1. Summary of Fuse Testing for Barrel Module Fuse Boxes
Duke University
Jack Fowler

2. Fuse Box Production Summary
Fuse Boxes have been in production for ~ 12 months
35 sets of each type are being produced
This involves > 7500 fuses
Fuses were delivered from Oct 03 until Aug 04

3. Fuse Box Production Steps
Assemble Fuse Box components and solder
Test Fuse Resistance
Clean Fuse boxes and dry
Dry fuse boxes for minimum 3 hrs at < 55° C
Conformal coat fuse box components
Final Test Boxes - continuity at < 100 V and check for breakdown at 2 kV
Final assembly – add hardware and heat shrink and label cables

4. Fuse Boxes

5. Post Production Tests
In January ’05 all fuse boxes were place under current for conditioning.
After two weeks half of these fuse boxes were removed from current (Group A) and the remaining half remained under current until April ’05 (Group B). Each group contains ~3700 fuses.
The following slides show the test set up and the results of the testing for each group.

6. Fuse Box Conditioning

7. Fuse Box Connections

8. Group A Test Results

9. Group B Test Results

10. Summary
Before conditioning, fuse failures seemed to be stabilizing at ~ 0.1 % per week.
Group A had 12 failures in 16 weeks or 0.75 fuses / week.
Group B had 10 failures in 16 weeks or fuses / week.
Total failure was 22 fuses in 16 weeks or fuses / week.