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Specifications for “Modular High Voltage Test Bench for TWT”

I. General Requirements Compliance with
specs offered

1. The power supply shall consist of a cathode (Helix) supply, a DC heater

supply, BFE modulator, and Three depressed collector supplies that are
independently variable. The power supply should operate in pulsed and
CW modes.

2. This equipment shall be designed to withstand the expected load shorts

and resulting surges encountered in the course of testing of green TWTs.

3. The controls and status monitoring to be provided on the front panel.

The HV terminals should be from the left or right side of the chassis /
cabinet. The HV terminals should be properly isolated and covered by
Perspex or equivalent cover for operator safety.

4. The equipment should have high-speed electronic-crowbar system and

a mechanical crowbar that follows up in action. Under shutdown mode
of state or upon firing of the electronic crowbar, the mechanical crowbar
must short the HV Capacitors to ground at the output for safety.
By default, the mechanical crowbar must keep the HV capacitors in
discharged mode.
M/s. ROSS Engineering Corporation HV relay model EA25 or equivalent
similar make shall be provided for the mechanical crowbar.
The maximum permitted fault discharge energy (High voltage) into the
Device Under Test (DUT) is <2J. The response time of the electronic
crowbar to be lesser than 10 micro-seconds (to be demonstrated during
ATP). The maximum permitted arc current into the DUT to be restricted
to lesser than 1000A, in the event of a fault.

5. The equipment should have built-in fan cooling. Nominal input power is
410V, 3, 5 Wire, 50Hz.

6. An oscilloscope (Tektronix Model TBS1202C or equivalent model offering

similar screen size, specs, etc.) floating at the cathode potential shall be
provided inside the TWT test bench, with permanent connection to
monitor the BFE pulses from the modulator.

7. For monitoring the Cathode voltage with respect to GND, a Precision

High Voltage Divider from M/s. ROSS Engineering Corporation model
VD15 or equivalent shall be provided. The monitoring available on the
front panel must have a resolution not lesser than 10V.

8. Provision shall be made to monitor the Pulse width, duty and PRI,
through a ground based view port on the front panel for confirming the
Modulator parameters before applying on the DUT, for ensuring the
safety of the DUT.

9. The unit shall be mounted on castor wheels for moving inside the room.
Hooks to be provided atop the unit for lifting the same with crane / rope
if necessary.
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10. Earthing / shorting /discharging rod to be available, connected with the

unit for safety of the personnel handling the unit.
Note: The combined load on all the high voltage power supply stages would not exceed 5 kW in
CW mode, due to specific mode of operation of the TWT with depressed collector stages. This note
is for enabling the manufacturer to offer most optimum solution, though pulsed power demand is
as high as 30kW.
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I. Specifications
a. Heater Power Supply
This DC power supply is voltage-regulated and current-limited. It is referenced to the cathode
voltage. The heater voltage is negative with reference to the cathode as shown in the block diagram.
The heater voltage and current limits are settable from the front panel and the measured heater
voltage and current reading must be displayed in the GUI screen. The heater once turned ON, a
settable time delay (from 1 minute to 5 min) must prevent application of high voltages such as
cathode /Helix and all collector stage voltages and disable the Modulator from pulsing.
Min Max units Compliance with
specs offered
i) Heater voltage (with respect to Cathode) 0.0 -10.0 V
ii) Voltage set resolution - 0.1 V
iii) Output current range 0.0 5.0 A
iv) Heater surge current limit - 150 %
v) Voltage Regulation (0A-5A output load current) --- 1 %
vi) Output voltage ripple (RMS, 5A output current) --- 50 mV
vii) Voltage Read-back Accuracy --- 0.5 %
viii) Current Read-back Accuracy 0.5 %

Note: The heater module should have a surge current limit of 150% of the set current value.
b. Cathode Supply / helix power supply electrical characteristics
This high-voltage DC power source is voltage-regulated and short-circuit-protected. The supply
provides the required power to the cathode. Measurement of voltage and current read and settable
on the GUI operating screen.

Cathode / Helix supply parameter Min Max unit Compliance with

specs offered
i) Cathode voltage (Ek) output (wrt Body or Helix / 0 -15 kV
Ground)
ii) Ek voltage ripple (Peak- Peak) 2 V
iii) Ek voltage regulation 0.1 %
iv) Ek set-point adjustment range 0 -15 kV
v) Ek set-point resolution 10 V
vi) Ek current range (Peak) (Droop<200V for 100 µsec) 0.0 2000 mA
vii) Ek current capability (Average) & Trip limits 5 50 mA
viii) Stability (per 8 hours) ±1 %
ix) Helix over-current protection range (peak) 50 2000 mA
x) Ek voltage Read-back Accuracy 0.1 %
xi) Ek current Read-back Accuracy 0.5 %
xii) Stored energy in high voltage (effective with crowbar 2 J
action)
xiii) A settable trip point must disable the Modulator from -0.5 -15.5 kV
Pulsing, if, Ek under voltage / over voltage is detected.

Note: The Helix over-current protection limit must be settable with a physical range switch or on
the user interface as required.
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c. Collector power supply (Exactly identical 3 stages of collector power supplies)

All collector power supplies are voltage-regulated. Each collector supply is independently
controlled to provide collector voltage flexibility. All the collector power stages are referenced to
Cathode supply as shown in the block diagram to deliver the required power to operate the TWT.
Each supply has an adjustable range. Every collector supply has built-in over power protection
circuit that prevents supply from overloading. Measurement of all voltages and currents read and
settable on the operating GUI.
Collector 1 to 3 parameters Min Max unit Compliance with
specs offered
i) Collector Power supply voltage range with respect 0 15 kV
to Cathode voltage reference
ii) Collector voltage set point resolution 10 - V
iii) Collector voltage ripple 50 V
iv) Collector voltage regulation 1 %
v) Current (Average)
1. Stage-1 0 300
2. Stage-2 0 300 mA
3. Stage-3 0 300
vi) Current (Peak) 0 2 A
vii) Stability (per 8 hours) 1 %
viii) Collector voltage Read-back Accuracy 0.5 %
ix) Collector current Read-back Accuracy 0.5 %
x) Stored energy in high voltage 2 J
(effective with crowbar in place)
xi) Isolation to Ground - 20 kV
(to be demonstrated at the isolation transformer for
the collector power stages)
xii) Under voltage / over voltage limits (Limits are -500 +500 V
specified with respect to the set collector voltage)
xiii) Collector current range (Peak) for Droop < 200V for 0.0 2 A
100 µsec

Note:
1. All the Collector Power Supply units shall be identical and modular in construction as a Line
Replaceable Unit.
2. The collector power supplies must be isolated from ground by at least 20kV for the safe
operation of the DUT / HV power supply
3. If necessary, the collector stages must operate in parallel to deliver more average power,
with reduced number of stages connected to the TWT (Example: One stage (collector-1) to
deliver 300mA, the other two stages connected together (at TWT) and connected to second
stage collector, must deliver 600mA, OR all the collector stages connected together (at TWT)
connected to Collector-1 stage of the power supply shall deliver 900mA (average)).
4. Collector Under voltage / Over voltage protection set must disable the modulator from pulsing
the electron beam.
5. The combined power on all the Collector power stages will not exceed 4.5kW under any test
conditions. While conducting the ATP, this condition would override all requirements limited
to this extent in combined power delivery.
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d. BFE Modulator
BFE modulator modulates the Beam focus electrode (BFE) with respect to Cathode potential. The
Modulator has two switches inside it operating in complementary mode to connect the output
either to the cathode potential or to the Bias power supply voltage set, depending on the
modulation pulse set as per the requirement. Their specifications are as following.
BFE modulator parameter Min Max unit Compliance
with specs
offered
i) Pulse ON voltage [ Pulse ON voltage is 500 2800 V
specified with respect to Bias supply]
ii) Bias supply voltage [defined with reference -3000 0 V
to Cathode voltage]
iii) Modulator Rise and fall times - 100 ns
iv) Modulator Pulsing frequency (continuously 1 20000 HZ
variable)
v) Pulse width 0.25 500 us
vi) Duty cycle (continuously variable from low 0.1 100 %
value)
vii) BFE / Grid interception Current (peak) 0 100 mA
viii) BFE/Grid interception current (Average) - 5 mA
ix) BFE / Grid Capacitance 10 50 pF
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II. Other Requirements of the Power Supply

Other Requirements of the Power Supply Compliance with

specs offered
i) All the voltages, currents and their trip levels shall be settable and readable from
the front panel display.

ii) Interlocks

High Voltage Interlocks

The high voltage control system will remove or prevent primary power being
applied to the high voltage supplies for any of the following conditions:

a. High voltages (All the Collector stages and Cathode /Helix power supplies) and
Pulse ON controls will be inhibited during the initial 5 minutes (max) of Heater
warm-up time.

b. Failure of internal cooling air (if necessary).

c. Opening of any external / internal interlocks (4 external interlocks would be

provided, which are normally closed. Opening of the interlock is to be
considered as an external fault and action to be taken accordingly in addition
to displaying interlock failure on the front panel)

d. The Modulator ON will be disabled in the absence of Collectors and Helix

voltages with suitable interlocks for operation.

e. A Service BYPASS mode should be provided, with a suitable switch (Hardware)

which enables Modulator operation without Collector stage and Cathode
voltages present, for checking Modulator performance. This switch must be
located inside the Cabin with a clear marking of the mode of operation (BYPASS
/ NORMAL). The GUI must display the mode of operation as Normal / Bypass
accordingly.

iii) Displays & Controls (Located on the front panel): All the Set and Measured
parameters must be displayed in a LCD / Fluorescent / Seven segment

a) Mains ON Indicator
b) Standby/status/Ready Indicator. (After 5 minutes of heater ON. Ready indicator for
applying High Voltages)
c) HV ON Control for Cathode, Collector1, Collector-2 and Collector-3
d) HV ON Indicator
e) Summary Fault Indicator (Excess Helix Current, Excess Temperature, Cooling Air
Flow failure, Cathode Overvoltage, Cathode under Voltage, Bias supply under
voltage, etc. )
f) Excess Helix Current Trip Indicator (Peak and Average)
g) External interlock Trip Indicator
h) Cathode voltage fault indicator (both over and under voltage)
i) Reset Switch (momentary contact to reset the fault to bring the operating mode to
Standby mode)
Standby mode: This mode of operation means, heater voltage and Bias supply
applied and no faults present till this mode of operation)
j) Variable controls for: Heater voltage, Cathode voltage, Modulator Pulse ON and
Bias supply voltages, Collector1 to 3 voltages
Cathode over voltage and under voltage,
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Collector over voltage and under voltage,

Bias supply under voltage.
iv) Protections

a) Excess Helix Current Must protect the tube from adjustable helix
currents (body current) or Peak current: 500
mA (Maximum) or Average current: 50 mA
(Max).
b) Excess Temperature Temperature switch contacts to be provided
c) PRF, Duty, Pulse-Width limit If exceeds specified values; Unit trips to STDBY
mode
d)
Cathode over-voltage / under- Removes cathode & collector voltage, goes to
voltage STDBY mode.
e) High-speed electronic crowbar Electronic Crowbar Fires in less than 10us
system followed in action by the mechanical crowbar
v) Mechanical

a. Cooling Air-cooled with built-in blower. Inlet air

temperature 40 0C (max)
b. Operational Temperature range 20oC to 45oC

c.Relative humidity (non- 50 to 90%

condensing)
d. Voltage stability +/-1% of set voltage over 8Hrs
e. Size (maximum) 250 x 100 x 180 cm.
f. Weight (maximum) 700 kg
g. All electrical leads for connecting the device shall be brought at the side panel. All
the HV leads brought to the side panel shall be provided with banana jacks.
Dedicated grounding and all connections shall be done with banana jacks.
vi) Side Panel

a. HV Terminals The HV terminals should be properly isolated and covered by

transparent fibre / Perspex cover for operator safety.

b. Interlocks 4 numbers of protection interlocks to be provided for interfacing

with the TWT. (The interlock would be normally closed position
wrt to ground). Open interlock shall trip/ prevent enabling the
High voltage power supplies and indicate interlock faults.
vii) Front Panel

a) ON MCB switch for switching on the mains power.

b) MAINS Mains on indicator.
c) HV OFF Switch/Indicator to switch off HV.
d) HV ON Switch/Indicator to switch on HV.
e) RESET Switch/Indicator for resetting tripping due to faults.
f) RDY Indicator. Glows after warm up time
g) HLX Indicator for excess helix current trip
h) TEMP Indicator for over temperature of TWT/ Power Supply.(The
interlock interlock would be normally closed position with respect to
ground)
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viii) General

a) The turn-on sequence is the following:

1. The heater supply turns ON first (Warm up timer duration is set by built-
in logic /computer)
2. BFE/Grid OFF Bias supply on
3. Collector 1-3 supplies turn ON (turn ON time <5000ms).
4. Helix/Cathode supply turns ON (turn ON time <5000ms).
5. Pulse on.
b) The turn-off sequence is the following:

1. BFE Modulator Pulse off (Modulator to turn to Bias Supply ON mode)

2. Cathode power supply off
3. Collector power supplies (1-3) off
4. Modulator Bias supply off
5. Heater supply off
Note: When the last collector supply is turned off, the crowbar must be fired to
safely remove all high voltages.

c) Clear Labelling of HV warning symbols, precautions, service manual, operating

and Maintenance manual should be provided both in Hard and softcopy
formats.

d) The Service Manual should completely bring out all the details of PCB layouts,
Assembly drawings, schematics, Test points, Troubleshooting should be clearly
provided along with necessary test points in the circuit and also logic levels as
and where applicable.

III. Special Terms and Conditions:

S/N. Description / Condition Compliance /

Non-compliance
1 Firm may provide a copy of its own QA report containing similar or
additional information while delivery.

2 The quotation is invited only from the original manufacturer or their

authorized representative (with authorization certificate). Quotations
without authorization certificate will be considered null and void.

3 Compliance statement to be provided along with the quote. Compliance

statement must contain the specifications offered. (Quotation without
compliance statement or partial compliance statement will be
considered non-compliance to the specifications).

The firm must agree to provide the test results and Certificate of
Conformity (COC) (from the OEM, in applicable case) along with the
supply.
4 ATP will be carried out at the Vendor’s site / Or at MTRDC before the
unit is dispatched /accepted at MTRDC.
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5 Important: The firm to submit a proposal based on commercial-off-

the shelf power modules (for all the power supplies / modules
shown in the Block diagram) available from reputed manufacturers like
M/s. Spellman, M/s. Glassman, M/s. Genvolt, M/s. Technix, M/s. TDK-
Lambda or similar manufacturers, and for the Modulator from M/s.
BEHLKE or similar module with equivalent only. This is a mandatory
requirement. All internal support systems for HV stand-off, isolation etc.,
must be accordingly designed.

At the time of PDR, the firm must make a presentation on the design
architecture and MTRDC to approve the same before executing the
work. ATP would be conducted based on this PDR only.

Any clarification on any of the conditions or design requirements shall be

communicated to MTRDC and clarity shall be obtained before submitting
the techno-commercial offer.

MTRDC would monitor / the firm to update MTRDC on the status /

progress of the work during the period from supply order to delivery &
acceptance of the test station at MTRDC.

6 Important: The GUI for programming set points / trip levels, readouts,
etc., to be placed at a suitable position on the front panel of the cabinet
after discussion with MTRDC only.

Minor modifications, which does not impact cost of the system may be
permitted by the firm on mutually agreeable terms for modifying few
parameters / logical sequencing / GUI at the time of ATP or before, for
bettering system while using.

7. Important :
1. Operating Manual of the Modular HV Test Bench to be
provided
2. Schematic of the Modular HV Test Bench such as Schematics of
wiring, PCBs etc., (outside the Modular HV Power supplies /
Power units) to be provided.
3. Operating software files to be provided along with delivery of
the Modular TWT Test Bench (Firmware (if applicable) and
supporting software along with IDE, programming cable etc.).
8 The firm may offer the charges for the AMC for a period of 5 years after
the expiry of the warranty of the “Modular High Voltage Test Bench for
TWT”
9 The “Modular High Voltage Test Bench for TWT” must be covered
under warranty for period of 1 Year from the date of acceptance at
MTRDC.