500 mhz solid state amplifier design results of the 4kw

Paul Scherrer Institut • 5232 Villigen PSI 12th ESLS - Diamond - 10/2008 M. Gaspar

500 MHZ Solid State Amplifier Design Results of the 4KW Prototype

M. Gaspar, M. Pedrozzi


4KW Validation Prototype – Components Produced and Tested

PC Master Controller: 2 Available and Already Tested (PSI Design)

Power Supply Controller:

25 Boards Available (Programmed and Tested) (PSI Design)

Power Splitter:

2 8-Way Prototypes Working (PSI Design)

New 18-way Design in Progress (PSI Design)

250W Amplifier Module:

22 Modules Available (Assembled and Tested) (PSI Design)

High Power Coupler: 1 Piece Available and Calibrated. Tested OK @ Pout=4KW (Industry)

New Design in Progress (PSI Design)

Output Power Combiner: 2 18-Way Combiners Ready (Finished and Tested)

(PSI Design)

Also Successfully Tested under Maximum Output Power


4KW Amplifier Configuration


4KW Basic Components( 3D Conceptual View – Not To Scale )

+

+

2x

18x

18x

+

+

=4.5KW max!


250W Amplifier Module

Key Performance Parameters

3D-View of 500MHz Amplifier Module

Output Power(with Circulator)

250W 280W

Gain 22dB 20dBEfficiency ~ 54% ~ 50%

Operation Max

Pout(W) vs Pin(W)

0

50

100

150

200

250

300

0 0.2 0.4 0.6 0.8 1 1.2 1.4 1.6 1.8 2Pin(W)

Pout

(W)

Pout (dBm)

Phase(S21) (°) vs Pout(W)

80.00

90.00

100.00

110.00

120.00

130.00

140.00

150.00

0 50 100 150 200 250 300Pout(W)

Phas

e(S2

1) (°

)

Phase (°)



Output Power versus Input Power Efficiency versus Output Power

Performance of all available RF Modules

Pout(W) x Pin(W)

0

50

100

150

200

250

300

0 0.5 1 1.5 2 2.5Pin(W)

Pout

(W)

M#1

M#2

M#3

M#4

M#5

M#6

M#7

M#8

M#9

M#10

M#11

M#18

M#19

M#20

M#13

M#16

M#12

M#21

M#17

M#15

M#0

Efficiency(%) x Pout(W)

0.0

10.0

20.0

30.0

40.0

50.0

60.0

0 50 100 150 200 250 300

Pout(W)

Effic

ienc

y(%

)

M#1

M#2

M#3

M#4

M#5

M#6

M#7

M#8

M#9

M#10

M#11

M#18

M#19

M#20

M#13

M#16

M#12

M#21

M#17

M#15

M#0



Gain versus Output Power Phase Delay versus Output Power

Performance of all available RF Modules

Mag(S21) (dB) x Pout(W)

0

5

10

15

20

25

0 50 100 150 200 250 300Pout(W)

Mag

(S21

) (dB

)

M#1

M#2

M#3

M#4

M#5

M#6

M#7

M#8

M#9

M#10

M#11

M#18

M#19

M#20

M#13

M#16

M#12

M#21

M#17

M#15

M#0

Phase(S21) (°) x Pout (W)

0

20

40

60

80

100

120

140

160

180

200

0 50 100 150 200 250 300

Pout (W)P

hase

(S21

) (°)

M#1

M#2

M#3

M#4

M#5

M#6

M#7

M#8

M#9

M#10

M#11

M#18

M#19

M#20

M#13

M#16

M#12

M#21

M#17

M#15

M#0



Pout(W) x Vdd(V)

150

170

190

210

230

250

270

290

22 24 26 28 30 32 34

Vdd(V)

Pout

(W)

Pin=1.77WPin=1.65W

Phase(S21) (°) x Vdd(V)

120121122123124125126127128129130

22 24 26 28 30 32 34

Vdd(V)

Phas

e(S

21) (

°)

Pin=1.77WPin=1.65W

Output Power Variation due to Forced Compression Phase Delay Variation due to Forced Compression

1.

Since our Power Supply Controllers allow the Power Supply Voltage (Vdd) to be changed remotely we use Forced Compression to equalize the output powers of all amplifiers and then maximize the Combining Efficiency.

2.

Notice that the Phase Delay is not very much influenced by variations in Power Supply Voltage. So Forced Compression is a viable method.

Forced Compression as a Useful Method



• Total 22 Modules Produced Now (18 for Amplifier, 4 Spares).

• All Modules Fully Assembled and Tested.

• Performance Agrees With Previous Results from Prototype.

• Remote Monitoring Working all right.


18 Way Combiner – 500MHz

BW > 10MHz (S11 < -30dB)

Precision Required for 18 Ways Realized with no Extra Costs

Efficiency > 99.6% (Overall Loss < 20W @ Pout=4.5KW)

Key Performance Parameters

Measurement

HFSS Simulation

PSI development

Inner Conductor Temperature @ Pout=4KW = 65°C (estimated)

Outter Conductor Temperature @ Pout=4KW = 43°C

High Power Temperature Measurement Results


Power Supply Controller (and Complete Monitoring System)

RS485Network

Power SupplyOutput

AmplifierMonitoring

Extra DigitalI/Os

Extra AnalogI/Os

DC/DC Converter

High Voltage Input and Filtering

Output Power:

600W

Output Voltage Range:

16.7V to 33.5V

Input Voltage Range:

200V to 400V

Efficiency:

~ 90%

Can be Remotely Programmed and Monitored

Extra Analog and Digital I/Os

Multi-tasking Script Operating System (SOS)

Interlock Reaction Time: ~ 1uS

Full Monitoring Loop Time:

~ 150mS

Main Features

25 Pieces Available Now

19 Pieces – No Failures in Long Duration Tests

LEDs for Interlock and operation

Design Finished


• Total 25 Boards Produced (18 for Amplifier, 7 Spares).

• Operating System Installed.

• All Tests Completed (Power and Monitoring).

• 19 Boards Passed Initial Long Duration Tests without Failures.

Power Supply Controller


Output Power versus Input Power Overall Efficiency versus Output Power

Measurement Results

4KW Solid-State Power Amplifier

Pout[W] x Pin[W]

0

500

1000

1500

2000

2500

3000

3500

4000

4500

0 5 10 15 20 25 30 35

Pin[W]

Pout

[W]

Efficiency[%] x Pout[W]

0

5

10

15

20

25

30

35

40

45

50

0 500 1000 1500 2000 2500 3000 3500 4000 4500

Pout[W]

Effic

ienc

y[%

]


SOSDAQ

Linux Data Acquisition and Monitoring Software

Results @ Pout=4KW

Client-Server Design

Graphical User Interface provided by Web-Browser

Data Interpolation, Translation and Interlock Checks Easily Configurable.

Hardware and Software Devices Allowed.

Easily Expandable for Larger Installation.

Main Features


4KW Solid-State Power Amplifier Teststand in SLS

Monitoring PC (Linux)

4KW Solid-State Power Amplifier

22KW Water Cooler

Interlocks Plus Low Level RF

Water Flux Measurement

Water Temperature Sensors


Conclusions

• 18 RF Modules Successfully Combined and Tested Under High Power.

• Very Stable Operation. About more than a Month of Operation and

Tests.

• All Produced Modules showed very Similar Performance as the First Prototype RF Module.

•

Forced Compression Proven to be Easy and Useful Method to Improve Amplitude Equalization of all RF Modules and to Optimize Overall Efficiency. At Pout=4KW the Output Power of all Modules could be Equalized to about +/-5% around the Average value.

• Power Supply Controller Heavily Tested. Monitoring and Data Acquisition Concept Proven.

• 18-Way Power Combiner Successfully Tested under High RF Power.

• Long Duration Tests in Preparation.

• Complete Amplifier proven to be Very Compact and Light.

500 mhz solid state amplifier design results of the 4kw

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