500 MHZ Solid State Amplifier Design Progress Report

Paul Scherrer Institut • 5232 Villigen PSI 5th CWRF Conference - CERN - 3/2008 M. Gaspar

500 MHZ Solid State Amplifier Design Progress Report

M. Gaspar, M. Pedrozzi


Comissioning of 4KW Validation Prototype

PC Master Controller: 2 Available (PSI Design)

Power Supply Controller: 25 Boards Available (Programmed and Tested) (PSI Design)

Power Splitter: 2 8-Way Prototypes Working (PSI Design)

250W Amplifier Module: 12 Modules Available (Already tested). 10 Ready for Tests (PSI Design)

Cooling Bar: Ready to Accommodate New DC-DC Converter.

High Power Coupler: 1 Piece Available and Calibrated (Industry)

New Design in Progress (PSI Design)

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

Cables: Waiting for Delivery (1 or 2 weeks more) (Industry)

Watter Cooled Load: 1 Piece Available (Industry)


4KW Amplifier Configuration


4.5KW Basic Components( 3D Conceptual View – Not To Scale )

+

+

2x

18x

18x

+

+

=

5KW max!


250W Amplifier Module

Key Performance Parameters

3D-View of 500MHz Amplifier Module

Output Power (with Circulator)

250W 280W

Gain 22dB 20dB

Efficiency ~ 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 2

Pin(W)

Po

ut(

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 50 100 150 200 250 300

Pout(W)

Ph

as

e(S

21

) (°

)

Phase (°)



Pout(W) x Pin(W)

0

50

100

150

200

250

300

0 0.5 1 1.5 2 2.5

Pin(W)

Pout

(W)

M#1

M#2

M#3

M#4

M#5

M#6

M#7

M#8

M#9

M#10

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

iency

(%)

M#1

M#2

M#3

M#4

M#5

M#6

M#7

M#8

M#9

M#10

Output Power versus Input Power

Efficiency versus Output Power

Performance of first 10 RF Modules



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

0

5

10

15

20

25

0 50 100 150 200 250 300

Pout(W)

Mag

(S21

) (dB

)

M#1

M#2

M#3

M#4

M#5

M#6

M#7

M#8

M#9

M#10

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)

Phas

e(S21

) (°)

M#1

M#2

M#3

M#4

M#5

M#6

M#7

M#8

M#9

M#10

Gain versus Output Power

Phase Delay versus Output Power

Performance of first 10 RF Modules



K - Stability Factor

0

10

20

30

40

50

60

70

80

0.00E+00 5.00E+08 1.00E+09 1.50E+09 2.00E+09 2.50E+09 3.00E+09 3.50E+09 4.00E+09 4.50E+09

f (Hz)

db

(K)

db(K)

B1 - Stability Factor

0

0.5

1

1.5

2

2.5

0.00E+00 5.00E+08 1.00E+09 1.50E+09 2.00E+09 2.50E+09 3.00E+09 3.50E+09 4.00E+09 4.50E+09

f (Hz)

B1 B1

Amplifier is Unconditionally Stable



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=1.77W

Pin=1.65W

Phase(S21) (°) x Vdd(V)

120

121

122

123

124

125

126

127

128

129

130

22 24 26 28 30 32 34

Vdd(V)

Phas

e(S2

1) (°

) Pin=1.77W

Pin=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).

• 12 Modules Fully Tested.

• 10 Modules Assembly Finished But Not Yet 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


RF Switch

RF Rise Time/Fall Time: 1us

Operating Frequency: 500MHz

On/Off Switching Time: < 20ns

Remote Controlled Through Network

RF Limitter/Protection Included

External Interlock Reaction Time: < 100ns

In/Out Isolation: 80dB

Insertion Loss: 0.5

Main Performance Parameters

Design Finished All Components Available

Construction to Start Soon

Status


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

LEDs for Interlock and operation

Design Finished


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

• Operating System Installed.

• All Tests Completed (Power and Monitoring).

• Boards Ready To Use.

Power Supply Controller


SOS (Save Our Souls)(Originally: Script Operating System)

Runs ASCII Scripts: No Need for Previous Compilation

Available Commands for Analog and Digital I/O

Simplified IBM BSC Protocol implementation for Network Applications

Can also be used in Autonomous Applications (No Network)

Optimized for Data Acquisition

Multi-tasking Environment: Allows Monitoring and Data Taking Simultaneously

Precise Time-Base for Timing Applications: 1mS

Almost all Code Portable to other Microcontrollers

Designed in House: No Commercial Licen$e Needed

Main Features

Actual Version: SOS v2.97.4Programmed in All Power

Supply Controllers


Power Supply Controller

and Monitoring System Tests

Power Supply Output

High VoltageInput

(220Vac)

RFin

Amplifier Monitoring

RS485Network

RFout

Cooling Plate


Status• Voltage Stabilizer not Yet Available (2 to 3 weeks more).

• RF Components all Available.

• RF Switch in Progress.

• Power Supply Controllers Ready.

• High Power Output Directional Coupler: Prototype Tests OK, Design in Progress.

• RF Cables waiting for Delivery.

• Monitoring and DAQ Software in Preparation (Linux).

Conclusions• Rf Module Design proven and working. Unconditional Stability proven. High Gain and High Power available.

• All monitoring is working all right as designed.

• Available parameters for monitoring per RF module:

Output Forward Power, Input Forward Power, Output Reflected Power, Transistor Temperature, Power Supply Current, Power Supply Voltage.

• Power Supply Voltage can be set remotely.

• Power Supply controller heavily tested. Monitoring and Data Acquisition concept proven.

• Whole 5KW Prototype will be ready and operational soon.

500 MHZ Solid State Amplifier Design Progress Report

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