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➢ Experience with the SOLEIL 352 MHz HP SSA’s ➢ R&D with HP SSA’s at SOLEIL ➢ HP SSA’s in other facilities

EnEfficient RF Source Workshop, Cockcroft Institute,

Daresbury, Warrington, UK June 3 - 4, 2014,

P. Marchand

SOLEIL EXPERIENCE WITH HIGH POWER SOLID STATE AMPLIFIERS (HP SSA’S)

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Respect and gratitude to Ti Ruan, who was THE pioneer in the domain of high power solid state RF amplifiers

Ti RUAN, 1936 - 2014

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➢ En : 100 MeV ! 2.75 GeV (rep. 3 Hz) ; VRF : 0.2 ! 1 MV @ 352 MHz!➢ 1 x 5-cell Cu cavity (CERN LEP) ! Ptot : 25 kW (Pdis : 20 kW, Pbeam : 5 kW) !➢ 1 x solid state amplifier ! 35 kW CW @ 352 MHz (developed in house)

Cavity in the BO ring BO RF room (amplifier & LLRF)

SOLEIL Booster RF system

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35 kW SSA of the SOLEIL Booster

330 W CW - 352 MHz amplifier module

VDMOS D1029UK05 from SEMELAB

(G = 11 dB, ƞ = 62 %)

600 W - 280 / 28 V dc power converter

Power combiner (8 x 8 x 2)

8 dissipaters of 16 + 2* modules

* driver amplifiers

146 modules of 330 W at 352 MHz with their individual power supplies, bolded on 8 water cooled dissipaters

35 kW

35 kW SSA power combination

520 kW

24 W !240 W

330 W

20 kW

30 W

8 x 8

40 kW

2.5 kW

19 W !192 W

div. 8

div. 8

20 kW

40 kW

2.5 kW

330 W

Booster RF control system

AMPLIFIER CAVITY AND LLRF

SOLEIL CONTROL « TANGO »

µcontroller Hardwired fast interlock

I dc x 2 x 147 & Pi, Pr x 16 MULTIPLEXING

AI Cmd

Ethernet

An.

& d

ig. I

/ O

Vacuum

Machine interlock

PSS

Pref (ampli-out)

Water flows, Temperatures, …

Pin Poutto amplifier

Power supplies off

RF switch

RS232

LLRF : Low Level RF Electronics (amplitude, phase & frequency loops)

CPCI

PLC PC

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Operational experience with the Booster RF system

The Booster RF plant is in operation since mid 2005. After ~ 50 000 running hours over 9 years,

only a single trip in operation, due to a human mistake (2006). !

The 35 kW solid state amplifier still exhibits a 100% op. availability In 9 years, only 8 (out of 150) modules have broken down,

5 bad quality soldering and 3 failing transistors, which did not affect at all the operating conditions

and could be quickly repaired during scheduled machine shutdowns.

! Advantage of the built in modularity and redundancy

SOLEIL SR RF system

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➢ E = 2.75 GeV, ΔE = 1.2 MeV, Ib = 500 mA! ! PRF = 600 kW & VRF : 3 - 4 MV @ 352 MHz!➢ 2 cryomodules (CM), each containing a pair of

single-cell s.c. cavities (Nb/Cu)!➢ Each of the 4 cavities is powered with a 180 kW

solid state amplifier !➢ Both CM’s are supplied with LHe (4.2 K) from a

single cryogenic plant

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Same principle as for the BO one, extended to 4 towers of 45 kW à 10 dissipaters of 18 modules per tower à 726 modules / amplifier x 4 cavities ! 16 towers & ~ 3000 modules

SOLEIL SR 180 kW SSA’s

Amplifiers 1 & 2 (2 x 4 towers) powering the 2 cavities of

Cryomodule 1

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SR SSA elementary modules

352 MHz - 315 W amplifier module (LDMOS transistor - Polyfet LR301)

Cu slug stamped into the Al box

600 W – 280 Vdc / 28 Vdc converter

G : 13 dB η : 62 %

SMD

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SR SSA power combination components

352 MHz

power splitters 2, 8, 10 - ways

352 MHz

power combiners

2.5, 25, 100, 200 kW

All the amplifier components have been designed in house and then the series production contracted to the industry

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AMPLIFIERCAVITY AND LLRF

SOLEIL CONTROL « TANGO »

!µcontroller Hardwired

fast interlock

I x 2 x 680 modules Pi, Pr x 80

MULTIPLEXING

AI Cmd

Ethernet

An.

& d

ig. I

/ O

Vacuum

Machine interlock

PSS

P ref

Water flows, Temperatures, …

Pin Poutto amplifier

Power supplies off

RF switch

PLC

CPCIRS232

PLC Cryo

PC

SR RF control system

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SR SSA control display (µcontroller)

Top transistor currents

Bottom transistor currents

Pi & Pr 2.5 kW combi

1 tower

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SR SSA operational experience

0%

5%

2006-2007 2009 2011 2013

Transistor FailureSoldering Failure

Year

Preventive maintenance

- The SR SSA’s have proved to be very reliable : after ~ 40 000 running hours over 8 years, only 5 short downtimes ! ~ 100 % op. availability, MTBF ~ 1.5 year (4 A) ~ 6 years (1A) - Average module failure rate of ~ 3.5 % a year (< 2 % in 2012 and 2013) ! ~ no impact on the operation, mainly a matter of maintenance 2 types of failures : - transistor breakdown ( ) - damaged soldering due to thermal fatigue ( )

Infant mortality

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Upgrade of the SOLEIL SSA’s

Take advantage of using a transistor of 6th generation, the BLF574XR from NXP, which is much more robust and has higher performance than the LR301, at relatively low cost : - Higher power capability ! additional operational flexibility (3/4 amplifiers @ 500 mA) - Change only transistor + a few components, re-use old PCB * ! ~ 10% of amplifier cost - Benefit from significant gain in efficiency (+ 6% in ηmod , higher G ! less mod, lower σG & σφ) ! resulting electrical power savings compensate for the upgrade costs in less than 4 years - More robust transistor & lower temperature ! lower failure rate ! lower maintenance cost

Parameters LR301 BLF574XR Benefits of BLF574XR

Pnom 315 W 330 W

Pmax 330 W 450 W more powerful

Gain 13.5 20 less preamplifiers

Mod. efficiency 62 % 68 % better efficiency

Gain spread ± 0.8 dB ± 0.2 dB no sorting

Phase spread ± 7.5° ± 2.5° better combining efficiency

Tmax 130 °C 80 °C less thermal stress

Upgrade schedule - In 2013 : Modif. of all pre-amplifiers (160 modules of 1st & 2nd stages) - From 2014 : Modif. 3rd stage modules at a rate of 1-2 towers a year

* Re-use the same power combination and the same dc power supplies with modified cabling in order to provide 50 V instead of 28 V at each module.

SOLEIL R&D with 352 MHz SSA’s

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6th generation transistors (Vdc = 50 V) + SOLEIL expertise ! fast progress

! Pmod ~ 700 W, G ~ 20 dB, η > 70% at 352 MHz

[ Current LR301 mod. (Vdc = 28 V) : P = 315 W, G = 13 dB, η = 62 % @ 352 MHz ]

! Huge improvement : Pmod x 2.2 , better performance (G , η , linearity) & thermal stress strongly reduced (ΔT : - 60 °C) ! longer lifetime

!! Beg. 2009, transfer of technology agreement concluded with ELTA-AREVA à ESRF contract for 7 SOLEIL type amplifiers of 150 kW (14 x 75 kW towers)

• June 2010 : Successful test of a 10 kW unit (16 mod.) at SOLEIL • June 2011 : Commissioning of the first 75 kW tower at ESRF • March 2012 : Commissioning of the 4 x 150 kW amplifiers of the

booster; they’ve run quite satisfactorily for 2.5 years ; η : 58% * * With new ac-dc converters, η > 60% expected η : overall amplifier efficiency including PS and circulators • Beg. 2014 : Delivery of the 3 amplifiers for the SR, slightly modified

as compared to the booster ones for handling high CW VSWR; they are now commissioned and operational ESRF 150 kW 352 MHz amplifier

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R&D with 352 MHz cavity combiner at ESRF

The cavity is made of 22 water cooled “wings” On each wing 6 modules of ~ 650 W Each module is magnetically coupled (loop) to the cavity

- “Fully planar” module efficiency ~ 65% - With only 3 active water cooled “wings” - 3 external 10 kW power supplies (1 per wing) - Up to 12 kW with an efficiency ~ 63 %

- Eliminates the power coaxial cables and minimizes the nb of connections - Compactness - Efficiency coupling spread ? - Tolerable VSWR - “Narrow” bandwidth (~ 500 kHz) - Replacing a failing module needs for removing a wing of 6 modules

Tests on prototype

! Full power test (22 wings) is scheduled for 2015

~ 80 kW ~ 80 kW

April 2010 in Campinas-Brazil : the SOLEIL - LNLS team, after successful tests of the amplifiers

Two amplifiers of 50 kW @ 476 MHz for LNLS (Brazilian LS) SR with components designed by SOLEIL (400 W modules with BLF574)

LNLS – SOLEIL Collaboration

The two 50 kW SSA have run satisfactorily on the LNLS SR for ~ 4 years

! Use of SSA’s (500 MHz) for SIRIUS, their new light source

LNLS 50 kW RF plants

SSA R&D at 500 MHz

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230 V_ac - 50 V_dc power converters of high efficiency (96%) in modules of 2 kW Remote voltage control ! optimum amplifier efficiency at different working points

(! Nico Pupeter’s talk )

Modules of 650 W at 500 MHz using 6th generation LDMOS BLF578 from NXP

❖ RF Output Power: 650 W CW ❖ Gain : 17 dB ❖ Efficiency ≈ 63 % at Pn ❖ Gain dispersion : +/- 0.2 dB at Pn ❖ Phase dispersion : +/- 5° at Pn

❖ Input Return Loss : < - 40 dB at Pn ❖ Unconditional stability (K >10 dB)

500 MHz power combination components

2 & 4 - way splitters 8-way splitter Pi - Pr monitoring coupler

Power combiners

8 x 650 W8 x 5 kW2 x 40 kW2 x 80 kW

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WaCCo

22

MUX D (1 per dissipater of 16 modules)

MUX D1 µC

MUX Master

Ethernet

n MUX slaves (1 per dissipater)

16 modules 16 modules 16 modules 16 modules

Ethernet

Local PC supervision Remote

control

4 pre-ampliMUX D2 µC

MUX D5 µC

MUX D6 µC

8 x (2 currents + 1 temp. ) ½ dissipator - top

P_incident

P_reflected

P_incident

P_reflected

µC

Multiplexer

Multiplexer

Co

mp

ara

tor s

Eth

erne

t

ADC

ADC

ADCADCADCADC

Wate

r flow

Thermo-s

witch

Interlock PS

Interlock RF

I/O

8 x (2 currents + 1 temp.) ½ dissipator - bottom

I/ORS485

address

½ dissip. top (8 mod.)

½ dissip. bottom (8 mod.)

SSA control

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AC-DC power supplies

2.5

m

2 m1.5 m

!- Integration into a cabinet

- 6 dissipaters with 16 modules : 96 modules of 600 W - 3 x 15 x 2 kW AC-DC converters

Status and schedule : - Most of the components are

already ordered - Tests on dummy load at SOLEIL

are scheduled by the end of 2014

500 MHz - 50 kW amplifier for ThomX*

* Compton Xray source under

construction in Orsay-France

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2.5

m

- Integration into a cabinet !- 16 dissipaters of 16 modules : 256 modules of 600 W !- 8 x 15 x AC-DC converters of 2 kW - 2 x 75 kW WaCCo

500 MHz - 150 kW amplifier

3 m2 m

WaCCoAC-DC power supplies Initially designed for

SESAME, the LS under construction in Jordan

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500 MHz 80 kW amplifier for SESAME

- Integration into a cabinet !- 10 dissipators of 16 modules : 160 modules of 600 W !- 5 x 15 x AC-DC converters of 2 kW

➢ First 80 kW amplifier is being built at SOLEIL (collaboration SESAME-SOLEIL) ➢ End of 2013, SOLEIL concluded an agreement of transfer of know-how with the French

company, SIGMAPHI ELECTRONICS, which will be able to build the 3 other ones

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CW HP SSA’s in other facilities

75 kW @ 162 MHz for FERMILAB

SIGMAPHI ELECTRONICS GANIL : 2.5, 5, 10, 20 kW @ 88 MHz IAP Frankfort : 10 kW @ 88 MHz 12 kW @ 176 MHz FERMILAB : 75 kW @ 162 MHz 10 kW @ 325 MHz BNL : 20 kW @ 704 MHz JLAB : 10 kW @ 748 MHz HZDR - ELBE : 10 kW @ 1.3 GHz HZB - BerlinPro : 16 kW @ 1.3 GHz

CRYOELECTRA 40 kW & 75 kW

@ 500 MHz for HZB – Bessy II

N. Pupeter’s talk

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Summary - Conclusions

❑ SOLEIL has now run for ~ 8 years with 352 MHz SSA’s (35 kW in the BO and 4 x 180 kW in the SR); they have shown an outstanding operational availability. This experience has demonstrated that the SSA’s can advantageously replace the vacuum tubes in such an application (extreme modularity, absence of HV, very low phase noise).

❑ The R&D carried out at SOLEIL has allowed improving the original design towards more

compactness in doubling the power per modules while still reducing the thermal stress, at 352 MHz and also at 500 MHz. !

❑ Four 150 kW - 352 MHz SSA’s, based on this technology, have run quite satisfactorily for 2.5 years in the ESRF booster ; 3 other ones were recently put into operation in their SR. The achieved efficiency is 58% and one expects an overall efficiency, η > 60% (circulators and PS included), with the newly used ac-dc converters. !

❑ Two 50 kW - 476 MHz SSA's, realized within the frame of a collaboration between SOLEIL and LNLS, have also run quite satisfactorily for 4 years in the LNLS SR (η ~ 57 %).

❑ SOLEIL is building 500 MHz SSA's, 50 kW for ThomX and 80 kW for SESAME; a 150 kW

version is available as well; expected η ~ 55 %. ❑ SSA technology has now reached maturity ; it is being adopted by several other accelerator

facilities and taken up by the industry for applications ranging from 80 MHz (η > 70 %) up to 1.5 GHz (η ~ 50 %) ! Higher performance with the new Gallium Nitride transistors ?

❑ The French company SIGMAPHI ELECTRONICS is SOLEIL licensee since Dec. 2013.

Acknowledgements

Patrick MARCHAND

Robert LOPES

Fernand RIBEIRO

Helder A. DIAS

Massamba DIOP Marc LOUVETRajesh SREEDHARAN

Cyril MONNOT

Jean-Pierre BAETEJulien SALVIA

Jean-Pierre POLLINA

Jocelyn LABELLE

Sylvain PETIT Renaud CUOQ

SOLEIL RF and LINAC group

Jorn JACOB and Michel LANGLOIS (ESRF) who have provided information about the status of their cavity combiner

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Respect and gratitude to Ti Ruan, who was THE pioneer in the domain of high power solid state RF amplifiers

Ti RUAN, 1936 - 2014