This publication also addresses specific design
and manufacturing fundamentals for high-voltage power supplies. To this end,
it is essential that readers responsible for implementing high-voltage power
supply designs (program managers, engineering managers, design engineers, et
al.) become familiar with the contents of Section 5
manufacturing high-voltage power supplies requires many additional disciplines
beyond those required in low-voltage power supplies:
- Corona Prevention
- High-Voltage Field Gradient Analysis
- Insulation Systems
- High-Voltage Field Testing
- High-Voltage Field Magnetics Design
- High-Voltage Field Manufacturing Disciplines.
High-voltage power supplies have well recognized, long-term degradation
characteristics if corona and arc suppression are not adequately addressed.
Corona steadily degrades the primary insulation and field gradient design
margin. The testing required to demonstrate the absence of these undesirable
characteristics in a properly configured high-voltage power supply is both
sophisticated and controversial.
Contamination is probably the largest failure mechanism in high-voltage
power supplies. Proper training of assembly personnel should be the first and
foremost requirement. All assembly and test operations should be done in a
controlled atmosphere with trained personnel wearing white cotton (lint-free)
gloves. The failure mechanisms of high-voltage power supplies are listed in
All components and assemblies should be screened and burned-in at their
High-voltage power supplies do not permit simple element replacement.
Packaging constraints minimize the level of repairability within the power
supply subassemblies. Manufacturing requirements force configuration control
and repeatability of critical wire path routings. This greatly limits the
ability of anyone not intimately familiar with a particular power supply from
providing meaningful repair and replacement services. Due to packaging and/or
encapsulation techniques. It is both difficult and expensive to provide repair
and replacement services.