Here's a much older piece of spacecraft equipment:
Hughes Traveling Wave Tube & HV Power SupplyIf you're not familiar with
Traveling Wave Tubes (TWTs), these are vaccuum-tube RF amplifiers which work by modulating a beam of electrons across a multi-wavelength distance (similar to a klystron). Before microwave-frequency transistors were available and reliable (esp. in 10W+ or 100W+ power levels), these were the main way to build a multi-Ghz RF amplifier. Accelerating the electron beam requires a high (multi-kV) DC voltage, and generating the free electrons in the vacuum requires a low-voltage filament - generating both these voltages, as well as health monitoring etc. is the job of the attached power supply (called the "Electronic Power Conditioner" or EPC in the TWT world).
According to the seller (who has another of these, and was kind enough to give me a good discount), this particular unit came from
Intelsat, and was originally part of a life test rack - normally this is where production electronics are exercised continuously, sometimes under elevated temperatures or other rough conditions, to check for early failures. The Intelsat V family of communications satellites were built by Ford Aerospace: it seems strange for a car company to have a satellite business, but at some point in the early 60's they acquired
wide-ranging electronics company Philco and aerospace company
Aeronutronic, to form their military & aerospace business. This aerospace division produced several families of communications satellites and various military projects, but was later sold off to become "Space Systems/Loral" and then Lockheed Martin, all part of the big, dumb game of "military-industrial-complex trading cards".
The TWT & power supply were built by Hughes Aircraft, though, who had their own thriving communications satellite business (the first entry in this thread came from them as well).
There's not much to see with the TWT itself, esp. as the label warns about the beryllium oxide inside. Combining high thermal loads (esp. at the "collector" in a TWT which dissipates the leftover energy in the electron beam after coupling to the RF output) with high voltages means that this is a prime place for very thermally-conductive but electrically-insulating ceramics.
There's also a little RF module which the input(?) RF signal passes through, before reaching the TWT. No idea what this is, as I wasn't able to get it open, but it's 2-port & passive.
So, let's look inside the power supply.
Power Supply BoardThe 10-20W RF output of the TWT means the power supply is probably rated for well under 100W, so there's nothing crazily high-power here. The box is a thin metal shell with the PCB attached at both top & bottom with angle brackets, for rigidity. After taking out a lot of screws, snipping the output wires to the TWT, and un-sticking a bit of adhesive, I was able to pull the PCB out of the box to get a better view:
They really did not skimp on the conformal coating here! There's a very thick layer of yellow coating over both the bottom and the top sides of the board, which gives the components an interesting "underwater" look because of the refraction. The orange and yellow of the board nicely matches the fall colors of the leaves where I took the photos outside my apartment though.
At the right-hand side, there's a 15-pin D-sub connector for interfacing to the outside world, plus 3 power transistors in interesting packages (with Texas Instruments logos).
I can't connect the part numbers on these unusual power transistors to anything publicly accessible, but
the '72 TI power device catalog shows this as their standard "QQ" package (p.93). The 2N3263-3266 (p.192) seems like a good candidate for what parts these might be, as they're meant for "high-speed switching applications", which fits the switch-mode power supply application here. Rated power dissipation is 67W even at 100°C case temperature, which shows that the Rth-jc is nice and low at ~1.5 K/W, and that they can dissipate a
lot of power if properly heatsinked. The only other place I've seen this type of transistor package is in
the both fascinating-and-horrifying Minuteman III guidance system.
On the bottom, underneath this control and switching section, are three ICs:
2 have the AMD logo and are labeled LH2823; I can't find any references to this part number, but from the pinout & connections (discussed later) these seem like op-amps, likely one of the AM102/AM112/AM216 series. The 1 remaining IC is also from AMD and has some kind of custom part number, but may be digital logic(?).
The most noticeable feature of the board is the big orange potted block in the middle. This likely has all the high-voltage stuff inside. You can see below...
- (top-right) a large toroidal transformer, probably for voltage step-up
- (top-middle) a dark-colored mystery block, which may contain high-voltage diodes and/or a voltage multiplier on the transformer output
- (top-left) a yellow-colored block of film capacitors, which probably provide the DC filtering for the high-voltage output(s)
- (bottom-right) a mystery cordwood module with some transistors
- (bottom-left) a small toroidal transformer
Here's a better view of the cordwood module and 2nd transformer:
The first 3 items in the list seem pretty clear as to function, but I'm not sure what the cordwood module and 2nd transformer are for: these might be over-current protection in series with the HV output, or maybe regulation for the filament voltage.
At the other side of the block, you can see some wires exiting: these are 4 of the 6 wires that go to the TWT.
I'd like to get a better view of what's inside this block to figure out what the extra parts are doing, but unfortunately the orange material is too hard to cut or peel away easily without damaging the components inside. I'd also settle for being able to get a smoother finish on the top face, so that it's optically clearer like the side face shown before, but it turns out this material is also too soft to use sandpaper effectively.
Finally, at the left-hand/output side of the board, there's some additional circuitry that includes:
- another LH2823 op-amp on the bottom, for some kind of secondary-side control
- a mystery Caddock resistor network up against the orange block, possibly used for sensing one of the output voltages?
- a high-voltage film cap on the bottom
ConnectionsNow let's talk about how it works! At a minimum, the TWT needs a low filament voltage, a cathode voltage (usually shared with one side of the filament), and an anode/collector voltage - go read the Wikipedia article linked earlier to see what these do inside the TWT. The seller's description also mentions that this TWT has additional collectors (which each have their own different HV potential, if I remember correctly) for higher efficiency.
The power supply has 4 wires coming out of the potted HV block (2x yellow, brown, & red) and 2 wires coming off the PCB (blue & black). On the TWT side, there's 3.4Ω from brown to yellow (filament), and both yellow wires are connected together: this suggests the yellows are a combined filament & cathode common connection. Black connects to the TWT housing. This leaves the blue & red wires for collector voltages.
Since the collectors & anode have to be positive relative to the cathode & filament, and the majority of the power dissipation is in the collectors, if I were designing a TWT I would want to make the collectors as close to enclosure-ground potential as possible. This would give me an easier time conducting heat away from the collectors, with less insulation (and therefore thermal resistance) needed between the collectors and the enclosure. So my best guess is that the cathode & filament are at a high negative voltage, while the various collector voltages get closer and closer to 0V (relative to enclosure ground); the black wire may even be the final collector, at 0V. This would also explain why the filament wire (brown) comes directly out of the HV block: the voltage across the filament is low, but it has to float at a very high common-mode voltage.
Circuit AnalysisUnfortunately, I wasn't able to do as thorough of a job of reverse-engineering this one as I'd like. The unfriendly HV-block potting material didn't help, and there's 5 different pieces of magnetics on the board with many windings each: I made educated guesses on the schematic below at how the windings are arranged internally, but not being able to do continuity tests through the thick conformal coating, I can't be sure and so some of the transformer connections are still a mystery.
Let's look at the auxiliary power supplies first though: these are the low voltages to power the op-amps and other control circuitry.
The DC power (likely 28V, by transistor & capacitor ratings) enters through an EMI filter, and charges the primary-side auxiliary supply ("+VauxPri") through a 220K resistor for startup. This auxiliary supply takes its input from the main power converter through a couple diodes, once that's running. There's also a nested switching arrangement, where aux. power to some devices is switched on and off separately ("+VauxPriSw"). One of the op-amps and a control-transformer winding are supplied through an additional switch ("+VauxPriSwSw").
One of the small transformers is part of a
push-pull blocking oscillator, which uses two transistors in a self-oscillating configuration to generate an isolated bipolar power supply for the secondary-side/output-side op-amp. An additional winding seems to be tapped off and goes to a mystery location on the HV module, possibly to be used as a power supply for the cordwood module judging by location. One of the collector waveforms also gets filtered to power one of the op-amps.
The powertrain consists of another much larger push-pull converter, with those unusual-looking transistors, feeding the primary side of the HV transformer inside the potted HV module.
This push-pull is current-fed, with a series inductor on the input, which gives it a boost-like characteristic, useful for stepping up the voltage on the primary side (and reducing the HV transformer's winding ratio). There's also an additional power supply that involves two of the metal-can transistors, powered from an additional winding on that boost inductor; I'm not sure what exactly they would feed inside the HV module: maybe a separate isolation transformer for the filament supply?
The control scheme is confusing, as it involves 4 separate transformers, none of which I can continuity-check as discussed before. The "small transformer (right-hand)" has its own self-oscillating converter to generate the auxiliary supplies, but the roles of the "small transformer (left-hand)" and the two series emitter transformers ("CT 1", "CT 2") are less clear. CT 1 & 2 probably provide some positive feedback to help switch the main power transistors on or off faster, but I'm not sure if they actually control the switching, because "small transformer (left-hand)" also has a charge pump which puts a negative voltage on the power transistor bases to switch them off. The "small transformer (left-hand)" also either is driven by or drives a separate connection to CT 1 & 2 (see the 2 series diodes), and these are also both connected to the self-oscillating aux. supply collectors via "Aux_C1" and "Aux_C2" - I don't know if the aux. supply actually generates the switching frequency for the whole system, or if this is just a startup mechanism and the main power supply self-oscillates via some combination of CT 1 & 2, and "small transformer (left-hand)".
One of the op-amps generates a control voltage that connects to CT 1 & 2, and likely somehow controls the duty cycle or frequency of switching. I don't see any reflected-transformer-voltage primary-side sensing of the output, so either the power supply runs open-loop (and the op-amp control voltage is for soft-start and/or protection), or there's some feedback path inside the HV module, maybe through the small toroidal transformer.
The secondary-side output circuitry was too thickly coated for me to be able to follow the connections, so all that I was able to tell is that the blue wire is some kind of high-voltage output from the HV module, fed through a 100KΩ+ series resistance and filtered with the 1kV(?) film cap on the bottom side of the board. This could be one of the intermediate TWT-collector voltages. I was completely unable to figure out how the black wire & the Caddock resistor network connect to anything, unfortunately.
Wrap-UpAnyways, I hope this was interesting! Please let me know if you have any insights into how the surprisingly-complicated main powertrain's controls work.