Updated - SHB pulsed HPA ESD MARKUP Rev.1.pdf

Advanced Light Source Upgrade Project

Lawrence Berkeley National Laboratory

Advanced Light Source Sub-Harmonic Buncher Pulsed RF Amplifier

Engineering Specification Document

Release Date:

Document Number: AL-1887-8780 Revision: A

Document Status :

Document Type: SPECIFICATION

Category Code:

ALS LINAC Sub Harmonic Buncher Amplifier Systems

TABLE OF CONTENTS

1 Revision History

2 Approvals

3 Abbreviations and Acronyms

4 Requirement Definitions

5 Introduction

5.1.1 HPA General Requirements

5.1.2 HPA RF Specifications

5.1.3 Environmental Parameters ................................. Error! Bookmark not defined.

5.3 RF Power Module

5.4 RF Amplifier Modules, Pre-Amplifier Modules

5.5 RF Power Combiner, Splitter, Coupler Signals

5.6 DC Power Scheme

5.7 Forced Clean Air Cooling

5.8 External Interfaces

5.9 Design and Manufacturing Requirements

5.10 Construction Requirements

5.11 Control System

5.11.1 Control System General Requirements

5.11.2 HPA FO Input signals

5.11.3 HPA FO Output Signals

6 Applicable Documents

1 REVISION HISTORY

Rev. CM Number Description of Change A AL-1887-8780 Original Release

2 APPROVALS

The following individual(s) shall review and approve this document:

Approver Name Project Role Benjamin Flugstad Electrical Engineering Hardware Group Lead: Engineering and ALS Divisions Qiang Du Accelerator/Advanced Technology Group Lead David Nett RF System EE

3 ABBREVIATIONS AND ACRONYMS

AC Alternating Current ALS Advanced Light Source

ALS-U

ANSI

Advanced Light Source Upgrade American National Standards Institute

AR

ASCE

ASME

BW

Accumulator Ring American Society of Civil Engineers American Society of Mechanical Engineers Band Width

COTS

CW

dB

DC

DFMECA

EIA

EN

Commercial Off The Shelf Continuous Wave Decibel Direct Current Design Failure Mode, Effects, and Criticality Analysis Electronic Components Industry Association European Norms

EPICS

EPS

ES&H

ESD

FCC

FDR

Experimental Physics and Industrial Control System Equipment Protection System Environment Safety and Health Engineering Specification Document Federal Communications Commission Final Design Review

FET

FO

Field Effect Transistor Fiber Optic

FPGA Field-Programmable Gate Array

FSM

GaN

Finite State Machine Gallium Nitride

HMI Human Machine Interface HPA High Power Amplifier

ID

IEC

IEEE

IP

IP

ISM

Identification International Electrotechnical Commission Institute of Electrical and Electronics Engineers Ingress Protection Internet Protocol Industrial, Scientific and Medical

LBNL Lawrence Berkeley National Laboratory

LCW

LED

Low Conductivity Water Light Emitting Diode

LDMOS Laterally Diffused Metal Oxide Semiconductor LLRF Low-Level RF

LOTO

MCB

MCCB

MTBF

NFPA

NIR

Lock Out Tag Out Miniature Circuit Breaker Molded Case Circuit Breaker Mean Time Between Failure National Fire Protection Association Non Ionizing Radiation

NRTL Nationally Recognized Test Laboratory

NUM

OPC-UA

OSHA

PDR

Number Open Platform Communications United Architecture Occupational Safety and Health Administration Preliminary Design Report

PIN P-type/Intrinsic/N-type semiconductor (diode)

PLC

PRF

PRI

Programmable Logic Controller Pulse Repetition Frequency Pulse Repetition Interval

PS

QCP

Power Supply Quasi Constant Power

RF

RMS

RPM

RPM

RTU

SHB

SFC

Radio Frequency Root Mean Squared Requirements and Policies Manual Revolutions Per Minute Remote Terminal Unit Sub Harmonic Buncher Sequential Function Chart

SSA

ST

TCP

UL

Solid State Amplifier Structured Text Transmission Control Protocol Underwriters Laboratories

VAC Voltage Alternating Current

VHDL

VSWR

(VHSIC-HDL) Very High Speed Integrated Circuit Hardware Description Language Voltage Standing Wave Ratio

4 REQUIREMENT DEFINITIONS

The meaning of the words used in the Requirement/ Specifications Definitions are as follows

May – is used to indicate a desire or goal of a specification. This can also be interpreted ‘as nice to have’ and are not contractually binding.

Shall – is used to indicate that a specification is contractually binding and must be implemented.

Should – is used to indicate a desire or goal of a specification. This can also be interpreted ‘as nice to have’ and are not contractually binding.

Will – is used to inform intent or declaration of purpose. This is not a specification.

5 INTRODUCTION

This document provides the engineering specifications and requirements for two RF pulsed HPA units, having flat top RF output power of 25 kW with one HPA unit operating at approximately 125

MHz and second HPA unit operating at approximately 500 MHz, to be designed and built using the latest solid state LDMOS FET OR GaN FET OR Equivalent /better FET technologies. The 125 MHz HPA unit will be hereinafter referred to as HPA-1. The 500 MHz HPA unit will be hereinafter to simply as the HPAs in this document. These HPAs are required for providing very stable pulsed

RF high to the two Sub Harmonic Buncher (SHB-1 and SHB-2) RF Cavities operating at nearly 125

MHz and 500 MHz respectively, in the LINAC of the Advanced Light Source (ALS) at LBNL. The new solid state HPAs will be replacing the existing tube-based pulsed HPAs for the SHB’s cavities as the existing HPAs are nearing end of their service life and they have been operating with reduced performance for quite some time.

The requirements & specifications cover various subsystems of the HPAs including RF, AC and DC power, cooling, construction, standards, controls, etc. in the following sections. The pulsed RF power output shall be realized by efficiently combining the pulsed RF output power from many RF Amplifier

Modules using a suitable RF power combiner.

The HPAs will follow a product life cycle managed by a single vendor as follows:

(1) Preliminary Design by the Vendor

(2) Preliminary Design Review (PDR) conducted by the Vendor together with LBNL

(3) Final Design by the Vendor

(4) Final Desk Safety Review certification by a NRTL to International standards with Vendor and LBNL Final Design Review (FDR) conducted by the Vendor together with LBNL

(5) Manufacturing of the HPAs at the Vendor

(6) Preliminary NRTL evaluation certification to International standards with Vendor and LBNL

(7) Continuous 100 hour heat run reliability test (Conducted by the Vendor and witnessed by

LBNL representative at the Vendor site)

(8) Factory Acceptance Test (Conducted by the Vendor and witnessed by LBNL at the Vendor)

(9) Shipment of HPAs from Vendor to LBNL

(10) Installation of HPAs at LBNL with guidance and oversight from vendor representative

(11) Site Acceptance Tests (at LBNL with Vendor present to conduct the tests)

(12) Operating Phase with ongoing technical support by Vendor

The HPAs shall be designed and manufactured to meet the following requirements and specifications:

5.1 High Power Amplifier (HPA)

5.1.1 HPA General Requirements

ID NUM

(S09-09-)

Requirement

020000 The RF pulsed HPAs shall be turn-key, modular built, fault-tolerant, and self-protecting and NRTL safety approved.

020005 Wherever possible the vendor shall try to adopt and implement identical engineering designs in both HPAs (HPA-1 and HPA-2) except for what is required to support the different operating frequencies.

020010 The HPAs shall be designed and built to have very high reliability with MTBF > 150,000 hours for continuous, round the clock (24/7) indoor operation at RF pulsed flat top output power of 25 kW. A typical operating year will have 5000-7000 hours. The HPAs shall be fault tolerant and not interrupt their RF outputs more than 4 times per year.

020015-R This Requirement has been eliminated.

020020 The total number of RF Amplifier Modules (T) (T ≤ 40) used in the HPA should be minimized to improve reliability and serviceability due to lower quantity of parts but not to push the operating point or temperature of components to near maximum ratings.

020025-R The HPAs should have a fast acting, voltage-controlled RF PIN diode switch at the HPAs RF input. It shall be an absorptive type switch having fast switching speed ≤ 200 ns, isolation ≥ 40 dB and be configured for fail safe operation.

This Requirement has been modified.

020030-R This Requirement has been eliminated.

ID NUM

(S09-09-)

Requirement

020035-R As a part of reliability testing and Factory Acceptance Tests (FAT), the HPAs must be successfully tested for round the clock operation for a time period of at least 100 hours at HPA output pulse top duration = 60 us, pulse repetition frequency (PRF) = 10 Hz, pulsed flat top RF output power level = 25 kW with corresponding fixed pulsed RF input power at constant ambient temperature of 35°C. During such testing, the data for pulsed RF output power level, output-minus-input phase variations, HPA cabinet internal air temperature, and ambient air temperature shall be recorded after every 5 minutes. The HPAs shall operate without any faults (caused by failures internal to HPAs) during such heat run test period and the measured data should remain within specification. The above 100 hour heat run tests shall be witnessed by LBNL representatives and the test results & data shall be written into a report by the vendor and delivered to LBNL prior to FAT.

This Requirement has been modified.

020040-R Vendor shall provide all information necessary to demonstrate reliability goals can be achieved. This may include detailed HPAs Design Failure Mode, Effects, and Criticality Analysis (DFMECA) OR Equivalent to identify the critical parts and then perform HALT testing OR Equivalent testing OR analysis on identified critical parts to ensure that it meets the reliability goals.

This Requirement has been modified.

020045-R The typical RF input to the HPAs from the LLRF systems shall be a pulsed RF carrier modulated in amplitude and phase. The HPAs shall faithfully amplify these input modulations with negligible distortions within the HPA’s power bandwidth. The vendor shall provide such test reports for review and acceptance by LBNL.

The CW Operation Requirement for both HPAs has been eliminated.

5.1.2 HPA RF Specifications

5.1.2.1 PULSED RF MODE OF OPERATION (ALS OPERATIONAL MODE)

ID NUM

(S09-09-)

RQMT

DEF Requirement Description Value Unit

020100 Shall HPA-1 Center Frequency (fc) 124.910 and 124.911

MHz

RQMT

DEF Requirement Description Value Unit

HPA-2 Center Frequency (fc) 499.642 and 499.646

MHz

020105 Shall HPAs Output Pulsed RF Peak Power (in pulse flat top region) with < 1dB compression

≥ 25 kW

020110 Shall HPAs Input Pulsed RF power (in pulse flat top region) for ≥ 25 kW output :

≤ 0 dBm

020115-R

Shall HPAs Output Power P1 dB ( ≥ 25 kW) Bandwidth (BW) around center frequency: (P1dB BW) This Requirement has been modified.

+/- 2.5 MHz for HPA-1 &

HPA-2

MHz

020120 Shall HPAs Output Pulsed RF flat top (ideally) duration excluding the rise, overshoot, fall times :

15 to 60 µs

020125 Shall

HPAs Pulse Repetition Frequency

(PRF):

Also the vendor shall perform pulsed RF device testing and provide limits, if any, to the range of pulse repetition frequency and to the range of duty cycle for no damage to LDMOS / GaN FETs due to such low frequency thermal cycling and/or fatigue.

0.5 to 10 Hz

020130 Shall

HPAs Output Pulsed RF Power Envelope Droop (in pulse flat top (ideally) region) in open loop :

< 1 %

020135

Should

HPAs Output Pulsed RF Power Envelope Overshoot and Undershoot:

< 5 %

RQMT

DEF Requirement Description Value Unit

020140 Shall HPAs Output Pulsed RF Power Envelope Rise time and Fall time (10 % to 90 % of final value) :

< 200 ns

020145 Shall

HPAs Group Delay (over the P1 dB bandwidth of 5 MHz) :

< 100 ns

020150 Shall HPAs Group Delay variation (over the P1 dB bandwidth of 5 MHz) :

< 5 ns

020155 Shall

HPA Output pulsed power stability: pulse-to-pulse and also long term (8 hours)

< 2 % (short term)

< 5% (long term)

020160 Should

HPAs Output pulsed power phase stability : pulse to pulse and also long term (8 hours)

< 2 deg for 125 MHz

HPA-1

< 8 deg for 500 MHz

HPA-2

Deg

020165 Shall HPAs Output Reverse Power handling capability

Full 100% reflection at any phase

020170 Shall

HPA Redundancy from failure of RF Amplifier Modules to maintain reduced RF output power of 20 kW minimum.

The HPA shall continue to be operational delivering reduced 20 kW RF output power with up to this volume of failed RF Amplifier modules

Up to 10 % -----

RQMT

DEF Requirement Description Value Unit

020175 Shall

HPA Redundancy from failure of DC Power Supply Modules

The HPA shall continue to be operational delivering 20 kW output power with remaining working DC PS modules

N+2 (N is minimum modules needed)

020180 Shall HPAs RF Input drive power limit for no damage to HPAs

≥ 10 dBm

020185 Shall

HPAs RF Output Power (1kW to 25 kW) Phase variation from RF Input power sweep in 10 µs : the Phase variation must be monotonic:

< 15 deg

020190 Shall

HPAs RF Output Power ( 1kW -25 kW) Gain variation from RF Input power sweep in 10 µs :

the Gain Variation must be monotonic:

± 0.5 (max) dB

020195 Shall HPAs Power Gain (over the P1dB BW and over 15-35°C ambient temperature range)

> 74 dB

020200 Should

HPAs Linearity : HPAs overall Output referred Third Order Intercept point power (OIP3 in dBm) relative to HPAs pulsed output power (in dBm) at 1dB compression (Pout @1dB compression)

≥ 9 dB

020205 Shall HPAs Noise Figure over P1dB bandwidth : < 8 dB

020210-R

This Requirement has been eliminated.

020215 Shall HPAs Input VSWR and Output VSWR (over P1 dB Bandwidth) < 1.3 ----

RQMT

DEF Requirement Description Value Unit

020220 Should

HPAs DC to RF output efficiency (in pulse flat top region) :

≥ 50 % ----

020225-R This Requirement has been eliminated. ----

020230 Shall HPAs RF output Second Harmonic at all RF output power levels :

< -40 dBc

020235 Shall HPAs RF output Third Harmonic at all RF output power levels :

< -60 dBc

020240 Shall

HPAs cabinet highest internal air temperature at all internal locations (at 25 kW pulsed RF output at 60 us pulse ON and PRF = 10 Hz and at 35 deg C ambient temp after 30 minutes of start)

< 40 deg C

020245 Should HPAs Overall Reliability (MTBF) > 150,000 Hours

020250-R Shall

Audible noise Limits at all HPA output power levels (measured at 1 m from cabinet on all four sides of HPAs with doors closed) :

This Requirement has been modified.

< 65 @ 1m dBA

5.1.2.2 – THIS REQUIREMENT HAS BEEN ELIMINATED

(S09-09-)

RQMT

DEF Requirement Description Value Unit

020300-R This Requirement has been eliminated.

020305-R This Requirement has been eliminated.

020310-R This Requirement has been eliminated.

5.1.3 Environmental Parameters

RQMT

DEF Requirement Description Value Unit

Environmental Parameters

020400 shall Working Ambient Temperature: 05 -35

(41-95) °C (°F)

020405 shall Working Elevation: (above sea level) 304.8

(1000) m (ft)

020410 shall Working Relative Humidity: 10 – 85 %

5.2 AC Input Power

(S09-09-)

Requirement

020500-R The HPAs shall have a rated and NRTL listed, enclosed, LOTO lockable, 3-phase, 208 VAC of suitable current rating not less than 35 kA Molded Case Circuit Breaker (MCCB), referred to as the Main Circuit Breaker.

1. Three pole, fixed thermal trip

2. Pad-lockable handle lock hasp, off-only version

3. Short Circuit Current Interrupt Rating: preferably ≥ 35 kA

020505-R The HPAs shall have a rated and NRTL listed, LOTO lockable, 1-phase, 120 VAC, 20A, MCB (miniature circuit breaker) referred to as the Control Power MCB protecting the control power circuit of the HPA.

1. Short Circuit Current Interrupt Rating should be 10 kA

This Requirement has been modified.

020510 The HPAs shall have one rated and UL listed Voltage Test Station device for the 3-phase 208 VAC Main circuit breaker on the line side and the load side connections.

020515 The HPAs should have one rated and UL listed Voltage Test Station device for the 1-phase 120 VAC Control Power circuit breaker on the line and the load side connections.

020520 The HPAs 3-phase AC input line currents shall be balanced within 10 %

Requirement

020525-R Suitable UL Listed AC or DC fuses shall be incorporated in all AC or DC branch line circuits respectively for fault isolation. All such fuses shall be easily accessible for replacements, if needed.

This Requirement has been modified.

020530 The HPAs shall not suffer any damage due to sudden power outages, brown outs or power sags events of any combination of the 3-phase 208 VAC input and 1-phase 120 VAC input sources when operating at full RF output power.

After such events get cleared, the HPA should be ready for a normal restart from the Fault state with latched interlocks. A Fault Reset is required to clear the HPAs Fault state to the OFF state.

RQMT

DEF Requirement Description Value Unit

020600 Shall

HPAs AC Input Main power:

Will be fed from upstream 50A lockable panel mounted circuit

3 phase

208 ± 5% VAC,

60 Hz, Y-source, 5-wire (one wire is ground)

V

020605 Shall

HPAs AC Input Control power:

Will be fed from a upstream 20A lockable panel mounted circuit

1 phase

120 ± 5% VAC,

60 Hz 3-wire (one wire is ground)

V

020610-R Should HPAs AC Input (both 3 phase and 1 phase) power factor:

> 0.90 ---

5.3 RF Power Module

(S09-09-)

Requirement

020700 The RF Amplifier Modules in the HPAs may be grouped such that each group is mounted onto a single forced air cooled heatsink and such group(s) may be referred to as RF Power Modules. The HPAs system shall be designed such that all RF Power Modules are interchangeable to any position without need of gain balancing or phasing adjustments.

Requirement

020705-R This Requirement has been eliminated.

020710-R This Requirement has been eliminated.

5.4 RF Amplifier Modules, Pre-Amplifier Modules

(S09-09-)

Requirement

020800-R The Pre-Amplifier should be designed and built to have high linearity, high gain. The first pre-amplifier shall have a low noise figure and high gain. They shall be mounted on appropriate forced air cooled heat sinks.

This Requirement has been modified.

020805 The RF Amplifier modules (excluding the RF preamplifier stage modules) used in the Driver stage and Final Amplification stage shall be based on recent / latest generation of RF LDMOS push pull FET device OR suitable latest GaN FET OR equivalent OR better Transistor (TBD by vendor) with manufacturer part production & support longevity for at least ten years.

020810-R Each RF Amplifier module shall have sufficient power rating to handle all reverse powers due to possible open/ short conditions at the HPA Output Port. This shall include reverse power from SHB cavities during operation, reverse power in the event of failures of other RF amplifier modules, and mismatches in the output power combiner.

This Requirement has been modified.

020815-R This Requirement has been eliminated.

020820-R This Requirement has been eliminated.

020825 The RF LDMOS FET or GaN FET flange should be mounted to a copper heat spreader and the heat spreader shall be thermally bonded to appropriate forced-air cooled heat sink. The RF Transistor package shall be ceramic package due to its better pulsed mode heat endurance at low repetition rate.

020830 Each RF Amplifier module shall also have a suitable RF protection on its input side whereby the failure of any RF Amplifier module(s) shall not affect the operation of the RF input splitter and/or affect the amplitude/phase of the RF input signals to other RF Amplifier modules.

Requirement

020835 The RF Amplifier Modules shall have stable operation with a LDMOS FET OR GaN FET Drain bias voltage of less than or equal to 50 V.

020840-R This Requirement has been eliminated.

020845 The gate bias network shall incorporate Zener diode based or other suitable overvoltage protection.

020850 Every module shall have temperature monitoring on the heat sink and suitable over temperature protection.

020855-R This Requirement has been eliminated.

020860-R The DC bulk storage capacitors utilized should have high load life endurance rating of at least 5000 hours at 105 °C and very low ESR and positioned close to each Amplifier Module Drain Bias circuit.

020865-R This Requirement has been eliminated.

RQMT

DEF Requirement Description Value Unit

020900-R Should

RF LDMOS FET or GaN FET maximum junction temperature (at 25 kW pulsed RF 60 µs pulse width at 10 Hz PRF output) This Requirement has been modified.

< 150 °C

020905-R This Requirement has been eliminated.

°C

020910-R This Requirement has been eliminated.

020915-R This Requirement has been eliminated.

020920-R This Requirement has been eliminated.

Deg

020925 Should RF Pre-Amplifier devices (S) junction temperature (at HPA RF output of 25 kW)

< 150 °C

5.5 RF Power Combiner, Splitter, Coupler Signals

(S09-09-)

Requirement

021000-R Suitable dual directional couplers shall be utilized for monitoring the Forward and the Reverse RF power at HPAs RF input port stage and shall be displayed in HMI.

This Requirement has been modified.

021005 Suitable dual directional couplers shall be utilized for monitoring the Forward and the Reverse RF powers at each RF Amplifier Module downstream of module RF circulator and they shall be displayed in HMI.

021010-R This Requirement has been eliminated.

021015-R This Requirement has been eliminated.

021020 A suitable 1-5/8 inch OR 7/8 inch EIA coaxial line dual directional coupler shall be utilized for monitoring the Forward and the Reverse RF powers at HPA RF output port and these power levels should be displayed on the HMI.

Small sampled RF Output Forward and Reflected powers (with coupling about -50 dB) shall be provided on front panel with N type (F) connectors for user tests/ measurements.

RQMT

DEF Requirement Description Value Unit

021100 Should RF High Power Combiner port isolation

≥ 20 dB

5.6 DC Power Scheme

(S09-09-)

Requirement

021200-R This Requirement has been eliminated.

021205-R DC power supply modules that fault for any reason shall be seamlessly disconnected in a paralleled operation mechanism without causing any disruption to the HPA operation to continue delivering RF output power.

Requirement

021210 The LDMOS / GaN FET Drain DC quiescent bias current for class AB operational mode of the RF Amplifier modules should be provided from separate highly regulated, very low ripple DC PS module(s) operating in CV mode to the same user set Drain voltage value below 50 V with having parallel M+1 redundancy to another common bus. Necessary diodes (for blocking reverse currents) shall be used for each LDMOS/ GaN drain connection.

021215 The LDMOS / GaN FET Gate bias voltages for class AB operational mode of the RF Amplifier modules should be provided from separate highly regulated, very low ripple DC PS module(s) operating in CV mode with parallel P+1 redundancy to another common bus.

021220-R The Gate bias voltage for each LDMOS / GaN FET should be over-voltage protected and have fine adjustability, if needed, for the RF Amplifier module set up.

This Requirement has been modified.

021225-R The aforesaid DC PS module types shall have built in Over Voltage protection, Over Current protection, Over Temperature protection, Short Circuit Protections.

The Requirement has been modified.

021230-R Vendor must specify the bleed discharge time of any capacitors within the HPA that have a stored energy of >100 Joules.

RQMT

DEF Requirement Description Value Unit

021300-R This Requirement has been eliminated.

021305 shall DC PS modules Ripple voltage (peak to peak) (5 Hz to 1 MHz)

< 100 mV

021310 shall Reliability MTBF of DC PS modules > 100000 Hours

5.7 Forced Clean Air Cooling

Requirement

021400 The HPAs shall implement forced clean air cooling using fans for providing adequate airflow for cooling and all internal component power dissipations including the DC PS modules and RF Amplifier Modules.

021405 The fans used for forced clean airflow cooling should preferably implement variable speed control.

021410 For effective airflow management, appropriate baffles shall be utilized inside the cabinet to seal any openings which would allow the airflow to bypass the heat generating equipment’s inside cabinet.

021415 The HPAs cabinet shall incorporate appropriate dust filters, to provide clean and dust free airflow.

021420-R This Requirement has been eliminated.

021425 The fans used for forced clean airflow cooling shall make low audible noise so as to meet the overall HPAs audible noise specification.

021430 The fans used for cooling should have high reliability (MTBF) > 100000 hours

5.8 External Interfaces

(S09-09-)

Requirement

021500-R 3 ph 208V, 5-wire, AC input power shall be fed via metal conduit.

This Requirement has been modified.

021505-R 1 ph, 120V, 3-wire, AC input power shall be fed via metal conduit.

This Requirement has been modified.

021510-R This Requirement has been eliminated.

021515-R This Requirement has been eliminated.

021520 RF Output Port 1-5/8 inch or 7/8 inch EIA with end flange connector shall be mechanically secured to withstand insertion or extraction forces of at least 10 kgf and transverse forces of at least 5 kgf.

021525 Human Machine Interface (HMI) 15” Color (preferably from Allen Bradley) touch screen display for control and monitor

021530-R This Requirement has been eliminated.

021535 One 1000 Base-T (Gigabit) Ethernet port for interfacing with EPICS IOC

RQ

MT

DEF

Requirement Description Value Unit

021600-R RF Input connector This Requirement has been eliminated.

021605-R Shall

RF Output connector

1-5/8” OR 7/8 inch EIA Coaxial Transmission Line is to protrude vertically outside the HPA cabinet for length 10.2cm-15.2cm (4-6 inches) modified.

Inch

021610-R eliminated.

m

021615 Shall

Quantity Four, Fiber Optic Input Receivers Ports.

Quantity Four, Fiber Optic Output

Transmitters Ports

FO Receiver, Avago part number

AFBR-2624Z

FO Transmitter, Avago part number

AFBR-1624Z

5.9 Design and Manufacturing Requirements

(S09-09-)

Requirement

021700-R The vendor shall ensure to establish a contract with an OSHA approved NRTL company early on in design phase for all of following:

(a) Desk review of vendor HPAs design documents and approval certification by the NRTL prior to conducting Final Design Review (FDR)

(b) Final NRTL field inspection of both HPAs to applicable International standards at vendor factory site prior to conducting FAT tests

(c) For smoothly carrying out aforesaid NRTL inspections to International standards, the vendor is strongly advised to establish a contract with a reputed NRTL company having worldwide business operations including in the vendor’s country and in the USA.

Requirement

021705-R Such NRTL desk review and field evaluation certifications of HPAs shall be to applicable International standards which are to include but not limited to NFPA 70, NFPA 70E, UL- 508A, UL-61010-1, UL- 60950-1 etc. This shall be vendor responsibility.

This Requirement has been modified.

021710 The vendor shall ensure that HPAs are designed and built in conformity with various LBNL specific engineering standards / requirements and safety documents as referenced in Reference # [1] through [11] in Table 6.1 in the Applicable Documents section. This shall be vendor responsibility.

021715-R HPA cabinet must successfully obtain the structural integrity including lifting/ rigging and seismic integrity & cabinet base anchoring certification as per relevant California code standards from a California licensed engineer. LBNL may provide seismic engineering support upon request, however, compliance shall be the responsibility of the Vendor.

LBNL will only provide non-financial support in collaborative and iterative feedback in carrying out review & eventual concurrence from LBNL mechanical / structural engineer in such process.

This Requirement has been modified.

021720-R The vendor shall ensure that HPAs are designed and manufactured to conform with LBNL Non-Ionizing Radiation (NIR) safety document as referenced in Reference # [12] in Table 6.1 (Applicable Documents section).

The HPA shall be surveyed for NIR levels at various locations external to the HPA cabinets/rack and the NIR power density shall be less than 1 mW/cm2 for HPA-1 and 1.67 mW/cm2 for HPA-2 time averaged over 6 minutes at all HPA RF output power levels and PRF ranges. The vendor shall provide such NIR test certifications for LBNL review and acceptance.

This Requirement has been modified.

021725 The vendor shall ensure that the HPAs are designed and manufactured in conformity with standard UL-94 for safety of flammable materials. The vendor shall provide the necessary documentation for LBNL review and acceptance.

5.10 Construction Requirements

Requirement

021800-R This Requirement has been eliminated.

021805-R This Requirement has been eliminated.

021810-R All electrical equipment, components, cables, conductors etc., used in HPAs should be UL Listed / Certified wherever available.

021815-R Vendor shall make a best effort to ensure that critical fasteners like used for HPA mechanical cabinet integrity, seismic anchoring, electrical high current contacts in HPA etc., are not counterfeit.

This Requirement has been modified.

021820-R The vendor shall provide the Center of Gravity (CG) location of HPAs cabinet with fully assembled internal parts and the full weight of HPAs with all parts.

This Requirement has been modified.

021825 All materials used for construction of cabinet/racks and accessories shall be non-corroding and non-rusting when installed in an indoor location.

021830 Ingress Protection (IP) rating of HPAs cabinets shall be IP 51 (min).

021835-R This Requirement has been eliminated.

021840 All wires/cables in the HPAs shall have proper wire labelling with wire identification sleeves and proper terminal/ Input-Output device identification for ease of troubleshooting & maintenance.

021845 HPAs Cabinet shall have an M8x1 (5/16-18 equivalent) grounding stud(s).

This is to apply building ground to the HPAs cabinets.

021850 The HPAs cabinets ground shall have good electrical continuity with all metal parts of the enclosure by means of metal-to-metal contact (no non-conductive plating or paint on the metal-to-metal contact surfaces) Alternatively, an internal ground bonding conductor using ring terminals shall be used.

021855-R The HPA cabinet(s) shall be built with allowances for forklift forks to fit under each unit for lifting.

Requirement

021860 The HPAs cabinet base shall have provisions for forklifting & pallet-jack lifting from front and rear sides and the HPA cabinet shall be capable of being forklifted & pallet-jack lifted when it is fully loaded. Forklift channels shall not have any obstructions (e.g., protruding bolts). The flatness of the bottom of the HPA base shall be within ± 1.6 mm (± 1/16”) from a horizontal plane.

021865-R This Requirement has been eliminated.

021870 All electrical wires/ cables and materials should be Zero Halogen Low Smoke and fire retardant /non-flammable.

021875 The vendor shall provide good workmanship in neatly laying out the components and also properly segregating and routing the cables.

021880-R This Requirement has been eliminated.

021890-R This Requirement has been eliminated.

5.11 Control System

5.11.1 Control System General Requirements

ID NUM

(S09-09-)

Requirement

022000 The HPAs control system architecture should be distributed control system implemented using suitable PLC (preferably Allen Bradley) and/or suitable FPGA controllers. It shall have all requisite control, monitor, display, interlock, logging, self-protection etc, logic and functionality.

022005-R This Requirement has been eliminated.

022010-R The HPAs control system shall be operable in two modes i.e., either from local HMI (Local mode) or from remote EPICS IOC (Remote mode) using EtherNet/IP protocol a protocol compatible with EPICS (preferably EtherNet/IP). The HPAs control system shall allow the HPAs to operate in CW mode in Local mode only. The HPAs control system shall allow the HPAs to operate in pulsed RF mode in both Local and Remote modes.

Requirement

022015-R The HPAs controls shall support full status reporting and read capability for remote mode EPICS IOC-based communication. The HPAs will preferably provide this via EtherNet/IP protocol over fast Ethernet 6 interface but other EPICS-compatible protocols, such as ModbusTCP or OPC UA are also acceptable. This capability shall allow remote reading of all HPA PLC registers pertaining to various signal parameters, readings, status, interlocks, time stamps etc. The HPAs controls shall have limited remote mode EPICS IOC-based write capability to the HPA PLC registers for the HPA states commands and the Fault Reset only.

This Requirement has been modified.

022020 HPAs shall have 15" color HMI (preferably from Allen Bradley) with main / home page and other navigation pages for controls interface and display of HPA states & display of signals readings with latched interlocks status of various HPA signals & parameters.

022025 The HMI shall have Password protected access in Local Mode only to the HMI configuration settings page for setting / changing the parameter set values, warnings limits, interlocks limits etc.

022030-R All HMI display parameters and values should be updated at a rate of 5 Hz or higher rate. This Requirement has been modified.

022035 The HPAs controls shall chronologically display in HMI, and also log/ store in storage device, all the event actions on HPA made by operator and also fault occurrence description with signal name, parameter values with respective date & time stamps for later troubleshooting.

022040 The HPAs control signals must be implemented as failsafe positive logic i.e., absence of voltage is considered as fault and will disable the system operation. Similarly, absence of light in FO is considered as fault and will disable the system operation.

Requirement

022045-R The various monitor & control signals with parameter values & their status with latched interlocks that should be in such HMI display pages are to include but not limited to following:

(1) Finite State Machine operation (FSM States: Off, Standby, DC, RF, Fault)

(2) Has been eliminated

(3) Has been eliminated

(4) Fault Reset

(5) 3-Ph AC input line voltages & line currents Over and Under voltages

(6) Various DC PS module-wise status & DC output voltages & currents

(7) HPA RF Output Forward & Reflected power

(8) Set Drain Voltage

(9) Cooling Fans status and speed

(10) Internal cabinet air temperature

(11) RF amplifier (including preamplifier) module-wise parameters like drain voltage & currents, Module Output Forward & Reflected powers etc.

(12) Has been eliminated

(13) FO signals status indicators for all FO input and all FO output signals

The HPAs control system shall have relevant latched interlocks status when signals value is out of range and protections logic for aforesaid signals for self-protection of the HPA.

This Requirement has been modified.

022050-R This Requirement has been eliminated.

022055 The HPA’s PLC & associated control system modules should be capable of rebooting and also have firmware and program updates through password protected access from the Ethernet port OR USB port located on the front panel.

Requirement

022060-R The HPA’s Control system modules/hardware shall be sufficiently electromagnetically shielded from the RF signals, so that the RF signals do not cause any unwanted interference and/or affect the functionality of the control system.

This Requirement has been modified.

022065-R Vendor shall provide complete HPAs control system PLC program code in Ladder Logic and FPGA program code along with any other associated relevant firm ware, if any. Such control program code shall be modular structure with sufficient annotations for easy understanding of program code workings.

RQMT

DEF Requirement Description Value Unit

Control Parameters

022100-R Should PLC scan rate This Requirement has been modified.

≥ 5 Hz

022105-R Should HMI display parameters update rate This Requirement has been modified.

≥ 5 Hz

022110 Shall ADC resolution ≥ 12 Bits 022115 Shall DAC resolution ≥ 12 Bits

022120-R Shall

Measurement accuracy of the various AC/DC Voltage, AC/DC Current, Temperature monitor signals values in HMI display This Requirement has been modified.

≤ 10 % ---

022125-R Shall

Measurement accuracy of the various RF Forward and Reverse power monitor signal values on HMI display This Requirement has been modified.

≤ 0.25 dB

022130 Should Slow Interlocks response speed using PLC < 100 ms

022135 Shall

Fast Interlocks (for FO input / output signals and RF input /output power signals) response speed using FPGA or otherwise

< 10 µs

5.11.2 HPA FO Input signals

Input # FO Input Signal Functionality

1 HPAs Permit (from Master

Interlock PLC to HPAs )

When FO light is present, the HPAs operation is enabled to deliver RF output.

When FO light is absent, the HPAs operation is disabled to deliver RF output power but HPAs shall NOT go into Fault state. The relevant FO indicator in HMI to show its status with text message & time stamp in HMI

2 HPAs Oscillation detection and

Permit (from LLRF to HPA)

When FO light is present, the HPAs operation is enabled to deliver RF output.

When FO light is absent the HPAs operation is disabled to deliver RF output power and

HPAs shall go into Standby or Fault state.

The relevant FO indicator in HMI to show its status with text message & time stamp in HMI

3,4 Spare & Un-assigned When FO light is present, the HPA operation is enabled. When FO light is absent, the HPA operation is disabled

5.11.3 HPA FO Output Signals

Output # FO Output Signal Functionality

1 HPAs healthiness / internal fault

(from HPAs to Master PLC)

FO light shall be present when the HPAs are in any of the No-Fault states i.e., operational states. FO light shall be absent when the HPAs are in Fault state.

2,3, 4 Dummy Tests Use (for providing temporary loopback FO signals during local troubleshooting / testing)

FO light shall be present when the respective FO output button in HMI is toggled to ON. The FO light shall be absent when such respective FO button is toggled to OFF.

6 APPLICABLE DOCUMENTS

This section identifies applicable documents that are considered to be a part of this document.

Reference Number

Document Name / Number Title/ Description

LBNL Engineering Division Electrical Equipment Build Standard (Revision 6) including its Appendices A, B, C and D

Electrical Equipment Build Standard

LBNL Electrical Safety Manual (Revision 1)

Electrical Safety Manual

LBNL RPM on Safe Electrical Installation Policy

Safe Electrical Installation Policy

LBNL ES&H Manual (PUB-3000) Chapter 08 - Electrical Safety Program

Electrical Safety Program

LBNL ES&H Manual (PUB-3000) Chapter 14 – Electrical Equipment Safety Program

Electrical Equipment Safety Program (NRTL inspection)

6 LBNL RPM on Seismic Safety Seismic safety

Lateral Force Design Criteria” Resource Document (RD3.22) (version 18)

Seismic safety

LBNL RPM on Cranes, Hoists, and Rigging Safety

Cranes, Hoists, and Rigging Safety.

LBNL ES&H Manual (PUB-3000) Chapter 27 - Cranes, Hoists, and Rigging Safety.

Cranes, Hoists, and Rigging Safety.

LBNL Facilities Master Specifications

Section 260519.11 – 600 Volt Conductors and Cables

LBNL Facilities Master Specifications

Section 260523 – Low Voltage Electrical Power Conductors and Cables (24 volt ac/dc or less)

Reference Number

Document Name / Number Title/ Description

LBNL ES&H Manual (PUB-3000) Chapter 43 – Non Ionizing Radiation

Non Ionizing Radiation

Table 6.1: Applicable Documents

5.1.3 Environmental Parameters

6 Applicable Documents