+-----------+----------------------+------------------------+---------+
| f         | **Fermi National     |                        |         |
|           | Accelerator          |                        |         |
|           | Laboratory**         |                        |         |
|           |                      |                        |         |
|           | **Batavia, IL        |                        |         |
|           | 60510**              |                        |         |
+-----------+----------------------+------------------------+---------+
| **LQF**   |                      |                        |         |
|           |                      |                        |         |
| **5 TURN  |                      |                        |         |
| QUADRANT  |                      |                        |         |
| 1/3**     |                      |                        |         |
|           |                      |                        |         |
| **COIL    |                      |                        |         |
| WINDING   |                      |                        |         |
| T         |                      |                        |         |
| RAVELER** |                      |                        |         |
+-----------+----------------------+------------------------+---------+
| **        |                      |                        |         |
| Reference |                      |                        |         |
| Dra       |                      |                        |         |
| wing(s)** |                      |                        |         |
|           |                      |                        |         |
| **5 Turn  |                      |                        |         |
| ME        |                      |                        |         |
| -351095** |                      |                        |         |
+-----------+----------------------+------------------------+---------+
| **Budget  |                      | **Project Code: CCW**  |         |
| Code:     |                      |                        |         |
| FGA**     |                      |                        |         |
+-----------+----------------------+------------------------+---------+
| *         |                      | **Date:**              |         |
| *Released |                      |                        |         |
| by:**     |                      |                        |         |
+-----------+----------------------+------------------------+---------+
| *         |                      |                        |         |
| *Prepared |                      |                        |         |
| by:** R.  |                      |                        |         |
| Safarik   |                      |                        |         |
+-----------+----------------------+------------------------+---------+
| **Title** |                      | **Signature**          | *       |
|           |                      |                        | *Date** |
+-----------+----------------------+------------------------+---------+
| **TD /    |                      |                        |         |
| E&F       |                      |                        |         |
| Process   |                      |                        |         |
| Engi      |                      |                        |         |
| neering** |                      |                        |         |
+-----------+----------------------+------------------------+---------+
| **TD /    |                      |                        |         |
| E&F       |                      |                        |         |
| A         |                      |                        |         |
| ssembly** |                      |                        |         |
+-----------+----------------------+------------------------+---------+
| **TD /    |                      |                        |         |
| E&F       |                      |                        |         |
| Tooling** |                      |                        |         |
+-----------+----------------------+------------------------+---------+
| **TD /    |                      |                        |         |
| E&F       |                      |                        |         |
| Fa        |                      |                        |         |
| brication |                      |                        |         |
| Manager** |                      |                        |         |
+-----------+----------------------+------------------------+---------+
| **TD /    |                      |                        |         |
| E&F       |                      |                        |         |
| Device    |                      |                        |         |
| Design**  |                      |                        |         |
+-----------+----------------------+------------------------+---------+
| **TD /    |                      |                        |         |
| QA/QC     |                      |                        |         |
| Manager** |                      |                        |         |
+-----------+----------------------+------------------------+---------+
| **TD /    |                      |                        |         |
| E&F       |                      |                        |         |
| D         |                      |                        |         |
| epartment |                      |                        |         |
| Head**    |                      |                        |         |
+-----------+----------------------+------------------------+---------+

**[Revision Page]{.underline}**

  -------------- ----------------------------------------------------- ----------
  **Revision**   **Revision Description**                              **Date**

                                                                       

  A              Major re-write due to first edition changes. TRR No.  4/4/97
                 0640                                                  

                                                                       

  B              Changed Budget Code to 'FGA' on cover page. Corrected 8/15/97
                 text in Step(s) 6.4 to read 'five turn'. Inserted     
                 Step(s) 5.10 to indicate location of possible         
                 conductor joint. TRR No. 0696                         

                                                                       

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

**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 Cover the LQF Coils with green Herculite (Fermi stock 1740-0100)
when not being serviced or assembled. Completed coils are to be stored
in the LQF Coil Storage Area.

2.0 [Parts Kit List]{.underline}

2.1 Attach the completed Parts Kit List for the LQF 5 Turn Coil Winding
to this traveler. Ensure that the serial number on the Parts Kit List
matches the serial number of this traveler. Verify that the Parts Kit
received is complete.

Process Engineering/Designee Date

**\[This Page Intentionally Left Blank\]**

3.0 [Coil Winding Table Setup Procedure]{.underline}

3.1 Set up the winding fixture as indicated in below for the coil which
is about to be wound. Attach the Outside End Plate (Return End
MD-185811) to the winding fixture. All coil contacting surfaces of the
fixture must be cleaned with KPC 820N (Fermi stock 1920-0700) and Heavy
Disposable Wipers (Fermi stock 1660-2600) or equivalent

  ----------- -------------- -------------------- -------------------- -----------
  **LQF Coil                                                           
  Winding                                                              
  Fixture**                                                            

  **Turns**   **Quadrant**   **Print Number**     **Fixture Number**   **Init.**

  5           1 / 3          ME-351095            ME-135575            
  ----------- -------------- -------------------- -------------------- -----------

Technician(s) Date

**X** 3.2 Using a Steel Measuring Tape (Starrett Cat. No. W530F-50 or
equivalent) verify the length of the winding mandrel from the two outer
most sides of the fixture. The nominal length is indicated in the table
below. Complete the table.

  ----------- -------------- --------------- --------------- --------------- ------------
  **LQF Coil                                                                 
  Winding                                                                    
  Fixture**                                                                  

  **Turns**   **Quadrant**   **Print         **Fixture       **Fixture       **Length**
                             Number**        Number**        Length**        

  5           1 / 3          ME-351095       ME-135575       38.182\"        
  ----------- -------------- --------------- --------------- --------------- ------------

Lead Person Date

3.3 Set the adjustable tensioning arm on the spindle to the half way
point. Position the winding fixture so that the transition is facing the
tensioning arm. Turn the fixture so that the transition Step is vertical
to the winding table. (See diagram below).

![](media/image1.emf){width="2.9166666666666665in"
height="2.263888888888889in"}

**Pictures for Reference only.**

Technician(s) Date

**\[This Page Intentionally Left Blank\]**

4.0 [Conductor Prep]{.underline}

**X** 4.1 Perform a BB Inspection of the conductor cooling passage with
a .344\" diameter ball bearing. Cover the exit hole on the reel of
conductor with a rag or slide a glove over the end of the conductor to
catch the ball bearings. Use minimum required air pressure (1 to 10
psi.) to test the reel of conductor.

Reel \# 1 Pass Fail

**Note(s):**

**If the BB Inspection fails notify supervisor.**

Lead Person Date

4.2 After clamping the conductor to the winding fixture, anneal
sufficient conductor to complete the first 90° Bend BEFORE winding.
Flame anneal at a temperature of 800° F to 1200° F. Monitor the
conductor temperature using Temperature Crayons (McMaster-Carr Part
Numbers 3261K91 (800° F), (1000° F), (1200° F) or equivalent).

**Note(s):**

> **The conductor should be clamped to the fixture in a manner such that
> the joint will NOT be closer than 6" from any bend.**

Technician(s) Date

4.3 Engage the adjustable tensioning arm, backing it away from the
fixture, increase the pressure on the Phenolic block until the gage
reads 1000 lbs. force ± 100 lbs. not to exceed 1100 lbs. force. and stop
the tensioning arm.

Technician(s) Date

5.0 [5 Turn Winding]{.underline}

**Note(s):**

> **For all subsequent operations of the winding table refer to the
> Large Turn Table (Winding Table) Operation Procedure
> (5525-OP-318944).**

**At no time is a hammer to be used directly against the conductor.**

**At no time is a hammer to be used directly against the conductor. The
following materials are acceptable wood or nylon.**

**Ensure that no twist has occurred in the conductor between the reel
and the Phenolic guide block.**

5.1 Engage the winding table in the clockwise direction for 90°, use
minimum hammer force necessary to form the turn to the fixture and avoid
conductor damage. Monitor the clamping cylinder pressure so that the
load cell gauge reads 1000 lbs. force ± 100 lbs. Maximum pressure should
not exceed 1100 lbs force. Adjust the pressure to the clamping cylinder
as necessary.

Technician(s) Date

5.2 Energize the Tilt-Top and rotate the winding fixture 90° forming the
conductor to the fixture. Winding through the transition down on to the
two (2) turn layer section of the winding fixture. Maintain tension with
the adjustable tensioning arm on the tensioning device. Clamp the
conductor to the winding fixture using Clamps (MC-185804/MC-185805) as
required. Attach the Outside End Plate (MD-185808) to the lead end over
the conductor.

Technician(s) Date

5.3 Adjust the pressure valve to maintain the tensioner clamping
cylinder at 1500 lbs. force ± 100 lbs. as winding continues for the next
180°, then stop. Ensure that the maximum readings do not exceed 1600
lbs. force. Use minimum hammer force necessary to form the turn and
avoid conductor damage. Restrain the conductor to the end plate as
necessary by using Clamps (MC-185804 / MC-185805).

Technician(s) Date

**X** 5.4 Verify that the tension of the conductor load cell gauge reads
1500 lbs. force ± 100 lbs measured during the continued winding table
rotation. Ensure that the maximum readings do not exceed 1600 lbs force.

Record Actual Tension Pass Fail

Lead Person Date

**X** 5.5 Perform a Height and Width Dimension Check of the conductor
half-way between the tensioner and the winding fixture before winding
the coil.

  ----------- --------------- --------------- ------ ------ ---------------
  Dimension   Limit           Actual          Pass   Fail   Out of
                              Measurement                   Tolerance

  Height      1.485" to                                     
              1.505"                                        

  Width       .615" to .630"                                
  ----------- --------------- --------------- ------ ------ ---------------

Lead Person Date

5.6 Energize the Tilt-Top and form the conductor to the fixture as it
rotates 90°. Use minimum hammer force necessary to form the turn and
avoid conductor damage.

Technician(s) Date

5.7 Rotate the winding table clockwise 180°, forming the conductor to
the winding fixture as it rotates. Use minimum hammer force necessary to
form the turn and avoid conductor damage, clamping the conductor to the
winding fixture using the Clamps (MC-185804/MC-185805) as required.

Technician(s) Date

5.8 Cut a .0299\" shim (MA-xxxxxx) to a length fitting the saddle
section of the coil. Position the shim between the turns as the Tilt-Top
rotates 90°, form the conductor to the fixture as it rotates. Use
minimum hammer force necessary to form the turn and avoid conductor
damage.

Technician(s) Date

5.9 Cut a .0299\" shim (MA-xxxxxx) to a length of 25\". Position the
shim along the straight section of the coil between the turns as the
winding table rotates clockwise 180°, forming the conductor to the
winding fixture as it rotates. Use minimum hammer force necessary to
form the turn and avoid conductor damage, clamping the conductor as
required to the winding fixture using Clamps (MC-185804/MC-185805).

**Note(s):**

> **At no time are there to be shims placed at the one inch radius from
> the saddles to the straight sections or straight sections to the
> saddles. The shims from the straight sections and the saddles shall
> not protrude out (into the one inch radius area) from the conductor in
> such a way as to effect the winding of the two turn layer.**

**At NO TIME during the winding process is the conductor to be pulled**

**free of the tensioning device.**

Technician(s) Date

5.10 Using the following picture, mark the location of any conductor
splices.

![](media/image2.emf){width="4.583333333333333in"
height="2.1666666666666665in"}

Distance from lead end: Turn count:

Technician(s) Date

5.11 Repeat steps 5.8 through 5.9 until five (5) turns may be counted on
both sides (straight sections) of the winding fixture.

Technician(s) Date

6.0 [Lead Bending Procedure]{.underline}

**X** 6.1 Verify that all 5 turns are wound, that no twist is in the
conductor and that the shims are installed between the turns and the
saddles. Ensure that none of the shims extend into the transition
between the straight sections to the saddles interfering with the six
turn layer.

Lead Person Date

> 6.2 Rotate the winding table clockwise 90°, forming the conductor to
> the winding fixture as it rotates. Use minimum hammer force necessary
> to form the turn and avoid conductor damage, clamping the conductor to
> the winding fixture using a c-clamps as required. Attach The Bend
> Attachment (MC-185784) to the winding fixture.

Technician(s) Date

6.3 Clamp the conductor presently going to the tensioner to the winding
fixture. Mark the lead to be cut beyond the winding fixture. Release the
tensioning device.

Technician(s) Date

**XX** 6.4 Verify that the fixture is of the correct configuration to
bend the five turn layer lead. Verify that the lead is marked long
enough to allow the lead to be bent by hand, ensuring that once the lead
is bent, there is a sufficient amount of material remaining to scribe
the lead as indicated by the bending fixture.

Lead Person Date

Crew Chief Date

6.5 Cut the leads beyond the end of the fixture, using a portable band
saw or equivalent.

Technician(s) Date

6.6 Anneal the conductor BEFORE completing the Lead Bending. Flame
anneal at a temperature of 800° F to 1200° F. Monitor the conductor
temperature using Temperature Crayons (McMaster-Carr Part Numbers
3261K91 (800° F), (1000° F), (1200° F) or equivalent).

Technician(s) Date

6.7 Bend the conductor to conform to the bending fixture attachments.
Use minimum hammer force necessary to form the turn and avoid conductor
damage. Scribe the lead as indicated by the bending fixture attachment.

![](media/image3.emf){width="2.4583333333333335in"
height="2.1805555555555554in"}

Technician(s) Date

**X** 6.8 Verify that the conductor lead conforms to the bending fixture
attachments and the leads have been

scribed as indicated by the bending fixture attachments.

Lead Person Date

6.9 Using a hand drill and vise or equivalent with a 1/2\" drill bit,
clamp the leads into the vise and counter bore the leads to a depth of
3/8\".

**Note(s):**

**When drilling, [DO NOT]{.underline} drill through the side of the
conductor.**

Technician(s) Date

6.10 Position two (2) pieces into the counter bored holes, one (1) per
lead of 1/2\" x .032\" x 3\" Soft Copper Tubing (Fermi stock 1065-0075)
or equivalent. Heat the copper conductor with a torch until the area
surrounding the joint is cherry red. Apply Sil-Fos \# 15 (MA-116256) at
the joint. Feed the Sil-Fos #15 into the joint and move the torch around
the joint to produce 100% Sil-Fos #15 flow and a uniform braze. Refer to
the General Brazing Specification (ES-318973).

**Note(s):**

**CAUTION, material and areas being heated represent a burn hazard.**

**Do not over heat the material causing the copper to flow.**

**Do not use water to cool the joint. Allow all brazed joint to air
cool.**

Allow the joints to cool to below 100° F before proceeding to the next
step.

Technician(s) Date

6.11 Remove all c-clamps/clamping fixtures. Remove the bolts from both
the inside and outside end plates located at the return and lead end of
the winding fixture.

**Note(s):**

> **When disassembling the winding fixture use extreme caution so as not
> to damage the wound coil.**

Technician(s) Date

**X** 6.12 Ensure that there are no further obstructions that may
interfere with the removal of the wound coil from the winding fixture.

Lead Person Date

6.13 Remove the coil from the winding fixture. Install Tie-Wraps
**(MX-XXXXXX)** to retain coil shape. Transport the wound coil to the
coil staging area using a coil transport cart and cover the coil with
green Herculite (Fermi stock 1740-0100) .

Technician(s) Date

**\[This Page Intentionally Left Blank\]**

7.0 [Production Complete]{.underline}

**XXX** 7.1 Process Engineering verify that the LQF 5 Turn Coil Winding
Traveler (5520-TR-333197) 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, 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

**XXX** 7.2 Assembly verify that the LQF 5 Turn Coil Winding Traveler
(5520-TR-333197) 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:

Assembly/Designee Date

8.0 Attach the Process Engineering \"Okay to Proceed\" Tag to the coil.

Process Engineering/Designee Date

9.0 Proceed to the next major assembly operation - LQF 5 Turn Coil Prep
Traveler (5520-TR-333209).