+-----------+--------------------+--------------------------+---------+
| > f       | > **Fermi National |                          |         |
|           | > Accelerator      |                          |         |
|           | > Laboratory**     |                          |         |
|           | >                  |                          |         |
|           | > **Batavia, IL    |                          |         |
|           | > 60510**          |                          |         |
+-----------+--------------------+--------------------------+---------+
| > **NLC   |                    |                          |         |
| > FXC RF  |                    |                          |         |
| > ST      |                    |                          |         |
| RUCTURE** |                    |                          |         |
| >         |                    |                          |         |
| > **w/FWG |                    |                          |         |
| >         |                    |                          |         |
|  COUPLERS |                    |                          |         |
| >         |                    |                          |         |
|  ASSEMBLY |                    |                          |         |
| > T       |                    |                          |         |
| RAVELER** |                    |                          |         |
|           |                    |                          |         |
| ![](      |                    |                          |         |
| media/ima |                    |                          |         |
| ge1.wmf){ |                    |                          |         |
| width="5. |                    |                          |         |
| 997222222 |                    |                          |         |
| 222222in" |                    |                          |         |
| he        |                    |                          |         |
| ight="1.6 |                    |                          |         |
| 763888888 |                    |                          |         |
| 88889in"} |                    |                          |         |
+-----------+--------------------+--------------------------+---------+
| > **      |                    |                          |         |
| Reference |                    |                          |         |
| > Dra     |                    |                          |         |
| wing(s)** |                    |                          |         |
|           |                    |                          |         |
| **Final   |                    |                          |         |
| A         |                    |                          |         |
| ssembly** |                    |                          |         |
|           |                    |                          |         |
| **5520-MD |                    |                          |         |
| -404290** |                    |                          |         |
+-----------+--------------------+--------------------------+---------+
| >         |                    | **Job #:**               |         |
| **Project |                    |                          |         |
| > \#      |                    |                          |         |
| > /Task   |                    |                          |         |
| > #:**    |                    |                          |         |
+-----------+--------------------+--------------------------+---------+
| > *       |                    | **Magnet/Device          |         |
| *Released |                    | Series:**                |         |
| > by:**   |                    |                          |         |
+-----------+--------------------+--------------------------+---------+
| >         |                    | **Scan Pages:**          |         |
| **Date:** |                    |                          |         |
+-----------+--------------------+--------------------------+---------+
| #         |                    |                          |         |
| #### Prep |                    |                          |         |
| ared by:  |                    |                          |         |
| B. Jensen |                    |                          |         |
+-----------+--------------------+--------------------------+---------+
| **Title** |                    | **Signature**            | *       |
|           |                    |                          | *Date** |
+-----------+--------------------+--------------------------+---------+
| **TD /    |                    | ***Bob Jensen***         | ***1/2  |
| E&F       |                    |                          | 7/04*** |
| Process   |                    | **Bob Jensen /           |         |
| Engi      |                    | Designee**               |         |
| neering** |                    |                          |         |
+-----------+--------------------+--------------------------+---------+
| **TD /    |                    | # *Brian Smith*          | ***1/2  |
| NLC       |                    |                          | 7/04*** |
| A         |                    | # Brian Smith / Designee |         |
| ssembly** |                    |                          |         |
+-----------+--------------------+--------------------------+---------+
| **TD /    |                    | > *Tug Arkan*            | ***1/2  |
| NLC       |                    | >                        | 7/04*** |
| P         |                    | > Tug Arkan/ Designee    |         |
| roduction |                    |                          |         |
| E         |                    |                          |         |
| ngineer** |                    |                          |         |
+-----------+--------------------+--------------------------+---------+
| **TD /    |                    | ***Harry Carter***       | ***1/2  |
| NLC       |                    |                          | 7/04*** |
| Project   |                    | **Harry Carter /         |         |
| E         |                    | Designee**               |         |
| ngineer** |                    |                          |         |
+-----------+--------------------+--------------------------+---------+

Revision Page

  -------------- -------- ------------------------------------------- ------- ----------
  **Revision**   **Step   **Revision Description**                    **TRR   **Date**
                 No.**                                                No.**   

  **DRAFT**      N/A      Initial Release                             N/A     1/27/04

                                                                              

                                                                              

                                                                              

                                                                              

                                                                              

                                                                              
  -------------- -------- ------------------------------------------- ------- ----------

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

1.0 [General Notes]{.underline}

> 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 All personnel performing steps in this traveler must have
> documented training for this traveler and associated operating
> procedures.
>
> 1.6 Personnel shall perform all tasks in accordance with current
> applicable ES&H guidelines and those specified within the step.
>
> 1.7 Keep the product/assembly in dessicators under dry filtered
> nitrogen flow.

2.0 [Parts Kit List]{.underline}

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

Process Engineering/Designee Date

3.0 [RF Disk & Coupler Cleaning]{.underline}

Completed

1.  Clean all RF Disks and Couplers in accordance with Cleaning
    Specification

> ES-333725.

Technician(s) Date

3.2 Inspect disks and couplers for machining burrs with microscope.
Remove burrs as necessary

using approved methods.

Technician(s) Date

4.0 [RF Disk Electrical Measurements]{.underline}

4.1 Measure all disks required for assembly with Single Disk RF QC
Setup.

X 4.2 Disks are acceptable for further processing.

RF Measurement Engineer/designee Date

5.0 [RF Disk & Coupler Chemical Etching]{.underline}

5.1 Transport/Etch RF disks & couplers at an approved etching facility
and etch in accordance

with Chemical Etching Procedure (ES-333446).

Technician(s) Date

6.0 [Input Coupler Preparation]{.underline}

Completed

6.1 Acquire the following parts to assemble one (1 ea) Input Coupler

as per MC-404297:

Input WG Coupler Body MD-404298 1 ea

WG Coupler Cover MD-404299 1 ea

Coupler Braze Shim MC-404219 2 ea

UMC Cutoff Bushing MB-404266 1 ea

Bushing Braze Shim MA-404267 1 ea

Input WG Coupler Drift Tube MB-404300 1 ea

¼"-20 Mounting Bushing MB-404082 1 ea

Braze Paste (35%Au-65%Cu) A/R

2.  Verify that the Coupler Body and Coupler Plate are etched per
    Etching specification

> ES-333446

6.3 Clean all other parts using Cleaning Specification ES-333725.

Technician(s) Date

6.4 Record vendor serial numbers below.

  ------------------------------- ---------------------------------------
  **Item**                        **Vendor Serial Number**

  Input Coupler Body              

  Input Coupler Plate             
  ------------------------------- ---------------------------------------

6.5 Assemble the Input WG Coupler Body (MD-404298), WG Coupler Cover
(MD-404299),

and Coupler Braze Shim (2 ea)(MC-404219).

Note: When installing the Braze shim, bend the shim ends downward to

![](media/image2.wmf){width="3.3958333333333335in" height="3.09375in"}
help lock into place during assembly.

6.6 Apply Braze Paste (35%Au-65%Cu Braze Alloy) to Coupler Radius as
show below.

![](media/image3.wmf){width="3.34375in" height="1.59375in"}

Technician(s) Date

6.7 Clean with Alcohol and install two each (2 ea) Fermi Made Braze Foil
Disks

into each Mounting Bushing holes in the Coupler Body.

Note: Ensure Braze Foil Disks are free of burrs.

6.8 Install Mounting Bushing (MB-404082)(4 ea) into Coupler Assembly.

6.9 Clean with Alcohol and install Bushing Braze Shim (MB-404267) into
FXC WG

Coupler Cover ( (MC-404299). Ensure Braze Shim is fully inserted into
the

Coupler Cover.

Note: Fill Braze Ring Groove in UMC CutOff Bushing with 35/65% brazing
wire

![](media/image4.wmf){width="4.260416666666667in"
height="2.6666666666666665in"} (0.035" diam) prior to brazing.

6.10 Verify the UMC Cutoff Bushing (MB-404266) has been etched per
ES-333446,

then install onto the Bushing Brazing Shim (MA-404267).

6.11 Install the FXC Input WG Coupler Drift Tube onto the UMC Cutoff
Bushing. Apply

![](media/image5.wmf){width="4.427083333333333in"
height="2.1347222222222224in"} Brazing alloy (35%Au-65%Cu Braze Alloy)
to the Drift Tube/UMC Cutoff Bushing

joint.

Technician(s) Date

X 6.12 Verify Input Coupler is assembled correctly and braze shim is
installed correctly.

X 6.13 Verify Mounting Bushings and Input Drift Tube are properly
installed and

braze alloy is properly applied.

Lead Person Date

6.14 Prepare assembled Input Coupler for oven brazing.

Technician(s) Date

X 6.15 Verify Input Coupler is acceptable for oven brazing.

Lead Person Date

6.16 Transport Input Coupler to Brazing Oven.

Technician(s) Date

X 6.17 STOP!!! Input Coupler must be brazed with Output Coupler.

Lead Person Date

7.0 [Output Coupler Preparation]{.underline}

Completed

7.1 Acquire the following parts to assemble one (1 ea) FXC Output WG
Coupler (MC-404302):

> Output WG Coupler Body MD-404303 1 ea
>
> WG Coupler Cover MC-404299 1 ea
>
> Coupler Braze Shim MC-404219 2 ea
>
> UMC Cutoff Bushing MB-404266 1 ea
>
> Bushing Braze Shim MA-404267 1 ea
>
> Output WG Coupler Drift Tube MB-404304 1 ea
>
> ½"-20 Mounting Bushing MB-404082 4 ea
>
> 7.2 Verify that the Coupler Body and Coupler Plate are etched per
> Etching specification
>
> ES-333446

Technician(s) Date

7.3 Clean all other parts using Cleaning Specification ES-333725.

Technician(s) Date

7.4 Record vendor serial numbers below.

  ---------------------------- ------------------------------------------
  **Item**                     **Vendor Serial Number**

  Output Coupler Body          

  Output Coupler Plate         
  ---------------------------- ------------------------------------------

7.5 Assemble the Output WG Coupler Body (MD-404303), WG Coupler Cover
(MD-404299),

and Coupler Braze Shim (2 ea)(MC-404219).

Note: When installing the Braze shim, bend the shim ends downward to

![](media/image6.wmf){width="3.4583333333333335in"
height="3.2395833333333335in"} help lock into place during assembly.

![](media/image7.wmf){width="3.4375in" height="1.6770833333333333in"}
7.6 Apply Braze Paste (35% Au- 65% Cu) to Coupler Radius as shown below.

7.7 Clean with alcohol and install two each (2 ea) Fermi Made Braze Foil
Disks

into each Mounting Bushing holes in the Coupler Body.

7.8 Install Mounting Bushing (MB-404082)(4 ea) into Coupler Assembly.

7.9 Clean with Alcohol and install Bushing Braze Shim (MB-404267) into
FXC WG

Coupler Cover (MC-404299). Ensure Braze Shim is fully inserted into the

Coupler Cover.

![](media/image8.wmf){width="4.229166666666667in" height="3.34375in"}
Note: Fill Braze Ring Groove in UMC CutOff Bushing with 35/65% brazing
wire (0.035" diam) prior to brazing.

7.10 Verify the UMC Cutoff Bushing (MB-404266) has been etched per
ES-333446,

then install onto the Bushing Brazing Shim (MA-404267).

7.11 Install Output Coupler WG Drift Tube (MB-404304)(1 ea) onto UMC
Cutoff

Bushing (MB-404266). Apply Brazing alloy (35%Au-65%Cu Braze Alloy) to
the

![](media/image9.wmf){width="5.997916666666667in"
height="1.8138888888888889in"} Output Coupler Drift Tube.

Technician(s) Date

X 7.12 Verify Output Coupler is assembled correctly and braze shim is
installed correctly.

X 7.13 Verify Mounting Bushings and Output Drift Tube are properly
installed and

braze alloy is properly applied.

Lead Person Date

7.14 Prepare assembled Output Coupler for oven brazing.

Technician(s) Date

X 7.15 Verify Output Coupler is acceptable for oven brazing.

Lead Person Date

7.16 Transport Output Coupler to Brazing Oven.

X 7.17 STOP!! Output Coupler and Input Coupler must be oven brazed with
Input Coupler

Lead Person Date

X 7.18 Place the seven SLAC provided copper coupons in oven with Input
and

Output Coupler Assemblies. Verify that the recessed side of the coupons

is face down in the furnace

Lead Person Date

7.19 Braze in accordance with approved brazing procedure.

7.20 Remove both Input and Output Coupler Assemblies from brazing oven
and.

prepare for further processing.

Technician(s) Date

X 7.21 Remove the seven copper coupons. Ensure proper storage with
proper black plastic coupon

> container. Mark the proper labels

Remove one coupon and place in the container and label as "Input &
Output Coupler

> Brazing (35/65 cycle)".

Remove six coupons and place in containers for further brazing
processes.

Lead Person Date

7.22 Prepare Input & Output Coupler for delivery for machining of
coupler ends.

Technician(s) Date

7.23 Machine the coupler ends using the following:

Input Coupler Assy -- Machining ME-404297

Output Coupler Assy -- Machining ME-404301

X 7.24 Verify that the Input and Output Couplers have been machined in
accordance

with the following:

Input Coupler Assy -- Machining ME-404297

Output Coupler Assy -- Machining ME-404301

Lead Person Date

8.0 [Input Coupler/WG Flange Assembly]{.underline}

**Caution: During the Input Coupler/WG Flange Assembly, ensure that all
flange**

**sealing surfaces are protected from damage during handling.**

X 8.1 Receive Input Coupler Assembly (MC-404297) from Machine
processing. Verify

the Input Coupler was machined properly and can proceed with

further processing.

Lead Person Date

8.2 Install X-Band Flanges (MD-404094)(2 ea) on the Input Coupler
Assembly (MD-404297).

Insert Braze foil material (50%Au-50%Cu Braze Alloy) between RF Flanges
and Input

![](media/image10.wmf){width="5.59375in" height="2.6979166666666665in"}
Coupler Assembly.

X 8.3 Verify Input Coupler is acceptable and can proceed to Oven
Brazing.

Lead Person Date

X 8.4 STOP!! Input Coupler Assembly with X-Band Flanges must be brazed
with Output Coupler

Assembly with X-Band Flanges.

Lead Person Date

9.0 [Output Coupler/WG Flange Assembly]{.underline}

**Caution: During the Output Coupler/WG Flange Assembly, ensure that
all**

**flange sealing surfaces are protected from damage during handling.**

X 9.1 Receive Output Coupler Assembly (MC-404301) from Machine
processing. Verify

the Output Coupler was machined properly and can proceed with

further processing.

Lead Person Date

9.2 Install X-Band WG Flanges (MD-404094)(2 ea) on the Output Coupler

![](media/image11.wmf){width="4.864583333333333in"
height="2.9895833333333335in"} Assembly (MD-404301). Insert Braze foil
material (50%Au-50%Cu Braze Alloy) between

X-Band WG Flanges and Output Coupler Assembly.

X 9.3 Verify Output Coupler is acceptable and can proceed to Oven
Brazing.

Lead Person Date

X 9.4 STOP!! Output Coupler Assembly with X-Band Flanges must be brazed

with Input Coupler with X-Band Flanges.

Lead Person Date

X 9.5 Place the six copper coupons, baked and labeled from the previous
brazing cycle,

> into brazing oven with Input and Output Coupler Assemblies and with
> X-Band Flanges.

Verify that the recessed side of the coupons is face down in the
furnace.

Lead Person Date

Completed

9.6 Output Coupler beam tube has to be support during the brazing
assembly cycle using

![](media/image12.wmf){width="2.9166666666666665in"
height="3.8645833333333335in"} Fermi built support tooling.

X 9.7 Verify that the Drift Tube is perpendicular to the Output Coupler.

Lead Person Date

9.8 Braze the Output and Input Couplers.

Technician(s) Date

X 9.9 Remove the six copper coupons. Ensure proper storage with proper
black plastic coupon

> container. Mark the proper labels

Remove one coupon and place in the container and label as "Input &
Output Coupler

> To RF Flange Brazing (50/50 cycle)".

Remove five coupons and place in containers for further brazing
processes.

Lead Person Date

9.10 Vacuum Leak Check the Input coupler with X-Band installed Flanges.
Use 12 pt head

> SS bolts, copper gaskets and nuts to seal the RF Flanges. Use an
> alternating pattern for tightening. Use a maximum of 13 in/lbs of
> torque.
>
> Caution: Use two wrenches to tighten the bolts and hold the nuts in
> order not to twist the RF Flanges during sealing.

+-------+---------+--------+--------+----+------+------+------+------+
| PART  |         | SCALE  | SCALE  | D  |      |      |      |      |
|       |         | UNITS  | UNITS  | ET |      |      |      |      |
| NO.   |         | BEFORE | WHILE  | ER |      |      |      |      |
|       |         | HELIUM | ENC    | MI |      |      |      |      |
|       |         | PROBE  | LOSURE | NA |      |      |      |      |
|       |         |        | FL     | TI |      |      |      |      |
|       |         |        | OODING | ON |      |      |      |      |
|       |         |        |        | OF |      |      |      |      |
|       |         |        |        | M  |      |      |      |      |
|       |         |        |        | IN |      |      |      |      |
|       |         |        |        | IM |      |      |      |      |
|       |         |        |        | UM |      |      |      |      |
|       |         |        |        |    |      |      |      |      |
|       |         |        |        | DE |      |      |      |      |
|       |         |        |        | TE |      |      |      |      |
|       |         |        |        | CT |      |      |      |      |
|       |         |        |        | AB |      |      |      |      |
|       |         |        |        | LE |      |      |      |      |
|       |         |        |        | LE |      |      |      |      |
|       |         |        |        | AK |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
| DATE  | OPER    |        |        | M  |      |      |      |      |
|       | ATOR\'S |        |        | DS |      |      |      |      |
| TIME  | LAST    |        |        | (( |      |      |      |      |
|       | NAME    |        |        | Re |      |      |      |      |
|       |         |        |        | sp |      |      |      |      |
|       |         |        |        | on |      |      |      |      |
|       |         |        |        | se |      |      |      |      |
|       |         |        |        | -B |      |      |      |      |
|       |         |        |        | ck |      |      |      |      |
|       |         |        |        | gn |      |      |      |      |
|       |         |        |        | d) |      |      |      |      |
|       |         |        |        | Le |      |      |      |      |
|       |         |        |        | ak |      |      |      |      |
|       |         |        |        | Va |      |      |      |      |
|       |         |        |        | lu |      |      |      |      |
|       |         |        |        | e) |      |      |      |      |
|       |         |        |        | =  |      |      |      |      |
|       |         |        |        | M  |      |      |      |      |
|       |         |        |        | DL |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+

9.11 Vacuum Leak Check the Output coupler with X-Band installed Flanges.
. Use 12 pt head

> SS bolts, copper gaskets and nuts to seal the RF Flanges. Use an
> alternating pattern for tightening. Use a maximum of 13 in/lbs of
> torque.
>
> Caution: Use two wrenches to tighten the bolts and hold the nuts in
> order not to twist the RF Flanges during sealing.

+-------+---------+--------+--------+----+------+------+------+------+
| PART  |         | SCALE  | SCALE  | D  |      |      |      |      |
|       |         | UNITS  | UNITS  | ET |      |      |      |      |
| NO.   |         | BEFORE | WHILE  | ER |      |      |      |      |
|       |         | HELIUM | ENC    | MI |      |      |      |      |
|       |         | PROBE  | LOSURE | NA |      |      |      |      |
|       |         |        | FL     | TI |      |      |      |      |
|       |         |        | OODING | ON |      |      |      |      |
|       |         |        |        | OF |      |      |      |      |
|       |         |        |        | M  |      |      |      |      |
|       |         |        |        | IN |      |      |      |      |
|       |         |        |        | IM |      |      |      |      |
|       |         |        |        | UM |      |      |      |      |
|       |         |        |        |    |      |      |      |      |
|       |         |        |        | DE |      |      |      |      |
|       |         |        |        | TE |      |      |      |      |
|       |         |        |        | CT |      |      |      |      |
|       |         |        |        | AB |      |      |      |      |
|       |         |        |        | LE |      |      |      |      |
|       |         |        |        | LE |      |      |      |      |
|       |         |        |        | AK |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
| DATE  | OPER    |        |        | M  |      |      |      |      |
|       | ATOR\'S |        |        | DS |      |      |      |      |
| TIME  | LAST    |        |        | (( |      |      |      |      |
|       | NAME    |        |        | Re |      |      |      |      |
|       |         |        |        | sp |      |      |      |      |
|       |         |        |        | on |      |      |      |      |
|       |         |        |        | se |      |      |      |      |
|       |         |        |        | -B |      |      |      |      |
|       |         |        |        | ck |      |      |      |      |
|       |         |        |        | gn |      |      |      |      |
|       |         |        |        | d) |      |      |      |      |
|       |         |        |        | Le |      |      |      |      |
|       |         |        |        | ak |      |      |      |      |
|       |         |        |        | Va |      |      |      |      |
|       |         |        |        | lu |      |      |      |      |
|       |         |        |        | e) |      |      |      |      |
|       |         |        |        | =  |      |      |      |      |
|       |         |        |        | M  |      |      |      |      |
|       |         |        |        | DL |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+

Technician(s) Date

10.0 [Final FXC Input Coupler/Coupler Disk Assembly]{.underline}

10.1 Acquire the following items required to final assembly the FXC
Input WG Coupler

FXC Input WG Coupler Assy-Machined MC-404297 1 ea

Input Coupler Disk (Cell #00) MD-404292 1 ea

![](media/image14.wmf){width="4.364583333333333in"
height="2.7083333333333335in"} Dowel Pin 3/32" X 0.500" long 1 ea

10.2 Assemble the Input Coupler Disk (Cell #00) (MD-404292) onto the
Input Coupler

10.3 Install Dowel Pin (3/32" X 0.500 long) to align Disk Cell #00 to
Input Coupler.

10.4 Apply Braze Alloy (72%Ag - 28%Cu)(0.035" diam wire) to the Flange
to

Coupler brazing groove.

X 10.5 Verify Input Coupler is acceptable and can proceed to Oven
Brazing.

Lead Person Date

10.6 Transport Input Coupler Assembly to brazing oven.

11.0 [Final FXC Output Coupler/Coupler Disk Assembly]{.underline}

11.1 Acquire the following items required to final assemble the FXC
Output WG Coupler

FXC Output WG Coupler Assy-Machined MC-404301 1 ea

Output WGS Disk (Cells #53 & #54) MD-404295 1 ea

![](media/image15.wmf){width="4.083333333333333in"
height="3.0520833333333335in"} Dowel Pin 3/32" X 0.500" long 1 ea

11.2 Install Output Coupler Disk (Cell #53&#54) (MD-404295) to the Input
Coupler.

11.3 Install Dowel Pin 3/32" X 0.500" long into Coupler Body aligning
Disk Cell #53 & #54

to the Coupler.

11.4 Apply Braze Alloy (72%Ag - 28%Cu) (0.035" diam wire) to the Flange
to Coupler

brazing grrove.

X 11.5 Verify Output Coupler is acceptable and can proceed to Oven
Brazing.

Lead Person Date

11.6 Transport Output Coupler Assembly to brazing oven.

X 11.7 Place the five copper coupons, baked and labeled from the
previous brazing cycle,

> into brazing oven with Input and Output Coupler Assemblies and with
> X-Band Flanges.

Verify that the recessed side of the coupons is face down in the
furnace.

Lead Person Date

11.8 Braze the Input Coupler and Output Couplers.

Lead Person Date

11.9 Remove the five copper coupons. Ensure proper storage with the
proper black plastic

coupon container. Mark the proper labels.

Remove one coupon and place in the container and label as "Input &
Output Coupler

to Disk Cell #00 and Cell #53 & #54 (27/28 cycle).

Remove four coupons and place in containers for further brazing
processes.

Lead Person Date

11.11 Perform a Vacuum Leak Check of the Input Coupler Assembly and
record results below.

Use 12 pt head SS bolts, copper gaskets and nuts to seal the RF Flanges.
Use an alternating

pattern for tightening. Use a maximum of 13 in/lbs of torque.

> Caution: Use two wrenches to tighten the bolts and hold the nuts in
> order not to twist the RF Flanges during sealing.

+-------+---------+--------+--------+----+------+------+------+------+
| PART  |         | SCALE  | SCALE  | D  |      |      |      |      |
|       |         | UNITS  | UNITS  | ET |      |      |      |      |
| NO.   |         | BEFORE | WHILE  | ER |      |      |      |      |
|       |         | HELIUM | ENC    | MI |      |      |      |      |
|       |         | PROBE  | LOSURE | NA |      |      |      |      |
|       |         |        | FL     | TI |      |      |      |      |
|       |         |        | OODING | ON |      |      |      |      |
|       |         |        |        | OF |      |      |      |      |
|       |         |        |        | M  |      |      |      |      |
|       |         |        |        | IN |      |      |      |      |
|       |         |        |        | IM |      |      |      |      |
|       |         |        |        | UM |      |      |      |      |
|       |         |        |        |    |      |      |      |      |
|       |         |        |        | DE |      |      |      |      |
|       |         |        |        | TE |      |      |      |      |
|       |         |        |        | CT |      |      |      |      |
|       |         |        |        | AB |      |      |      |      |
|       |         |        |        | LE |      |      |      |      |
|       |         |        |        | LE |      |      |      |      |
|       |         |        |        | AK |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
| DATE  | OPER    |        |        | M  |      |      |      |      |
|       | ATOR\'S |        |        | DS |      |      |      |      |
| TIME  | LAST    |        |        | (( |      |      |      |      |
|       | NAME    |        |        | Re |      |      |      |      |
|       |         |        |        | sp |      |      |      |      |
|       |         |        |        | on |      |      |      |      |
|       |         |        |        | se |      |      |      |      |
|       |         |        |        | -B |      |      |      |      |
|       |         |        |        | ck |      |      |      |      |
|       |         |        |        | gn |      |      |      |      |
|       |         |        |        | d) |      |      |      |      |
|       |         |        |        | Le |      |      |      |      |
|       |         |        |        | ak |      |      |      |      |
|       |         |        |        | Va |      |      |      |      |
|       |         |        |        | lu |      |      |      |      |
|       |         |        |        | e) |      |      |      |      |
|       |         |        |        | =  |      |      |      |      |
|       |         |        |        | M  |      |      |      |      |
|       |         |        |        | DL |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+

Inspector Date

11.12 Perform a Vacuum Leak Check of the Output Coupler Assembly and
record results below.

> Use 12 pt head SS bolts, copper gaskets and nuts to seal the RF
> Flanges. Use an alternating pattern for tightening. Use a maximum of
> 13 in/lbs of torque.
>
> Caution: Use two wrenches to tighten the bolts and hold the nuts in
> order not to twist the RF Flanges during sealing.

+-------+---------+--------+--------+----+------+------+------+------+
| PART  |         | SCALE  | SCALE  | D  |      |      |      |      |
|       |         | UNITS  | UNITS  | ET |      |      |      |      |
| NO.   |         | BEFORE | WHILE  | ER |      |      |      |      |
|       |         | HELIUM | ENC    | MI |      |      |      |      |
|       |         | PROBE  | LOSURE | NA |      |      |      |      |
|       |         |        | FL     | TI |      |      |      |      |
|       |         |        | OODING | ON |      |      |      |      |
|       |         |        |        | OF |      |      |      |      |
|       |         |        |        | M  |      |      |      |      |
|       |         |        |        | IN |      |      |      |      |
|       |         |        |        | IM |      |      |      |      |
|       |         |        |        | UM |      |      |      |      |
|       |         |        |        |    |      |      |      |      |
|       |         |        |        | DE |      |      |      |      |
|       |         |        |        | TE |      |      |      |      |
|       |         |        |        | CT |      |      |      |      |
|       |         |        |        | AB |      |      |      |      |
|       |         |        |        | LE |      |      |      |      |
|       |         |        |        | LE |      |      |      |      |
|       |         |        |        | AK |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
| DATE  | OPER    |        |        | M  |      |      |      |      |
|       | ATOR\'S |        |        | DS |      |      |      |      |
| TIME  | LAST    |        |        | (( |      |      |      |      |
|       | NAME    |        |        | Re |      |      |      |      |
|       |         |        |        | sp |      |      |      |      |
|       |         |        |        | on |      |      |      |      |
|       |         |        |        | se |      |      |      |      |
|       |         |        |        | -B |      |      |      |      |
|       |         |        |        | ck |      |      |      |      |
|       |         |        |        | gn |      |      |      |      |
|       |         |        |        | d) |      |      |      |      |
|       |         |        |        | Le |      |      |      |      |
|       |         |        |        | ak |      |      |      |      |
|       |         |        |        | Va |      |      |      |      |
|       |         |        |        | lu |      |      |      |      |
|       |         |        |        | e) |      |      |      |      |
|       |         |        |        | =  |      |      |      |      |
|       |         |        |        | M  |      |      |      |      |
|       |         |        |        | DL |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+

Inspector Date

12.0 [Water Tube Assembly (ME-404078)]{.underline}

![](media/image16.wmf){width="5.996527777777778in"
height="1.4236111111111112in"}

12.1 Acquire the following parts (X4) and clean using Cleaning

> Specification (ES-333725):

Water Tube ME-404306 1 ea

Water Tube End Cap RH MA-404307 1 ea

Water Tube End Cap LH MA-404308 1 ea

Flare Water Connector MB-404081 2 ea

Water Connector Braze Shim MA-404309 2 ea

Water Tube #1 Water Tube #2

Water Tube #3 Water Tube #4

12.2 Install 3/8" Flare Water Connector (MA-404081) with Water Connector

> Braze Shim (MA-404309) into Water Tube End Cap RH (MA-404307) and
>
> oven braze.
>
> Note: Use Braze Paste (35%Au-65%Cu) around Flare Water Connector.

Note: Ensure flats of the Flare Water Connectors are parallel to each
other.

Water Tube #1 Water Tube #2

Water Tube #3 Water Tube #4

12.3 Install 3/8" Flare Water Connector (MA-404081) with Water Connector

> Braze Shim (MA-404309) into Water Tube End Cap LH (MA-404308) and
>
> oven braze.
>
> Note: Use Braze Paste (35%Au-65%Cu) around Flare Water Connector.

Note: Ensure flats of the Flare Water Connectors are parallel to each
other.

Water Tube #1 Water Tube #2

Water Tube #3 Water Tube #4

> 12.4 Install 3/8" Flare Water Connectors with Water Tube End Caps
>
> (1 ea -- RH/1 ea -- LH) brazed assemblies onto the Water Tube
> (MB-404306).

Note: Ensure Flare Water Connector Assemblies are fully inserted into
the Water Tube.

Water Tube #1 Water Tube #2

Water Tube #3 Water Tube #4

> 12.5 Apply Braze Paste (50%Au-50%Cu Braze Alloy) around the outside of
> the Water Tube End Caps after installation into the Water Tube.

Water Tube #1 Water Tube #2

Water Tube #3 Water Tube #4

Technician(s) Date

X 12.6 Verify the Water Tube Assembly is assembled correctly and is
acceptable for

further processing.

Water Tube #1 Water Tube #2

Water Tube #3 Water Tube #4

Lead Technician Date

12.7 Load Water Tube Assemblies into the Water Tube Brazing
Fixture![](media/image17.wmf){width="4.53125in"
height="5.177083333333333in"} (MC-404325).

> Note: Load water tubes and position with Water Tube Carbon Snap.

Water Tube #1 Water Tube #2

Water Tube #3 Water Tube #4

X 12.8 Verify the Water Tube Assembly is assembled correctly and is
acceptable for

Oven Brazing.

Lead Technician Date

X 12.9 Place the four copper coupons, baked and labeled from the
previous brazing cycle,

> into brazing oven with Water Tubes.

Verify that the recessed side of the coupons is face down in the
furnace.

Lead Technician Date

12.10 Transport to the brazing oven and start the oven braze process of
the Water Tubes.

Technician(s) Date

12.11 Remove Water Tubes and fixture from Brazing Oven.

Technician(s) Date

X 12.12 Remove the four copper coupons. Ensure proper storage with
proper black plastic coupon

> container. Mark the proper labels
>
> Remove one coupon and place in the container and label as "Water Tubes
> Brazing (50/50 cycle)".

Remove three coupons and place in containers for further brazing
processes.

Lead Person Date

12.13 [Vacuum Leak Check the water tubes]{.underline}.

Water Tube #1

+-------+---------+--------+--------+----+------+------+------+------+
| PART  |         | SCALE  | SCALE  | D  |      |      |      |      |
|       |         | UNITS  | UNITS  | ET |      |      |      |      |
| NO.   |         | BEFORE | WHILE  | ER |      |      |      |      |
|       |         | HELIUM | ENC    | MI |      |      |      |      |
|       |         | PROBE  | LOSURE | NA |      |      |      |      |
|       |         |        | FL     | TI |      |      |      |      |
|       |         |        | OODING | ON |      |      |      |      |
|       |         |        |        | OF |      |      |      |      |
|       |         |        |        | M  |      |      |      |      |
|       |         |        |        | IN |      |      |      |      |
|       |         |        |        | IM |      |      |      |      |
|       |         |        |        | UM |      |      |      |      |
|       |         |        |        |    |      |      |      |      |
|       |         |        |        | DE |      |      |      |      |
|       |         |        |        | TE |      |      |      |      |
|       |         |        |        | CT |      |      |      |      |
|       |         |        |        | AB |      |      |      |      |
|       |         |        |        | LE |      |      |      |      |
|       |         |        |        | LE |      |      |      |      |
|       |         |        |        | AK |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
| DATE  | OPER    |        |        | M  |      |      |      |      |
|       | ATOR\'S |        |        | DS |      |      |      |      |
| TIME  | LAST    |        |        | (( |      |      |      |      |
|       | NAME    |        |        | Re |      |      |      |      |
|       |         |        |        | sp |      |      |      |      |
|       |         |        |        | on |      |      |      |      |
|       |         |        |        | se |      |      |      |      |
|       |         |        |        | -B |      |      |      |      |
|       |         |        |        | ck |      |      |      |      |
|       |         |        |        | gn |      |      |      |      |
|       |         |        |        | d) |      |      |      |      |
|       |         |        |        | Le |      |      |      |      |
|       |         |        |        | ak |      |      |      |      |
|       |         |        |        | Va |      |      |      |      |
|       |         |        |        | lu |      |      |      |      |
|       |         |        |        | e) |      |      |      |      |
|       |         |        |        | =  |      |      |      |      |
|       |         |        |        | M  |      |      |      |      |
|       |         |        |        | DL |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+

Water Tube #2

+-------+---------+--------+--------+----+------+------+------+------+
| PART  |         | SCALE  | SCALE  | D  |      |      |      |      |
|       |         | UNITS  | UNITS  | ET |      |      |      |      |
| NO.   |         | BEFORE | WHILE  | ER |      |      |      |      |
|       |         | HELIUM | ENC    | MI |      |      |      |      |
|       |         | PROBE  | LOSURE | NA |      |      |      |      |
|       |         |        | FL     | TI |      |      |      |      |
|       |         |        | OODING | ON |      |      |      |      |
|       |         |        |        | OF |      |      |      |      |
|       |         |        |        | M  |      |      |      |      |
|       |         |        |        | IN |      |      |      |      |
|       |         |        |        | IM |      |      |      |      |
|       |         |        |        | UM |      |      |      |      |
|       |         |        |        |    |      |      |      |      |
|       |         |        |        | DE |      |      |      |      |
|       |         |        |        | TE |      |      |      |      |
|       |         |        |        | CT |      |      |      |      |
|       |         |        |        | AB |      |      |      |      |
|       |         |        |        | LE |      |      |      |      |
|       |         |        |        | LE |      |      |      |      |
|       |         |        |        | AK |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
| DATE  | OPER    |        |        | M  |      |      |      |      |
|       | ATOR\'S |        |        | DS |      |      |      |      |
| TIME  | LAST    |        |        | (( |      |      |      |      |
|       | NAME    |        |        | Re |      |      |      |      |
|       |         |        |        | sp |      |      |      |      |
|       |         |        |        | on |      |      |      |      |
|       |         |        |        | se |      |      |      |      |
|       |         |        |        | -B |      |      |      |      |
|       |         |        |        | ck |      |      |      |      |
|       |         |        |        | gn |      |      |      |      |
|       |         |        |        | d) |      |      |      |      |
|       |         |        |        | Le |      |      |      |      |
|       |         |        |        | ak |      |      |      |      |
|       |         |        |        | Va |      |      |      |      |
|       |         |        |        | lu |      |      |      |      |
|       |         |        |        | e) |      |      |      |      |
|       |         |        |        | =  |      |      |      |      |
|       |         |        |        | M  |      |      |      |      |
|       |         |        |        | DL |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+

Water Tube #3

+-------+---------+--------+--------+----+------+------+------+------+
| PART  |         | SCALE  | SCALE  | D  |      |      |      |      |
|       |         | UNITS  | UNITS  | ET |      |      |      |      |
| NO.   |         | BEFORE | WHILE  | ER |      |      |      |      |
|       |         | HELIUM | ENC    | MI |      |      |      |      |
|       |         | PROBE  | LOSURE | NA |      |      |      |      |
|       |         |        | FL     | TI |      |      |      |      |
|       |         |        | OODING | ON |      |      |      |      |
|       |         |        |        | OF |      |      |      |      |
|       |         |        |        | M  |      |      |      |      |
|       |         |        |        | IN |      |      |      |      |
|       |         |        |        | IM |      |      |      |      |
|       |         |        |        | UM |      |      |      |      |
|       |         |        |        |    |      |      |      |      |
|       |         |        |        | DE |      |      |      |      |
|       |         |        |        | TE |      |      |      |      |
|       |         |        |        | CT |      |      |      |      |
|       |         |        |        | AB |      |      |      |      |
|       |         |        |        | LE |      |      |      |      |
|       |         |        |        | LE |      |      |      |      |
|       |         |        |        | AK |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
| DATE  | OPER    |        |        | M  |      |      |      |      |
|       | ATOR\'S |        |        | DS |      |      |      |      |
| TIME  | LAST    |        |        | (( |      |      |      |      |
|       | NAME    |        |        | Re |      |      |      |      |
|       |         |        |        | sp |      |      |      |      |
|       |         |        |        | on |      |      |      |      |
|       |         |        |        | se |      |      |      |      |
|       |         |        |        | -B |      |      |      |      |
|       |         |        |        | ck |      |      |      |      |
|       |         |        |        | gn |      |      |      |      |
|       |         |        |        | d) |      |      |      |      |
|       |         |        |        | Le |      |      |      |      |
|       |         |        |        | ak |      |      |      |      |
|       |         |        |        | Va |      |      |      |      |
|       |         |        |        | lu |      |      |      |      |
|       |         |        |        | e) |      |      |      |      |
|       |         |        |        | =  |      |      |      |      |
|       |         |        |        | M  |      |      |      |      |
|       |         |        |        | DL |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+

Water Tube #4

+-------+---------+--------+--------+----+------+------+------+------+
| PART  |         | SCALE  | SCALE  | D  |      |      |      |      |
|       |         | UNITS  | UNITS  | ET |      |      |      |      |
| NO.   |         | BEFORE | WHILE  | ER |      |      |      |      |
|       |         | HELIUM | ENC    | MI |      |      |      |      |
|       |         | PROBE  | LOSURE | NA |      |      |      |      |
|       |         |        | FL     | TI |      |      |      |      |
|       |         |        | OODING | ON |      |      |      |      |
|       |         |        |        | OF |      |      |      |      |
|       |         |        |        | M  |      |      |      |      |
|       |         |        |        | IN |      |      |      |      |
|       |         |        |        | IM |      |      |      |      |
|       |         |        |        | UM |      |      |      |      |
|       |         |        |        |    |      |      |      |      |
|       |         |        |        | DE |      |      |      |      |
|       |         |        |        | TE |      |      |      |      |
|       |         |        |        | CT |      |      |      |      |
|       |         |        |        | AB |      |      |      |      |
|       |         |        |        | LE |      |      |      |      |
|       |         |        |        | LE |      |      |      |      |
|       |         |        |        | AK |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
| DATE  | OPER    |        |        | M  |      |      |      |      |
|       | ATOR\'S |        |        | DS |      |      |      |      |
| TIME  | LAST    |        |        | (( |      |      |      |      |
|       | NAME    |        |        | Re |      |      |      |      |
|       |         |        |        | sp |      |      |      |      |
|       |         |        |        | on |      |      |      |      |
|       |         |        |        | se |      |      |      |      |
|       |         |        |        | -B |      |      |      |      |
|       |         |        |        | ck |      |      |      |      |
|       |         |        |        | gn |      |      |      |      |
|       |         |        |        | d) |      |      |      |      |
|       |         |        |        | Le |      |      |      |      |
|       |         |        |        | ak |      |      |      |      |
|       |         |        |        | Va |      |      |      |      |
|       |         |        |        | lu |      |      |      |      |
|       |         |        |        | e) |      |      |      |      |
|       |         |        |        | =  |      |      |      |      |
|       |         |        |        | M  |      |      |      |      |
|       |         |        |        | DL |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+

Inspector Date

13.0 [RF Disk Stacking]{.underline}

![](media/image18.wmf){width="5.979166666666667in"
height="6.020138888888889in"}

> 13.1 Stack the RF Standard Cells into the Carbon V-Block Fixture
> (MC-404310). Ensure
>
> to stack disk using Disk Rotation Aligning Bar (MB-404317). Record
> Disk Serial Numbers
>
> below.

Note: Use approved dry nitrogen, blow off the disk to remove any dusts,
dirts, or

other surface contaminants prior to placing on disk stack-up.

Note: Stack under Class 10 Clean Room Hood.

Note: Ensure to insert Braze Material (72% Ag --28% Cu) between disks
while stacking.

Note: Use 0.035"diameter pin gauge to verify the gaps between the disks
are correct.

  ------------- ---------------------- -- ---------- ----------------------
  No. \#        Disk Serial No.           No. \#     Disk Serial No.

  52 (Base)                               26         

  51                                      25         

  50                                      24         

  49                                      23         

  48                                      22         

  47                                      21         

  46                                      20         

  45                                      19         

  44                                      18         

  43                                      17         

  42                                      16         

  41                                      15         

  40                                      14         

  39                                      13         

  38                                      12         

  37                                      11         

  36                                      10         

  35                                      9          

  34                                      8          

  33                                      7          

  32                                      6          

  31                                      5          

  30                                      4          

  29                                      3          

  28                                      2          

  27                                      1 (Top)    
  ------------- ---------------------- -- ---------- ----------------------

Caution: Ensure Disk #1 (Top) does not have any brazing wire installed
during this step.

Technician(s) Date

13.2 Clamp disks onto Carbon V-Block tooling with Side Carbon Plate and
Side Weight.

Technician(s) Date

13.3 Remove Disk Rotation Aligning Bar (MB-404317) after all Side Carbon
Plates and Side

Weights have been clamped.

Technician(s) Date

13.4 Check the gap between all disks and the Carbon V-Block (MB-404311)
using a 0.001"

feeler gauge. Ensure both side of the Carbon V-Block are checked.

Technician(s) Date

X 13.5 Verify RF Disk Stack is acceptable to continue to oven brazing.
Verify proper

count and position of all disks. Verify that there is no brazing wire in
Disk #1.

Lead Person Date

X 13.6 Place the three copper coupons, baked and labeled from the
previous brazing cycle,

> into brazing oven with RF Disk Stack.

Verify that the recessed side of the coupons is face down in the
furnace.

Lead Person Date

13.7 Transport RF Disk Stack to Brazing Oven and braze in accordance
with

approved methods. Braze the Disk Stack with CUSIL Cycle.

Technician(s) Date

13.8 Remove the RF Disk Stack from the brazing oven and transport to the
next assembly area.

Caution: Ensure ALL flanges are properly protected from damage during

transport and further assembly/measurement processes.

Technician(s) Date

X 13.9 Remove the three copper coupons. Ensure proper storage with
proper black plastic coupon

> container. Mark the proper labels
>
> Remove one coupon and place in the container and label as "Disk Stack
> Brazing (CUSIL cycle)".

Remove two coupons and place in containers for further brazing
processes.

Lead Person Date

14.0 [Structure Assembly]{.underline}

**Caution: During the assembly of the RF Structure, ensure that all
flange sealing**

**surfaces are protected from damage during handling.**

14.1 Install Input Coupler Assembly w/WG Flange (MC-404296) on Disk
Stack.

14.2 Install Output Coupler Assembly w/WG Flanges (MC-404301) on Disk
Stack.

![](media/image19.wmf){width="3.6770833333333335in"
height="1.3020833333333333in"}

Note: Use Disk Rotation Aligning Bar Short (MB-404362) to align disk
stack

and disk coupler together.

Technician(s) Date

14.3 Insert two (2) layers of Cusil wire (0.015") into the circumference
between all disks including

disks on the Input and Output Couplers.

![](media/image20.wmf){width="5.997222222222222in"
height="1.7361111111111112in"} Note: Ensure both layers of Cusil Rod are
below the outer surface of the disks.

Technician(s) Date

14.4 Verify Structure Assembly is acceptable for oven brazing.

Lead Person Date

14.5 Transport Structure Assembly to oven and oven brazing.

Technician(s) Date

14.6 Place the two copper coupons, baked and labeled from the previous
brazing cycle,

> into brazing oven with RF Disk Stack and RF Couplers.

Verify that the recessed side of the coupons is face down in the
furnace.

Lead Person Date

X 14.7 Braze (CUSIL) the Structure Assembly in accordance with approved
methods.

Lead Person Date

14.8 Remove the Structure Assembly from the oven and transport to the
next assembly

area.

**Caution: Ensure ALL flanges are properly protected from damage**

**during transport and further assembly/measurement processes.**

Technician(s) Date

X 14.8 Remove the two copper coupons. Ensure proper storage with proper
black plastic coupon

> container. Mark the proper labels
>
> Remove one coupon and place in the container and label as "Disk Stack
> to Couplers Brazing (CUSIL cycle)".

Remove one coupon and place in containers for further brazing processes.

Lead Person Date

14.9 Vacuum Leak Check the RF Structure without Water Tubes. Use 12 pt
head

> SS bolts, copper gaskets and nuts to seal the RF Flanges. Use an
> alternating pattern for tightening. Use a maximum of 13 in/lbs of
> torque.
>
> Caution: Use two wrenches to tighten the bolts and hold the nuts in
> order not to twist the RF Flanges during sealing.

+-------+---------+--------+--------+----+------+------+------+------+
| PART  |         | SCALE  | SCALE  | D  |      |      |      |      |
|       |         | UNITS  | UNITS  | ET |      |      |      |      |
| NO.   |         | BEFORE | WHILE  | ER |      |      |      |      |
|       |         | HELIUM | ENC    | MI |      |      |      |      |
|       |         | PROBE  | LOSURE | NA |      |      |      |      |
|       |         |        | FL     | TI |      |      |      |      |
|       |         |        | OODING | ON |      |      |      |      |
|       |         |        |        | OF |      |      |      |      |
|       |         |        |        | M  |      |      |      |      |
|       |         |        |        | IN |      |      |      |      |
|       |         |        |        | IM |      |      |      |      |
|       |         |        |        | UM |      |      |      |      |
|       |         |        |        |    |      |      |      |      |
|       |         |        |        | DE |      |      |      |      |
|       |         |        |        | TE |      |      |      |      |
|       |         |        |        | CT |      |      |      |      |
|       |         |        |        | AB |      |      |      |      |
|       |         |        |        | LE |      |      |      |      |
|       |         |        |        | LE |      |      |      |      |
|       |         |        |        | AK |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
| DATE  | OPER    |        |        | M  |      |      |      |      |
|       | ATOR\'S |        |        | DS |      |      |      |      |
| TIME  | LAST    |        |        | (( |      |      |      |      |
|       | NAME    |        |        | Re |      |      |      |      |
|       |         |        |        | sp |      |      |      |      |
|       |         |        |        | on |      |      |      |      |
|       |         |        |        | se |      |      |      |      |
|       |         |        |        | -B |      |      |      |      |
|       |         |        |        | ck |      |      |      |      |
|       |         |        |        | gn |      |      |      |      |
|       |         |        |        | d) |      |      |      |      |
|       |         |        |        | Le |      |      |      |      |
|       |         |        |        | ak |      |      |      |      |
|       |         |        |        | Va |      |      |      |      |
|       |         |        |        | lu |      |      |      |      |
|       |         |        |        | e) |      |      |      |      |
|       |         |        |        | =  |      |      |      |      |
|       |         |        |        | M  |      |      |      |      |
|       |         |        |        | DL |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+

Technician(s) Date

15.0 [Bead Pull Measurements & RF Tuning]{.underline}

**Caution: Ensure ALL flanges are properly protected from damage**

**during transport and further assembly/measurement processes.**

> ![](media/image21.wmf){width="3.75in"
> height="4.114583333333333in"}15.1 Perform a Bead Pull Measurement and
> Disk Tuning on the RF Structure

Technician(s) Date

X 15.2 Review the results of the Bead Pull Measurement/Tuning. RF
Structure is acceptable for

for further processing.

Bead Pull Measurement Engineer/designee Date

16.0 [Water Tube Installation]{.underline}

**Caution: Ensure ALL flanges are properly protected from damage**

**during transport and further assembly/measurement processes.**

> 16.1 Install Water Tube Assemblies (ME-404078)(4 ea) onto the RF Disk
> Structure with proper tooling.

Technician Date

16.2 Transport RF Structure w/Water Tubes to Vacuum Oven for brazing.

Technician Date

X 16.3 Place the one copper coupon, baked and labeled from the previous
brazing cycle,

> into brazing oven with Final brazing parts.

Verify that the recessed side of the coupons is face down in the
furnace.

.

Lead Person Date

16.4 Braze (CusilTin) the RF Structure with Water Tubes.

Technician Date

16.5 Remove the RF Structure Assembly from the oven and transport to the
next assembly area.

> **Caution. Ensure ALL flanges are properly protected from damage
> during transport and further assembly/measurement processes.**

Technician Date

X 16.6 Remove one copper coupon. Ensure proper storage with proper black
plastic coupon

> container. Mark the proper labels
>
> Remove one coupon and place in the container and label as
>
> "Final Brazing (CusilTin cycle)".

Lead Person Date

17.0 [Vacuum Flange Installation]{.underline}

**Caution: Ensure ALL flanges are properly protected from damage**

**during transport and further assembly/measurement processes.**

17.1 Install Non-Rotatable Vacuum Flange (MB-404092) onto the Input
Coupler Drift Tube

and weld.

Note: Prior to welding, verify dimensions are correct. Refer to Step
18.0 for dimensions.

Technician(s) Date

Weldor Date

17.2 Install Rotatable Vacuum Flange (MB-404093) onto the Output Coupler
Drift Tube

and weld.

Note: Prior to welding, verify dimensions are correct. Refer to Step
18.0 for dimensions.

Technician(s) Date

Weldor Date

17.3 Vacuum Leak Check RF Structure Assembly. Use 12 pt head SS bolts,
copper gaskets

> and nuts to seal the RF Flanges. Use an alternating pattern for
> tightening. Use a maximum
>
> of 13 in/lbs of torque.
>
> Caution: Use two wrenches to tighten the bolts and hold the nuts in
> order not to twist the RF Flanges during sealing.

+-------+---------+--------+--------+----+------+------+------+------+
| PART  |         | SCALE  | SCALE  | D  |      |      |      |      |
|       |         | UNITS  | UNITS  | ET |      |      |      |      |
| NO.   |         | BEFORE | WHILE  | ER |      |      |      |      |
|       |         | HELIUM | ENC    | MI |      |      |      |      |
|       |         | PROBE  | LOSURE | NA |      |      |      |      |
|       |         |        | FL     | TI |      |      |      |      |
|       |         |        | OODING | ON |      |      |      |      |
|       |         |        |        | OF |      |      |      |      |
|       |         |        |        | M  |      |      |      |      |
|       |         |        |        | IN |      |      |      |      |
|       |         |        |        | IM |      |      |      |      |
|       |         |        |        | UM |      |      |      |      |
|       |         |        |        |    |      |      |      |      |
|       |         |        |        | DE |      |      |      |      |
|       |         |        |        | TE |      |      |      |      |
|       |         |        |        | CT |      |      |      |      |
|       |         |        |        | AB |      |      |      |      |
|       |         |        |        | LE |      |      |      |      |
|       |         |        |        | LE |      |      |      |      |
|       |         |        |        | AK |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
| DATE  | OPER    |        |        | M  |      |      |      |      |
|       | ATOR\'S |        |        | DS |      |      |      |      |
| TIME  | LAST    |        |        | (( |      |      |      |      |
|       | NAME    |        |        | Re |      |      |      |      |
|       |         |        |        | sp |      |      |      |      |
|       |         |        |        | on |      |      |      |      |
|       |         |        |        | se |      |      |      |      |
|       |         |        |        | -B |      |      |      |      |
|       |         |        |        | ck |      |      |      |      |
|       |         |        |        | gn |      |      |      |      |
|       |         |        |        | d) |      |      |      |      |
|       |         |        |        | Le |      |      |      |      |
|       |         |        |        | ak |      |      |      |      |
|       |         |        |        | Va |      |      |      |      |
|       |         |        |        | lu |      |      |      |      |
|       |         |        |        | e) |      |      |      |      |
|       |         |        |        | =  |      |      |      |      |
|       |         |        |        | M  |      |      |      |      |
|       |         |        |        | DL |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+
|       |         |        |        |    |      |      |      |      |
+-------+---------+--------+--------+----+------+------+------+------+

Technician(s) Date

17.4 After final vacuum leak check with vacuum flanges welded, RF
sStructure is to be processed

in the large vacuum furnace as below:

17.4.1 500^o^ C for 2 hrs in 1 torr positive presseure of 3%
hydrogen/97% argon atmosphere.

RequiredNot Required

17.4.2 500^o^ C for 72 hrs in full vacuum. (Must be performed)

Technician(s) Date

> 17.5 Upon completion of vacuum bake, immediately apply a positive
> pressure dry nitrogen purge to the RF Structure upon opening the oven.

Note: Structure is not vacuum leak checked after final bake-out.

Technician(s) Date

17.6 Cover all RF Flanges with aluminum foil, allowing nitrogen purge to
flow, prior to removal

from large furnace.

Technician(s) Date

17.7 While maintaining a positive pressure dry nitrogen purge, move the
RF Structure to the

> clean room.
>
> 17.8 Install all the vacuum blank-off flanges and RF Flanges while
> maintaining positive pressure dry nitrogen purge. Use 12 pt head SS
> bolts, copper gaskets and nuts to seal the RF Flanges. Use an
> alternating pattern for tightening. Use a maximum of 13 in/lbs of
> torque.
>
> Caution: Use two wrenches to tighten the bolts and hold the nuts in
> order not to twist the RF Flanges during sealing.
>
> 17.9 Fill RF Structure with dry nitrogen pressure and secure valve
> closed. Install cap on Nupro valve
>
> to prevent dust, etc from entering valve orifice and to prevent loss
> of nitrogen pressure.
>
> Record dry nitrogen pressure in table below.

  -----------------------------------------------------------------------
  **Pressure**

  **PSI**
  -----------------------------------------------------------------------

Technician(s) Date

18.0 [RF Structure Measurements (SLAC reqeusted)]{.underline}

18.1 Perform the appropriate measurements and record results in the
boxes indicated on

the drawing below.

![](media/image22.wmf){width="5.489583333333333in" height="7.625in"}

Inspector Date

19.0 [Structure/Girder Installation]{.underline}

**Caution: Ensure ALL flanges are properly protected from damage**

**during transport and further assembly/measurement processes.**

![](media/image23.wmf){width="5.995138888888889in" height="1.1625in"}

19.1 Install RF Structure onto girder and secure using girder fixtures.

Technician(s) Date

19.2 Install Beam Tube (Fermilab supplied) onto girder and secure.

Technician(s) Date

> 19.3 Verify and Record Dry Nitrogen pressure in table below.

  -----------------------------------------------------------------------
  **Pressure**

  **PSI**
  -----------------------------------------------------------------------

Technician(s) Date

19.4 Affix Girder/Structure identification.

19.5 Transport Girder Assembly to shipping container.

19.6 Insert girder assembly into shipping container and secure.

Technician(s) Date

20.0 [Documentation Update]{.underline}

20.1 Perform the following:

Update DSR Keywords

Location

Location Verified Date

Status

Make entry regarding work performed.

TD/E&F Process Engineering Date

21.0 [Production Complete]{.underline}

> 21.1 Process Engineering verify that the NLC RF Structure w/MC
> Couplers Assembly Traveler (5520-TR-333XXX) 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, Nonconformance Reports, Repair/Rework Forms, Deviation Index
> and dispositions have been reviewed by the Responsible Authority for
> conformance before being approved.

Comments:

Process Engineering/Designee Date