Tom Kubicki

 Booster HLRF System to be upgraded using 1kW Solid State Driver (SSD) Amplifiers.  Used to drive the 200kW Power Amplifier  Eliminates the tube amplifier components  Significant improvement in reliability  Each station uses 4 1kW SSD Amps, along with a combiner, provides up to 4kW of RF power  Components are modular, allows for quick repair and minimizes downtime

 Design based on Cubic Corp. 1kW amplifier used in the Main Injector RF Upgrade  Uses water-cooled heat sinks on the high power components  Design uses a pre-amplifier stage, 2 amplifier boards that each have 2 channels capable of 250W per channel, and an output combiner that sums all 4 outputs into one 1kW output (50 Ω system).

 Why build them here?  Cost of each amplifier built by Cubic would be ~$12K per amp.  All parts have been ordered, at a cost of ~$1.5K per amp.  Substantial cost savings!  Does not include labor, but that is “free”  84 Amplifiers to be built.

 Failure rate is essentially 0  No problem running 15Hz  Possibility to employ feedback for gain and phase regulation (local and global)  Far off into the future on this one, but impossible with current RF system  Plenty of additional drive power for additional beam requirements, and/or to provide beam loading compensation if necessary

 This has been ongoing since 2006, but really ramped up in late  As stated previously, all major parts have been ordered for the SSD amps.  Main amplifier board is stuffed, ferrites ordered, etc.  SSD control units: 20 have been built and tested. This is complete!  SSD Metering chassis: 10 units have been built and tested. 10 remaining, but have all the parts  Low priority on the remaining 10  All diode detectors built, 10 need to be calibrated

 To date, NIM modules used in the SSD rack and Modulator have been built and tested.  20 of each module built, includes spares and possible test station in the future  A few loose ends remaining, but have plenty of modules to complete East Gallery and most of West Gallery.  Booster SSD uses a Low-Level RF chassis, consisting of a phase shifter, variable gain amplifier (VGA), and output amplifier for increased gain.

 The LLRF chassis drives the 1kW SSD amps.  LLRF chassis provides phase adjustment, a linear RF output in proportion to the Solid State Drive Program  16 of these have been built and tested.  Parts have been ordered to build VGA’s, and the remaining LLRF chassis.  Stations 5 & 6 in the East gallery have been upgraded to solid-state.

 In near term, get cables pulled for upgrade to stations 1 & 2.  Cables can be phased-matched during normal operations.  Possible retrofit of Station 19, would get us 4 additional amps for either Station 1 or 2.  Order the rest of the cable needed, Heliax, RG- 58, etc.  List of cables required for tunnel and rack, RF engineers have been doing this

 Order NIM Power Supplies  Acquired 10 from surplus previously  Need 30 more  At a cost of $2.5K per supply, NIM supplies alone will cost an additional $75K!  One area with a large expenditure required!  Order 15 SSD Racks ($1.2K a rack, $18K)  Order any additional parts for SSD Rack (plumbing, connectors, etc.)

 BUILD AMPLIFIERS!!  Requires special jig for brazing heat sinks.  This item should be received shortly  May want to consider outside vendor to assemble the plumbing.  May be costly, but personnel is in short supply currently.  Would allow for more assembly line fabrication  May be necessary to meet future FY goals  Pre-fabrication of as many wires, cables, circuit boards, etc. as can be done

 In near term, one Screen Current Power Supply and Grid Bias Power Supply are being built for the Modulator.  Some parts remain to be ordered, but nothing show- stopping at the moment  20 of each supply will be built

 Labor estimate for SSD Amplifier Fabrication  Assumes heat sinks and as much pre-fabrication as possible (pre-assembly work)  Need at least 2 days for assembling first couple of amplifier modules (~ first 10), will progress faster once experienced.  Assuming 1.5 days on average, all 84 modules will require 126 days to be fabricated.  Very optimistic, will take longer depending on time to put heat sinks together.  Testing will (hopefully) be done in parallel with assembly.  T. Kubicki or J. Holm doing the testing?

 Testing of SSD Amps will take 1-2 days each.  Some are easier to calibrate than others.  Need RF tech(s) to build SSD relay racks.  5 have been built, just waiting for SSD amps.  Time consuming, depending on pre-assembly, can take up to 3 weeks to build one rack.  Verification of final assembly  At least one day to check out fully assembled rack at MI-60 test station

 Building Grid Bias and Screen Current Power Supplies  A lot of cables, wires need to be fabricated.  Assembly of components can begin.  Estimating ~3 weeks to fabricate either one Grid Bias or Screen Supply.  Very time consuming  Upgrading a Booster RF station  Takes about 2 days with prep work (i.e. cables cut, terminated, and phased matched)

 End of August  Have at least 1 SSD amplifier built and tested  Work out any “kinks” that may occur  At least One Grid Bias Supply and Screen Current Power Supply built and tested  Finish with the remaining NIM modules left to be tested  September-December ‘11  Have station 1 and 2 upgraded  Continue on building Amps, Power Supplies, Modulators, etc. Would like to see 20 SSD amps by Dec.  Assembly of SSD racks, cabling (rack and tunnel)

 January-March ‘12  Continue building racks, finish up with any remaining cables that need to be fabricated for the SSD rack.  Digital I/O cable  Have 40 amplifiers built and tested  Have at least 10 Grid Bias and Screen Current Power Supplies built and tested  April-June ‘12  All racks should be built by now

 Have at least 60 SSD amplifiers built and tested  Have at least 15 Grid Bias and Screen Current Power Supplies built and tested  East Gallery converted to Solid State by now, progression in the West Gallery  July-September ’12  Finish up with the remaining Solid State amplifiers  Finish up with the remaining Grid Bias and Screen Current Power Supplies  Finishing up converting the West Gallery to Solid State

 Needless to say, the RF group has a lot to do!  To meet FY 12 goals, we need additional personnel to assist.  Operations and other ongoing projects (NML, HTS, A0PI, etc.) still require our attention.  Additional Funding for FY 11 (we could use a chunk of the $1.4M) to help achieve FY 12 goal of an all Solid-State Booster RF System  Proven designs work well and are reliable, but much assembly work is left to do!  Questions/Comments