1-Px 13 M2B2-Px 14 14 M2A2-Px 52 M2A1-Px 51 M2B1-Px 12 M2B2-Px 5 15 M2A2-Px 62 M2A1-Px 61 M2B1-Px 4 M2B2-Px 11 16 M2A2-Px 64 M2A1-Px 63 M2B1-Px 2 M2B2-Px 3 17 M2A2-Px M2A1-Px 65 M2B2-Px 1 12
Fuse Box Connector Type 3 Side A Cable Labels M3C-Px M3D-Px From cable entrance Cable # HV Group Cable # HV Group Cable # HV Group Cable # HV Group 1.00 M3C3-Px 100 M3C1-Px 92 M3D1-Px 1 M3D3-Px 3 2.00 M3C3-Px 98 M3C1-Px 99 M3D1-Px 5 M3D3-Px 2 3.00 M3C3-Px 97 M3C1-Px 96 M3D1-Px 4 M3D3-Px 7 4.00 M3C3-Px 95 M3C1-Px 86 M3D1-Px 6 M3D3-Px 17 5.00 M3C3-Px 94 M3C1-Px 93 M3D1-Px 14 M3D3-Px 13 6.00 M3C3-Px 85 M3C1-Px 73 M3D1-Px 15 M3D3-Px 16 7.00 M3C3-Px 83 M3C1-Px 84 M3D1-Px 18 M3D3-Px 19 8.00 M3C3-Px 71 M3C1-Px 70 M3D1-Px 27 M3D3-Px 30 9.00 M3C3-Px 81 M3C1-Px 72 M3D1-Px 25 M3D3-Px 26 10.00 M3C3-Px 59 M3C1-Px 82 M3D1-Px 28 M3D3-Px 29 11.00 M3C5-Px 60 M3C5-Px 58 M3D5-Px 42 M3D5-Px 41 12.00 M3C5-Px 57 M3C5-Px 69 M3D5-Px 40 M3D5-Px 37 13.00 M3C5-Px 56 M3C5-Px 68 M3D5-Px 38 M3D5-Px 39 14.00 M3C5-Px 48 M3C5-Px 55 M3D5-Px 53 M3D5-Px 52 15.00 M3C5-Px 45 M3C5-Px 47 M3D5-Px 49 M3D5-Px 50 16.00 M3C4-Px 44 M3C2-Px 46 M3D2-Px 51 M3D4-Px 61 17.00 M3C4-Px 43 M3C2-Px 54 M3D2-Px 66 M3D4-Px 65 18.00 M3C4-Px 36 M3C2-Px 32 M3D2-Px 63 M3D4-Px 62 19.00 M3C4-Px 35 M3C2-Px 33 M3D2-Px 64 M3D4-Px 67 20.00 M3C4-Px 31 M3C2-Px 34 M3D2-Px 78 M3D4-Px 77 21.00 M3C4-Px 21 M3C2-Px 24 M3D2-Px 74 M3D4-Px 75 22.00 M3C4-Px 22 M3C2-Px 23 M3D2-Px 76 M3D4-Px 79 23.00 M3C4-Px 12 M3C2-Px 20 M3D2-Px 80 M3D4-Px 87 24.00 M3C4-Px 11 M3C2-Px 9 M3D2-Px 90 M3D4-Px 88 25.00 M3C4-Px 8 M3C2-Px 10 M3D2-Px 89 M3D4-Px 91 13
Fuse Box Connector Type 3 Side C Cable Labels M3A-Px M3B-Px From cable entrance Cable # HV Group Cable # HV Group Cable # HV Group Cable # HV Group 1.00 M3A3-Px 8 M3A1-Px 10 M3B1-Px 89 M3B3-Px 91 2.00 M3A3-Px 11 M3A1-Px 9 M3B1-Px 90 M3B3-Px 88 3.00 M3A3-Px 12 M3A1-Px 20 M3B1-Px 80 M3B3-Px 87 4.00 M3A3-Px 22 M3A1-Px 23 M3B1-Px 76 M3B3-Px 79 5.00 M3A3-Px 21 M3A1-Px 24 M3B1-Px 74 M3B3-Px 75 6.00 M3A3-Px 31 M3A1-Px 34 M3B1-Px 78 M3B3-Px 77 7.00 M3A3-Px 35 M3A1-Px 33 M3B1-Px 64 M3B3-Px 67 8.00 M3A3-Px 36 M3A1-Px 32 M3B1-Px 63 M3B3-Px 62 9.00 M3A3-Px 43 M3A1-Px 54 M3B1-Px 66 M3B3-Px 65 10.00 M3A3-Px 44 M3A1-Px 46 M3B1-Px 51 M3B3-Px 67 11.00 M3A5-Px 45 M3A5-Px 47 M3B5-Px 49 M3B5-Px 50 12.00 M3A5-Px 48 M3A5-Px 55 M3B5-Px 53 M3B5-Px 52 13.00 M3A5-Px 56 M3A5-Px 68 M3B5-Px 38 M3B5-Px 39 14.00 M3A5-Px 57 M3A5-Px 69 M3B5-Px 40 M3B5-Px 37 15.00 M3A5-Px 60 M3A5-Px 58 M3B5-Px 42 M3B5-Px 41 16.00 M3A4-Px 59 M3A2-Px 82 M3B2-Px 28 M3B4-Px 29 17.00 M3A4-Px 81 M3A2-Px 72 M3B2-Px 25 M3B4-Px 26 18.00 M3A4-Px 71 M3A2-Px 70 M3B2-Px 27 M3B4-Px 30 19.00 M3A4-Px 83 M3A2-Px 84 M3B2-Px 18 M3B4-Px 19 20.00 M3A4-Px 85 M3A2-Px 73 M3B2-Px 15 M3B4-Px 16 21.00 M3A4-Px 94 M3A2-Px 93 M3B2-Px 14 M3B4-Px 13 22.00 M3A4-Px 95 M3A2-Px 86 M3B2-Px 6 M3B4-Px 17 23.00 M3A4-Px 97 M3A2-Px 96 M3B2-Px 4 M3B4-Px 7 24.00 M3A4-Px 98 M3A2-Px 99 M3B2-Px 5 M3B4-Px 2 25.00 M3A4-Px 100 M3A2-Px 92 M3B2-Px 1 M3B4-Px 3 14