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Description
Two units of 500 MHz 60 kW CW AR RF High Power Amplifiers (HPA) has been designed and manufactured as per LBNL's Engg Specifications & Requirements Document through a joint effort between engineers at LBNL and engineers at vendor R&K Company Ltd, Japan. The HPA design documents were reviewed by LBNL and also desk reviewed by NRTL company UL to USA standards prior to conducting the Final Design Review (FDR) and the recommendations from such review were duly incorporated & resolved. Prior to conducting Factory Acceptance Test(FAT) the HPA's were successfully preliminary field evaluated by NRTL--UL at vendor factory site. Thereafter detailed and extensive FAT were carried out at vendors factory for checking conformance to various specifications & requirements in various HPA subsystems viz., RF, AC, DC, LCW, Mechanical, Controls, Interfacing, EMI/EMC etc. Detailed HPA functionality & interlocks checks for HPA operation from local HMI and also from remote EPICS IOC were carried out. This paper presents such UL preliminary inspection, Reliability Testing in hot temperature (continuous operation at 60 kW CW output for 100 hours at 35 degC ambient) and FAT Results and how some HPA technical issues faced during such tests were successfully resolved. Overall the FAT was successful and the two HPA units were safely shipped to LBNL with all transit shock/ vibration monitors intact. This paper also presents some of challenges faced in HPA site installation work activities like rigging & anchoring heavy HPA (each ~ 3 Tons), Electrical Panel & wireways, LCW installation (~ 40 gpm flow), and RF dummy Load (80 kW) installation etc., in preparation to conduct the Final field evaluation by NRTL UL inspector at LBNL and then after AHJ approval to conduct soon the Site Acceptance Tests (SAT) which will be a subset of FAT tests.
