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GTF Klystron Modulator #1 System Interlock Check

March 15, 2005 SAPE-119 Code 9005 Revision No. 0 Modification No. 0 page 2 of 14

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Revision/Modification list

Rev/Mod number

Description Date & Author/Signature

0/0 Original Document for GTF modulator #1 interlock check J. Schmerge 3-15-2005




1 Purpose To test and verify the interlock circuits of the GTF Klystron Modulator #1 System.

2 Discussion

2.1 System overview The GTF Klystron Modulator provides the necessary drive voltage for the Klystron tube. The charging potential can reach as high as 25kV @ 300mA.

2.2 Equipment Identification HV Power Supply Manufacturer: Maxwell (now known as General Atomics) Model No.: CCDS 4Kj Location: Rack B140-110 (North of the White Circuit enclosure in Building 140).

2.3 Operator Controls The supply can be operated either locally using the controls located on the front panel of the supply, or remotely via the GTF control computer.

3 Reference Documents

3.1 Drawings SD-444-251-93 MODULATOR #1 SCHEMATIC SD-444-274-13 MODULATOR HV INTERLOCK CHASSIS PS-730-569-R2 THYRATRON KEEP-ALIVE SUPPLY SCHEMATIC

3.2 Figures a. Page 11:

• Figure 1: The circuit breaker used to simulate thyratron fan failure is marked as well as the thyratron reservoir and filament variac controllers. • Figure 2: The modulator 1 interlock chain is shown along with the keys 1, 2 and HV on and off.

b. Page 12: • Figure 3: The GTF gun chiller is shown. A second unit (not shown to the left) is used to cool the SSRL gun and is interlocked to modulator 2. • Figure 4: The klystron cooling water LCW valve is shown behind Klystron 1.

c. Page 13: • Figure 5: The GTF waveguide pressure gauge and source selector are shown. GTF operators control the key to the source selector lock box.



• Figure 6: The modulator 1 fire and heat detector is shown. The alarm reset and heat sense buttons are marked.

d. Page 14: • Figure 7: The core bias and klystron filament power supplies are shown along with the modulator 1 kirk key. • Figure 8: The modulator 1 HV PS supply is shown along with the HV power supply interlock chassis with the HV ready light and average, peak and HV over current monitors.

4 Prerequisites • EWP, JHAMs, AHAs have been approved. • Two authorized, qualified employees are required to perform this procedure. • One LCW supply line, capable of up to 250psi, services the klystron tube. During the

normal interlock testing, only the SUPPLY line is to be turned off to simulate the absence of LCW, and should indicate so during the test.

• The MPS/PPS system protects the modulator system from system failure or operational errors. During the normal course of testing, the MPS/PPS system is not disabled and needs to be operational to carry out the interlock tests.

• The modulator needs to be released from GTF operations and in local mode.

5 Material, Tools, and Test Equipment • An ED&M #3218 key is required to open the rear door of rack B140-110 only. Access required

for interlock verification. • CAT III 1000 V DVM. • Hazard Risk Category 0 clothing, non-melting, flammable, (i.e. untreated cotton, wool,

rayon, silk or blends of these materials) shirt (long sleeve), pants (long). • Closed toe work shoes. • Electrical safety glasses/goggles with UV protection. • Caution tape (for barrier).

6 Precautions • Interlock tests are initially carried out with the HV supply locked off. Only the 3

interlock tests in Table 2 require the HV supply to be operational. • No RF power is required to perform the interlock checks. • The door interlocks only require that the door open ¼ inch to engage the switch.

7 Authorized Personnel This procedure shall be performed only by authorized employees that have completed CPR/First Aid, ES&H classes 239 and 251, and are knowledgeable in the use and operation of the test equipment.

Name(s) of authorized personnel are listed in the EWP.



8 Acceptance Criteria All the steps are successfully completed and discrepancies have been addressed. The GTF system manager shall be notified of any discrepancies.

9 Procedure This page lists all the interlocks, location, and checklist for verification of all the interlocks in the GTF Klystron Modulator #1 System (See Table 1).

Interlock tests are initially carried out with the HV supply locked off. Only the final 3 interlock tests require the HV supply to be operational (See Table 2). No RF power is required to perform the interlock tests. The door interlocks only require that the door open ¼ inch to engage the switch.



Step No.

Action

Define work to be done

Verified

(Initial / Date)

The steps must be performed in the order given. N/A 1.0 Personnel Notification: Notify the GTF System Manager and

SPEAR Operator on duty that modulator #1 interlock test is starting.

2.0 Verify EWP is signed and attached to this document before proceeding with interlock checks.

3.0 INTERLOCK CHECK PROCEDURE

3.1 If the HV supply is on, request a GTF operator to lower the voltage to zero. Place the supply in local mode and turn off the supply and lock off modulator #1 with the Kirk-key.

3.2 Verify that the HV supply will not turn on without the Kirk-key turned on in rack B140-110.

3.3 Verify that all the interlocks are made up (all lights on modulator are on) and the HV READY light is GREEN.

3.4 Interlock verification: Perform the following and record in Table 1.

• Trip the desired interlock.

• Verify that the HV READY light is RED and that the appropriate interlock status light is off (on modulator).

• Reset tripped interlock and check that the interlock chain is complete and the HV READY light is GREEN.

• Repeat above steps until all interlocks in Table 1 are tested.

3.5 Verify that all the interlocks are made up (all lights on modulator are on) and the HV READY light is GREEN.

3.6 Disconnect RF sub-booster (714-111-10) trigger input cable in rack B140-106B.

3.7 Obtain Kirk-key for Modulator #1, unlock and turn on Maxwell supply. Slowly raise output to 18.5 kV and complete last 3 interlock checks listed in Table 2.

Note Only the final 3 interlock tests listed in Table 2 require the HV supply to be operational and a trigger present.

N/A



Step No.

Action

Define work to be done

Verified

(Initial / Date)

3.8 Interlock verification: Perform the following and record in Table 2.

• Trip the desired interlock.

• Verify that the HV READY light is RED and that the appropriate interlock status light is RED (on modulator interlock chassis).

• Reset tripped interlock and check that the interlock chain is complete and the HV READY light is GREEN.

• Repeat above steps until all interlocks in Table 2 are tested.

3.9 Once high voltage testing is complete, turn HV power supply down to 0 volts, turn off supply, and lock Kirk-key in rack B140-108.

4.0 RESTORATION N/A

4.1 Reconnect RF sub-booster (714-111-10) trigger input cable in rack B140-106B.

4.2 Inform SPEAR operations Modulator #1 interlock tests are complete and return K1 Kirk-key.

4.3 Inform GTF System Manager Modulator #1 interlock tests are complete.

4.4 The GTF Klystron Modulator #1 interlock test is complete.



Table 1: Interlock Check List 1

Step No.

Table 1

Action

Verified

(Initial / Date)

5.0 Interlock Check List N/A

5.1 Klystron Filament Under Current, turn down klystron filament heater control until system trips around 7.6 A; restore to nominal value of 50.0 V, 16.0 A after interlock verified.

5.2 Thyratron Over Temperature (not tested at this time since it requires the cabinet to be open with exposed 120 V conductors).

N/A

5.3 Thyratron Filament Under Current, turn down thyratron filament heater control until system trips around 2.0 V; restore to nominal value of 6.2 V after interlock verified.

5.4 Thyratron Reservoir Under Current, turn down thyratron reservoir heater control until system trips around 3.0 V; restore to nominal value of 4.8 V after interlock verified.

5.5 Chiller H20 (Against B140 wall to the right of K1). Turn GTF gun chiller power off to simulate loss of cooling water.

5.6 Klystron Water Flow (Against wall behind modulator). Turn LCW supply valve, only, off to simulate loss of cooling water.

5.7 Fans (front of modulator cabinet) turn CB8 off to simulate thyratron fan failure.

NOTE

CAUTION: DO NOT open the door any further than required to engage the switch.

N/A

5.8.1 Modulator #1 Left Front Door Switch (Middle of door frame)

5.8.2 Right Front Door Switch (Middle of door frame)

5.8.3 Left Back Door Switch (Middle of door frame)

5.8.4 Right Back Door Switch (Middle of door frame)

5.8.5 Right Side Front Door Switch (Middle of door frame)

5.8.6 Right Side Back Door Switch (Middle of door frame)

5.8.7 Key 1 (front of modulator cabinet)

5.9 Key 2 (front of modulator cabinet)

Table 1 Verified



Step No. Action (Initial / Date)

5.10.1 Fire, test Smoke Detector at top of modulator cabinet. Requires “Smoke in a Can” aerosol to be sprayed into detector. Reset with alarm reset button on Smoke/Heat Detector chassis.

5.10.2 Fire, test Heat Detector at top of modulator cabinet. Push “Heat Sense” switch on Smoke/Heat Detector chassis. Reset with alarm rest button on Smoke/Heat Detector chassis.

5.10.3 Fire, wire test at top of modulator cabinet (not tested at this time since it is not connected).

N/A

5.11 Core Bias, turn down core bias control until system trips around 4.0 A; restore to nominal value of 6.2 V, 12.6 A after interlock verified.

5.12 PSI Waveguide (Against wall behind modulator). Ask GTF operator to slowly vent gas until interlock trips around 12 PSI.

5.13 Oil Temperature (not tested at this time since it requires the cabinet to be open with exposed 120 V conductors).

N/A

5.14.1 High Voltage Ready, press HV off switch. Reset by pressing HV on switch.

5.14.2 Rack B140-110 Back Door Switch (Middle of door frame). This interlock trips the High Voltage Ready interlock through the linac modulator HV power supply interlock chassis.



Table 2: Interlock Check List 2 requires HV power supply operable

Step No.

Table 2

Action

Verified

(Initial / Date)

NOTE

BEFORE starting the next series of checks, the klystron trigger must be enabled and the

rf driver trigger disabled. The HV power supply must be on and at the nominal

operating voltage of 18.5 kV.

N/A

5.1.7 Average Over-current (run setting @ 1.26 VDC). While monitoring the set point voltage, lower voltage until the interlock trips. System should trip at ? VDC. Return setting to original value.

Record trip setting here VAOC: ________

5.1.8 Peak Over-current (run setting @ 3.60 VDC). While monitoring the set point voltage, lower voltage until the interlock trips. System should trip at ? VDC. Return setting to original value.

Record trip setting here VPOC: ________

5.1.9 HV Over-voltage (run setting @ 3.60 VDC). While monitoring the set point voltage, lower voltage until the interlock trips. System should trip at ? VDC. Return setting to original value.

Record trip setting here VHVOC: ________



Figure 1: The circuit breaker used to simulate thyratron fan failure is marked as well as the thyratron reservoir and filament variac controllers.

Figure 2: The modulator 1 interlock chain is shown along with the keys 1, 2 and HV on and off.

CB8 Thyratron Fan

Thyratron Filament Control

Thyratron Reservoir Control



Figure 3: The GTF gun chiller is shown. A second unit (not shown to the left) is used to cool the SSRL gun and is interlocked to modulator 2.

Figure 4: The klystron cooling water LCW valve is shown behind Klystron 1.

K1 LCW Supply Valve



Figure 5: The GTF waveguide pressure gauge and source selector are shown. GTF operators control the key to the source selector lock box.

Figure 6: The modulator 1 fire and heat detector is shown. The alarm reset and heat sense buttons are marked.

GTF Pressurized Waveguide Source Selector

Alarm Reset

Heat Sense



Figure 7: The core bias and klystron filament power supplies are shown along with the modulator 1 kirk key.

Figure 8: The modulator 1 HV PS supply is shown along with the HV power supply interlock chassis with the HV ready light and average, peak and HV over current monitors.

HV Ready Lights

Modulator 1 Kirk Key

Core Bias Supply

Klystron Filament Supply

Average, Peak and HV Over Current Monitors

HV Power