An unexpected discharge may be a clearance problem, damaged insulation, an unwanted electron discharge, or another fault. The machine’s voltage, pressure, RF behaviour and protection all enter. The physics behind the controlled version is settled. Fresh surfaces carry whiskers, microscopic metal points at which the electric field concentrates, and particles that emit electrons, and a spark starts where electrons are emitted; each spark in the early regime is overwhelmingly likely to raise that site’s breakdown field, the field at which it next sparks, with the gains shrinking toward a limit (Werner (2004), p. 91-92). Fresh surfaces also carry gas that the first RF heating drives off, so the pressure rises in bursts and settles. Livingston and Blewett’s rule is that “no amount of smoothing or polishing will eliminate the necessity of some high-voltage conditioning under vacuum” after every opening (Livingston & Blewett (1962), p. 189). Within a procedure such as Wouters’, with its limits set beforehand and the protection in place, the expected course is a spark rate that falls and pressure bursts that decay. The AMIT cavity logged about a hundred arcs over a hundred hours with the rate falling below one an hour (Gavela et al. (CIEMAT), p. 3). The 63-inch called its RF solved only when it held 75 kV “for long periods” rather than touched it (Howard (ed.), p. 15). The rating is what the machine holds quietly, not what it reaches between sparks (Livingston & Boch (1952), p. 24).
The Mullins record lacks that amplifier protection and names it the obvious upgrade after ten to fifteen transistor pairs (hosted rf-dee-source note, §3.2). A spark shorts the dee to ground, the match is lost while it lasts, and the power the tank no longer accepts comes back at the amplifier. A sub-kilovolt dee is far below the voltages where the X-ray hazard appears, and the survey is how you know that for your machine rather than assume it.
The behaviours that are not surface conditioning, and what the record did about them: The voltage sits at a few hundred volts and will not rise, perhaps with a blue glow, while the amplifier delivers power. One documented cause is the low-voltage electron discharge, multipactor, electrons bouncing between the dee and the facing ground in step with the RF and knocking more electrons out of the metal at each impact, and its relatives, which the classical machines found living in a bounded voltage band and absorbing the drive (Livingston & Blewett (1962), p. 188, MacKenzie & Waithman (1946), p. 12, Smith (1960), p. 4). Those machines dealt with it by design: a DC bias on the dee, a steady voltage across the gap that pushes the electrons one way so they cannot bounce back and forth in step with the RF (Smith (1960), p. 4, MacKenzie et al. (1948), p. 23, Woo (1970), p. 13); less free volume around it; and, where the main oscillator was self-excited, taking its feedback from the dee itself and so unable to start into a dee loaded by the discharge, a small independent oscillator to push it through the band (MacKenzie & Waithman (1946), p. 12). One report describes a ring-down test, cutting the drive and watching the dee voltage decay, that shows the band’s edges on a given machine (MacKenzie et al. (1948), p. 23; Fulbright (1961), p. 2; Fulbright (1961), p. 4; the dee-coupling chapter’s discharge section). The same symptom can have other causes, a shorted or touching dee among them, and applying more RF power to push through an unidentified discharge is not a diagnostic method; identify it first, with the drive off. Running longer does not condition it away either. A spark rate that does not fall, or any discharge you cannot account for, is a reason to shut down and look, not something that earns the name “fault” after a trial period. Look for a particle, a sharp edge, a loose piece, a dee touching a lid (hosted note §2.2). Pressure that rises and stays up is gas being made faster than it is pumped, by a discharge or a hot surface. Wouters’ procedure stops at 10⁻⁴ torr for that reason (Wouters (1949)). Anything hot that should not be. An amplifier transistor at 190 °F is in the Mullins log beside a failure (§3.2), and a nickel-plated coil ran at 350 °C in one study (Fowler (1970), p. 4). Arcing outside the vacuum, at a feedthrough, in a cable, across air gaps, is never conditioning. The ORNL source-test unit’s dee voltage was capped by a stem spacing in air, not by any vacuum gap (Howard (ed.), p. 23), the air along the stem outside the chamber sparking first, and the Rutgers deflector’s persistent arcing was the stored energy in its coax, the cable feeding it, which holds charge as a capacitor does (Ponter (2010), p. 43-49). A match that has changed during the session is drift or a changed load, not conditioning (My RF circuit tunes up nicely on the bench. Why does it change when I close the chamber, pump down, turn on the source, or raise the power?).
If it does not work. The stop-and-review criteria are the ones the record wrote down, and they are specific to equipment rather than universal. Stop when the amplifier’s own protection trips, or when there is none and the load has become unknown. Stop when the pressure exceeds the figure you set beforehand, Wouters’ 10⁻⁴ torr being the historical one (Wouters (1949)). Stop on any discharge you cannot explain, and open the chamber expecting to find something physical. Stop on any smell, heat or sound from outside the vacuum. Stop if a survey instrument reads above background anywhere a person stands. Then review before resuming. What the forward and reflected power, the pickup, the pressure and the spark rate did over time, in the log, is the evidence that separates a conditioning trend from a fault. The Mullins log’s “blew two RF amps, maybe dee touching lid?” was followed by opening the chamber and finding the Viton spacers out of position, not by more drive (§2.2). “Conditioning sometimes appears in the literature” is not a reason to run through a problem; the literature’s conditioning was done on interlocked machines, with predefined limits, vacuum and reflected-power interlocks, and the shielding in place. An unresolved electrical problem is the default reading until a controlled conditioning process is established.
To understand it. The large machines automated what the small ones do by hand. An interlock is a circuit that cuts the drive by itself when a reading leaves its bounds. One on the ratio of dee voltage to oscillator current, which an arc holds low because the dee voltage collapses while the current does not, cuts the drive and recycles a second later so the vacuum can pump away the discharge products (Smith (1960), p. 7). A fast interlock acts on reflected power (Gavela et al. (CIEMAT), p. 3). Spark detection reads a microsecond collapse of the dee voltage and ramps back automatically (Gold & Sabaiduc (Best Cyclotron Systems), p. 2). Every dee spark is a system-wide transient that can propagate into the amplifier, so protection is layered by speed (Smith (1960)). Deliberate conditioning on the production machines ran to hundreds of thousands of sparks and roughly a hundred hours (Smith (1960), p. 4, Röcken et al. (Varian Medical Systems Particle Therapy), p. 1). A conditioned gap holds several times what it first held and loses some of that at every air exposure (the dee-coupling chapter; the safety page on dark current). The breakdown regime depends on pressure: vacuum breakdown, started by electrons drawn from the metal surfaces themselves, below about 10⁻⁵ torr and gas breakdown, the gas between the electrodes ionizing, above about 10⁻⁴. A gas-fed small machine often runs in the grey zone between (Werner (2004), p. 23; What pressure should I aim for when the cyclotron is running? Don't I need more gas to make ions, but less gas to let them spiral around?).