All eighty-one fundamental power couplers for the 805 MHz superconducting cavities of the SNS linac have been RF conditioned and installed in the cryomodules successfully. The couplers were RF processed at JLAB or at the SNS in ORNL: more than forty couplers have been RF conditioned in the SNS RF Test Facility (RFTF) after the first forty couplers were conditioned at JLAB. The couplers were conditioned up to 650 kW forward power at 8% duty cycle in traveling and standing waves. They were installed on the cavities in the cryomodules and then assembled with the airside waveguide transitions. The couplers have been high power RF tested with satisfactory accelerating field gradients in the cooled cavities.

A key technology issue of ERL devices for high-power free-electron laser (FEL) and 4th generation light sources is the demonstration of reliable, high-brightness, high-power injector operation. Ongoing programs that target up to 1 Ampere injector performance at emittance values consistent with the requirements of these applications are described. We consider that there are three possible approaches that could deliver the required performance. The first is a DC photocathode gun and superconducting RF (SRF) booster cryomodule. Such a 750 MHz device is being integrated and will be tested up to 100 mA at the Thomas Jefferson National Accelerator Facility beginning in 2007. The second approach is a high-current normal-conducting RF photoinjector. A 700 MHz gun will undergo thermal test in 2006 at the Los Alamos National Laboratory, which, if successful, when equipped with a suitable cathode, would be capable of 1 Ampere operation. The last option is an SRF gun. A half-cell 703 MHz SRF gun capable of delivering 1.0 Ampere will be tested to 0.5 Ampere at the Brookhaven National Laboratory in 2006. The fabrication status, schedule and projected performance for each of these state-of-the-art injector programs will be presented.

RF Test Facility has been completed in the SNS project at ORNL to support test and conditioning operation of RF subsystems and components. The system consists of two transmitters for two klystrons powered by a common high voltage pulsed converter modulator that can provide power to two independent RF systems. The waveguides are configured with WR2100 and WR1150 sizes for presently used frequencies: 402.5 MHz and 805 MHz. Both 402.5 MHz and 805 MHz systems have circulator protected klystrons that can be powered by the modulator capable of delivering 11 MW peak and 1 MW average power. The facility has been equipped with computer control for various RF processing and complete dual frequency operation. More than forty 805 MHz fundamental power couplers for the SNS superconducting linac (SCL) cavities have been RF conditioned in this facility. The facility provides more than 1000 ft2 floor area for various test setups. The facility also has a shielded cave area that can support high power tests of normal conducting and superconducting accelerating cavities and components.

The Spallation Neutron Source (SNS) makes use of 33 medium beta (0.61) and 48 high beta (0.81) superconducting cavities. Each cavity is equipped with a fundamental power coupler, which should withstand the full klystron power of 550 kW in full reflection for the duration of an RF pulse of 1.3 msec at 60 Hz repetition rate. Before assembly to a superconducting cavity, the vacuum components of the coupler are submitted to acceptance procedures consisting of preliminary quality assessments, cleaning and clean room assembly, vacuum leak checks and baking under vacuum, followed by conditioning and RF high power testing. Similar acceptance procedures (except clean room assembly and baking) were applied for the airside components of the coupler. All 81 fundamental power couplers for SNS superconducting cavity production have been RF power tested at JLAB Newport News and, beginning in April 2004 at SNS Oak Ridge. This paper gives details of coupler processing and RF high power-assessed performances.