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N63XX Series KU Band Operations Manual

1. sd 8 1 Electrical 43 8 2 Mechanical 43 8 3 Environmental 2 2 2 44 8 4 Characteristics 44 9 RELATED DOCUMENTS 2 2 2 44 APRENDA AO ket mee A Be Se Sd S45 APPENDEX B7 am yrhai Ace ues Boe eee oop ek E qvx 246 APPENDIX C xo ca a ee BOM Vote ie S ees Ren ion c E APPENDIX D gr mo 4 m hbo oe Se eu 49 APPENDIX E o 4X Reus exe ied on ee AS HBN63xx 1 Issue 8 Page 5 1 1 1 THANK YOU FOR BUYING STELLAR Thank you for buying a Stellar TWTA This e2v technologies antenna mount amplifier range provides RF power amplification at up to 180 W in the Ku band The amplifier 15 Compact Lightweight Portable can run off a wide range of mains input voltages and frequencies Designed for high reliability Before using your new amplifier we recommend that you spend a little time to read this manual to familiarise yourself with its operation and features If you have any further questions or recommendations about this manual please contact your distributor In addition to this manual your amplifier should be supplied with mains connector plug a control connector plug test results an air inlet cowl 6 32 UNC 2A x I inch waveguide screws 4 off Range of Options The N63xx series of antenna mount amplifiers includes the following variants and options
2. N6081D CONTROLLER 120 Q V4 W 120 Q 1 4 W HBN63xx 1 Issue 8 Page 48 APPENDIX Single Amplifier Configuration with Manual Control When operating in single amplifier mode with no serial bus controller it is possible to provide full control manually as shown below Notes 1 If switch 2 is set to XMIT on application of prime power the amplifier will automatically enter the XMIT state after 3 minutes warm up 2 To enter the OFF state switch 2 must be in the STBY position prior to the OFF state being selected via switch 1 3 The resistor values will depend on the type of LED used 4 f specific fault indication is required this circuit can be used Refer to section 5 2 1 for codes OFF 4 ro krr WARM UP 4 so rr STBY 4 co a XMIT 4 DO gL lo SUMFLT 2 EO gL UO w Er E 7 c4 x 1 SEE NOTE 4 a 1 l vo r 1 2 3 l zo K 1 1 a HO SWITCH 1 MOMENTARY ACTION CENTRE BIAS d OFF 0 0 K STBY XMIT LO E SWITCH 2 SPST SHOWN IN STBY POSITION STBY PO R Printed in England HBN63xx 1 Issue 8 Page 49
3. i M ES 1 E S m 0 y XILNI 1X3 HOLIMS 3dAL 4 vc SL 18V SNISn NMOHS N HOLIMS 9 M y I 9 RM MR M Mu H dH ANI ATIVNH3LNI 0 4 um HOlSIS3H NIN A0SSPSH GS Eu ONILWNIWYAL xy 01 Hs lt Vv VdH TA sl S p Id 3dAL AVM 6 NE SNOILO3NNOO YATIONLNOD t L9N t HBN63xx 1 Issue 8 Page 45 APPENDIX Dual Amplifier Redundant Configuration with Manual Control Basic control functions can be obtained by using manual toggle switches An example of the interface wiring for this is as follows HPA A WAVEGUIDE SWITCH HPA B A eS SS SSS Se A o 4 Q m a Bo o d 4 oB 1 1 o i e oC 4 l Do 4 o D 4 e a 4 6 o o i Uo e oU Q o SZ FfD fy c Ja Ed J 9 9 OFF OFF 5 oJ K o o sTBY STBY o o L XMIT i 0 0 e oP SELECT ot o SELECT A B So oS ko ok s n n o n Po o d to ot HBN63xx 1 Issue 8 Page 46 APPENDIX Phase Combination using the Compact Redundant Combiner Assembly CRCA If there is a requirement to provide two amplifiers w
4. User Interface Connections Refer to the appendices at the end of the manual for examples of wiring The amplifier is supplied with a user interface connector plug but no cable Additional connectors are available from e2v technologies please contact your distributor If the amplifier is to be used in applications where it is exposed to rain or subjected to condensation all attempts must be made to prevent moisture ingress into the connector and cable loom The connector plug accepts cable diameters up to a maximum of 15 mm For use with cable diameters less than 15 mm the effective cable diameter should be increased to approximately 14 to 15 mm to allow an effective seal to be made when the connector is assembled Self amalgamating tape or layers of adhesive heat shrink cable are recommended Connector back shells that accept adhesive heat shrink boots are available please contact your distributor Fully screened cable should be used for interface requirements Redundant Switch Configuration If two amplifiers are to be connected to a redundant switched system the control circuitry within the amplifiers can be used to implement a cost effective switch control solution The diagram on the following page shows the wiring connections required to implement a basic redundant switched system using the N6143 as the controlling device The N6143 control unit is connected to the serial interface of both amplifiers allowing remote switching a
5. 4 Stellar 24 Hour Hotline 4 Return Procedure 4 CONTENTS MES 1 THANK YOU FOR BUYING STELLAR 6 1 1 Range of Options 6 2 CARE OF YOUR AMPLIFIER tof 2 1 Storage 7 2 2 Handling wl 2 3 Unpacking 27 2 4 Cleaning Lu 2 Maintenance zx 3 INSTALLATION CONSIDERATIONS 8 3 1 Mounting Ve De Yos UE A E I 3 2 RE ConnectionS o oko mox e os Re Soe ws D 3 3 Cooling Considerations 1 3 4 Mains Supply Connection 413 3 5 User Interface Connections 15 4 BASIC OPERATION OF THE AMPLIFIER 17 4 1 Applying The Mains Supply 17 4 2 Mains Supply Interruptions 1 4 3 Functions 44 Operation in M DAS oak DR Ih Ra M n aur XI 4 55 oample Port quu d suspe um omoes ee Sa e AG Be USERWJNTEREAGES uuum hu Ro deux oam w 220 5 1 Pin Identification 20 5 2 User Interface Features 21 6 RS 485 SERIAL BUS fo Pat amp oe te ohn ds 6 1 General Description and Features Sted Ee gate dh dus APT 6 2 Protocol ih dle ane us SA 6 3 Summary Of Command Messages a 6 4 Examples Of Command And Response Nassaqos 36 6 5 Application Notes 40 PAU WES FINDING A au dE Ae we 8 ASBEGCIEICACBIONL 4 Lass OS ue RED
6. 6 1 11 6 1 12 6 1 8 3 Helix Current A command message requesting data that results in a response showing the helix current in mA If a request is sent in any mode other than transmit the response will show zero helix current see section 6 4 2 for details of command and response format Elapsed Hours A command message requesting data that results in a longer data string response showing the total elapsed hours and the elapsed hours in the transmit standby and off modes see section 6 4 4 for details of command and response format Operating Modes The following simple command messages that do not have an associated return of data allow control of the amplifier operating modes see section 4 3 for details of operating modes see section 6 4 1 for details of message format 6 1 10 1 Off Selects the off mode of operation 6 1 10 2 Standby Selects the standby mode of operation Results in the automatic initiation of the cathode heater warm up timer 180 seconds if selected from the off mode 6 1 10 3 Transmit Selects the transmit mode of operation Results in the automatic initiation of the cathode heater warm up timer 180 seconds if selected from the off mode Forward Power A command message requesting data that results in a response showing the RF output power in watts If a request is sent in any mode other than transmit the response will show zero forward power see section 6 4 2 for details of command and re
7. AUTO ENA Part of the redundant switch control facility toggles between the automatic and manual change over mode In the automatic mode a failure of the other amplifier will automatically route this amplifier to the antenna GND Automatic mode Not Connected Manual mode RF INHIB Only operational with the solid state amplifier option Allows the RF signal to be inhibited giving a minimum RF output attenuation of 45 dB GND RF Inhibited Not Connected RF enabled HBN63xx 1 Issue 8 Page 23 5 2 6 INV RF INHIB As above except inverted GND RF enabled Not Connected RF Inhibited SWITCH SENSE Part of the redundant switch control facility provides the waveguide switch position tell back input Should be connected to the waveguide switch so that this pin is connected to ground when the amplifier is routed to the dummy load GND RF output routed to dummy load Not Connected RF output routed to the antenna RED FLT I P Part of the redundant switch control facility receives the status feedback signal from the other amplifier When the other amplifier indicates a fault condition the RF output from this unit should be switched to the antenna This pin should be connected externally to the RED FLT O P Pin on the user interface connector of the other amplifier in the redundant switch system GND Other amplifier operational Not Connected Fault on other amplifier therefore switch EXT INTLK An external interloc
8. Notes 1 If the 10 MHz signal is too low or not present 2 The upconverter also contains its own stabilised internal reference that enables it to be used without an external 10 MHz locking signal This feature is activated automatically when the external 10 MHz locking signal is too low or not present Basic Upconverter Specification Output frequency UA 14 0 to 14 5 GHz UB variants A ux Tish RI E Sous ee ile le Ta 13 75 to 14 5 GHz Input frequency UA variants 950 1450 MHz UB variants 5 ls 950to 1700 MHz L band input level ox vus mm om omo dle A Eee vuSuu Se X a Se uus BOX Bm maximum s s s s s s External locking signal 10 MHz 0 dBm max 5 dBm min fed through IF cable Stability using internal 10 MHz reference 2ppm Notes 1 When using amplifiers fitted with both an upconverter and a digital electronically variable attenuator DEVA e g N6315DUB N6318DUA etc the L band input drive level should be set between 10 and 0 dBm and the DEVA control used to adjust the amplification For any upconverted amplifier if the L band input level is too high the mixer can be driven into saturation and intermodulation products may be experienced If the L band input level is too low 20 dBm signal mixing will be poor possibly with intermitt
9. RF output power variants 120 W N6312 150 W N6315 and 180 W N6318 RF system options Product type numbers with a C suffix indicate that the unit is not fitted with an integrated solid state preamplifier Product type numbers with a D suffix indicate that the unit is fitted with a digital electronically variable attenuator Product type numbers with a UA or UB suffix indicate that the unit is fitted with an integral L band to Ku band upconverter see section 4 4 for upconverter details Product type numbers with a W suffix indicate that the unit is capable of operating over the wider bandwidth of 12 75 to 14 5 GHz HBN63xx 1 Issue 8 Page 6 2 1 2 2 2 3 2 4 2 5 2 CARE OF YOUR AMPLIFIER Storage Store the amplifier in its normal horizontal orientation Storage temperature is from 40 to 80 C Do not use amplifier boxes to support the weight of any other item Retain the amplifier boxes for future use Avoid severe shocks Handling The amplifier nominally weighs 12 kg so care must be taken when attempting to lift or carry it Unpacking Only install and use the amplifier within the specified environmental limits Cleaning The amplifier is designed to be used in harsh environments without additional protective covers The internal forced air cooling system relies on the internal and external airways being free from blockages The cooling air enters and exits the unit through slott
10. waveguide switch should be configured so that each amplifier knows if it is connected to the antenna Switching time is dependent upon the waveguide switch selected but will be typically 50 to 100 ms The interface between the control unit and the amplifiers is via the local serial communications bus As the amplifiers do not contain a transmitter receiver termination the local serial communications bus should be fitted with 120 terminating impedances This should be done within the control connector backshell of the amplifier furthest from the N6143 control unit 120 1 1 4 W carbon film or similar resistors should be fitted between pin d and pin e Rx also between pin b Tx and pin c Tx of the 41 pin amplifier control connector Termination of the serial communications bus is dependent upon the length and type of cable used and should follow normal transmission line practice N6143 CONTROL UNIT LOCAL SERIAL COMMUNICATIONS BUS AMPLIFIER A AMPLIFIER B RED FLT O P RED FLT I P RED FLT I P RED FLT O P GND GND SWITCH SENSE RED SW1 RED SW2 SWITCH SENSE RED SW1 RED SW2 COIL A COIL B TELL BACK SWITCH RF WAVEGUIDE SHOWN WITH RF WAVEGUIDE SWITCH SWITCH COIL A ENERGISED AMPLIFIER A IS ROUTED TO THE ANTENNA Figure 6 Redundant switch configuration Notes 1 A wiring schematic diagram is given in the appendices for the connection
11. achieved The information contained within this section has been gained from both field experience and theoretical cooling system design knowledge As most installations differ the advice given is only general Any specific aspects of installation design can be discussed further by contacting or faxing the Stellar Product Support Team at e2v technologies Some Cooling Facts and Figures Minimum Air Flow 28 litre s 60 feet minute Minimum Duct Area 68 9 inch Total Maximum Core Duct Length corrugated 2 2 0 5m 1 65 feet smooth ee 3 3 feet Typical internal power dissipation nio te A ue RU his He eee ud 29007 VA Typical temp gitterence device s ll ls 40 C Absolute max temp qireenge across device s 50 C where TEMP difference TEMP our TEMP in The amplifier utilises an efficient integral forced air cooling system and is equipped with two thermal sensors to protect it in the event of an over temperature condition When the temperature of either thermal sensor exceeds preset levels the amplifier is automatically removed from the XMIT mode and placed into the STBY mode In the STBY mode the dissipation within the amplifier is greatly reduced and if the airflow is normal the amplifier will rapidly cool At this stage the installation cooling system should be visually inspected for blockages a
12. applications where it is exposed to rain or subjected to condensation all attempts should be made to prevent moisture ingress into the waveguide system It is recommended that all external waveguide joints are made using flanges fitted with O rings to prevent moisture ingress The amplifier is supplied with a plain waveguide flange so the external mating flange should include an O ring and groove An optional waveguide window is available which when fitted correctly stops the ingress of moisture into the amplifier waveguide system The waveguide window is approximately 10 mm in length and is fitted between the amplifier output flange and the external system flange see figure 4 with the O ring groove toward the amplifier Longer fixing screws are supplied with the waveguide window kit WINDOW EXTERNAL WAVEGUIDE RF OUTPUT FLANGE Figure 4 Waveguide window option position HBN63xx 1 Issue 8 Page 10 3 3 3 3 1 Cooling Considerations Temperature affects the life and reliability of high power electronic devices As the temperature of the device increases generally reliability and life expectancy decrease TWTAs are no exception Please follow the cooling considerations for your amplifier to ensure many trouble free years of use e2v technologies engineers have many years of experience working with customers to integrate equipment successfully and to ensure that long and reliable product lives are
13. automatically enters the STBY mode If the XMIT control input is linked to GND the unit then enters the XMIT mode Switching the XMIT control input between GND and open circuit will switch the unit between XMIT and STBY In addition as the mains supply is applied to the unit the internal digital electronically variable attenuator DEVA will be set to minimum attenuation if fitted units with a D suffix to the product type number This feature provides operation with the minimum of control connections Whilst in this mode all indicator outputs and other control inputs excluding the XMIT operate as normal 15 Black box mode Not Connected Normal mode 5 2 7 Miscellaneous functions 15 Auxiliary supply output of nominally 15 5 at 100 mA maximum Provides the user with a local low voltage output for use with type 3 user port control inputs and other external control interface circuitry GND Provides the ground return reference for many of the user interface lines HBN63xx 1 Issue 8 Page 25 RED SW 1 RED SW 2 RS TX RS TX RS RX RS RX RS GND HBN63xx 1 Issue 8 Page 26 Part of the redundant switch control facility provides two waveguide switch coil drive outputs Each output is nominally 24 V dc at 1 6 A pulsed for 100 ms An internal 1 8 A current limit is provided along with flywheel diodes for protection further simplifying the waveguide switch interface considerations RED SW 1 should be
14. connected so that when asserted the RF output from the unit is switched to the antenna RED SW 2 should be connected so that when asserted the RF output from the unit is switched to the dummy load Provides connection for a RS 485 or RS 422 interface allowing connection as a slave to an asynchronous half duplex multi drop four wire bus This gives full remote control and monitoring of the HPA as part of an integrated system The main features protocols and operation of the serial bus are described in section 6 6 1 6 1 1 6 RS 485 SERIAL BUS General Description and Features The amplifier HPA is equipped with a RS 485 interface allowing connection as a slave to an asynchronous half duplex multi drop four wire bus This gives full remote control and monitoring of the HPA as part of an integrated system The following section describes the main features protocols and operation of the HPA with the multi drop serial bus HPA Type A data request command that prompts a response giving the amplifier type number and the software issue see section 6 4 3 Status A data request command that prompts a response of 7 data bytes within which the status flags are contained see section 6 4 3 The following list summarises the status flags available on the 7 data bytes D1 summary fault If set indicates that the amplifier has seen at least one of the fault conditions described in this section The amplifier operation and re
15. correctly terminated It is particularly hazardous to look into open waveguides coaxial feeders or transmitter antennae when the amplifier is operating Input Drive Damage to the amplifier may occur if the RF input drive level or the input frequency are outside the limits given in the specification section 8 also summarised in section 3 2 Environmental Do not block or poke objects through the amplifier ventilation slots Do not spray aerosol cleaners directly on to the amplifier surfaces when cleaning Do not operate the amplifier on an unstable or unsafe surface Ensure that all cables cannot be walked on tripped over or damaged by furniture or movable equipment Do not place objects inside the waveguide STANDARDS COMPLIANCE Stellar amplifiers comply with the following requirements Further details may be provided if necessary EEC Directive 89 336 EEC Electromagnetic compatibility EEC Directive 93 97 EEC Satellite earth station equipment EEC Directive 73 23 EEC Low voltage directive e2v technologies quality management system is certificated to the requirements of 1509001 HBN63xx 1 Issue 8 Page 3 CUSTOMER CARE Stellar 24 Hour Hotline In the event of a Stellar product operational problem or urgent application enquiry 1s 2 Complete a Product Service Report Form before calling the Hotline A copy can be found at the back of this manual Contact the Stellar Hotline on 4
16. gt checksum ASCII lt ACK gt 50631501 lt ETX gt lt NUL gt Hex 06 35 30 36 33 31 35 30 31 03 00 The amplifier type is returned as 631501 N6315 operating with control software issue 01 Command ASCII Hex Status 1 31h Command Gen lt STX gt address 1 lt ETX gt checksum ASCII lt STX gt 51 lt ETX gt lt ENO gt Hex 02 35 31 03 05 Response Gen lt ACK gt address 1 D1 02 03 D4 D5 D6 D7 lt ETX gt checksum ASCII lt ACK gt 51P A A lt ETX gt Q Hex 06 35 31 50 40 41 40 40 41 40 03 51 HBN63xx 1 Issue 8 Page 37 D1 D7 are seven data bytes representing the status of the amplifier defined as follows D1 D2 bit 7 parity bit 7 parity bit 6 1 bit 6 1 bit 5 0 bit 5 0 bit 4 summary fault bit 4 0 bit 3 transmitting bit 3 output to antenna bit 2 standby bit 2 auto redundancy enabled bit 1 warm up bit 1 power too high bit O off bit O high power alarm enabled D3 D4 bit 7 parity bit 7 parity bit 6 1 bit 6 1 bit 5 0 bit 5 0 bit 4 0 bit 4 0 bit 3 power too low bit 3 heater current bit 2 low power alarm enabled bit 2 HV overload bit 1 RF enabled bit 1 0 bit O remote enabled bit O PFC fault D5 D6 bit 7 parity bit 7 parity bit 6 1 bit 6 1 bit 5 0 bit 5 0 bit 4 0 bit 4 0 bit 3 external interlock bit 3 0 bit 2 reflected power bit 2 0 bit 1 mean helix current bit 1 case too hot bit O peak helix current bit O Upconverter fault D7 bit 7 parity bit 6 1 bit 5 0 bit 4 0 bit 3 baseplate too hot bit 2
17. revert to the off mode automatically prime power must be removed and re applied to reset the trip HV overload set indicates that the amplifier has seen an internal HV overload fault trip The amplifier will revert to the standby mode and automatically attempt to reset three times for full reset details see section 5 2 1 PFC fault f set indicates that the amplifier has seen an internal power factor corrector fault trip The amplifier will revert to the off mode automatically prime power must be removed and re applied to reset the trip external interlock set indicates that the external interlock input is asserted This prevents the amplifier from entering the transmit state until the input becomes unasserted The amplifier will revert to standby if the external interlock is asserted while in transmit see section 5 2 5 reflected power If set indicates that the amplifier has seen excessive reflected power trip The amplifier will revert to the standby mode and automatically attempt to reset three times for full reset details see section 5 2 1 mean helix current f set indicates that the amplifier has seen an excessive mean helix current trip The amplifier will revert to the standby mode and automatically attempt to reset three times for full reset details see section 5 2 1 peak helix current set indicates that the amplifier has seen an excessive peak helix current trip The amplifier will revert to
18. 4 0 1245 355398 where your enquiry will be dealt with Return Procedure In the event of a Stellar product requiring return to e2v technologies 1 veeoeoeo B e o oe o 7 Have as many of the following details as possible to hand before contacting e2v technologies This will help us to respond promptly to your request Type number found on the end panel below the control interface socket Serial number found on the end panel below the control interface socket Has the product been damaged Description of any operational fault or problem Return address The Customer Service Team will issue you a Reference Number for the return Complete a Product Service Report Form a copy can be found at the back of this manual noting in particular any unusual occurrences before or at the time of failure The form must be returned with the product If the original packaging is in good condition use it to return the product If the original packaging is damaged e2v technologies can supply suitable replacement packaging for a small charge Clearly mark the outer packaging with the following information Reference number Type number Serial number Return address For further details refer to the e2v technologies Standard Conditions of Warranty a copy of which can be found at the back of this manual HBN63xx 1 Issue 8 Page 4 5 SAFETY NOTES 2 STANDARDS COMPLIANCE 23 CUSTOMER CARE
19. BN63xx 1 Issue 8 Page 29 6 1 4 3 Low Power Alarm A command message requesting data that results in a response showing the current low power alarm setting in watts see section 6 4 2 for details of command and response format 6 1 4 4 High Power Alarm A command message requesting data that results in a response showing the current low power alarm setting in watts see section 6 4 2 for details of command and response format Warm up Time A command message requesting data that results in a response showing the remaining warm up time in seconds see section 6 4 2 for details of command and response format Only active when in the warm up mode returns zero seconds in all other operating modes including the off mode Attenuator Control The following command messages allow the control monitoring of the built in digital attenuator feature if fitted 6 1 6 1 Set Attenuator Allows the digital attenuator level to be set in nominal units Units range from to 255 signifies zero attenuation or maximum gain see section 6 4 5 for details of passing parameters 6 1 6 2 Attenuator A command message requesting data that results in a response showing the current attenuator setting in nominal units of O to 255 0 corresponding to zero attenuation or maximum gain see section 6 4 2 for details of command and response format RF Control The following simple command messages that do not have an associated return of data allow
20. C bus fault P 0101 PFC fault P 0100 External interlock trip M 0011 Reflected power trip A 0010 Mean helix over current trip A 0001 Peak helix over current trip A Reset Code Description A Automatic reset Units that exhibit faults with this reset code will be immediately removed from the XMIT mode and placed into the STBY mode The unit will automatically attempt to reset to the XMIT mode after 3 seconds if this fails the unit will attempt a further two reset cycles If after the three reset attempts the amplifier still exhibits the fault condition the unit will remain in the STBY mode for 4 minutes before returning to the OFF mode unless the fault clears and the XMIT mode is reselected Advisory Units that exhibit faults with this reset code will remain in the XMIT mode the fault display will remain until the fault clears M Manual reset Units that exhibit faults with this reset code will be immediately removed from the XMIT mode and placed into the STBY mode The unit will remain in this mode for a period of 4 minutes before returning to the OFF mode unless the fault clears and the XMIT mode is reselected P Prime power reset Units that exhibit faults with this reset code will be immediately removed from the XMIT mode and placed into the OFF mode If the fault is seen to clear the mains supply should be removed for nominally 10 seconds before reapplying to reset the trip Indicator Outputs Type 2 Normally open relay
21. CONSIDERATIONS Mounting The amplifier can be used free standing mounted in a flight case mounted on the roof of a vehicle mounted to an antenna system The amplifier has a flange which should be used to mount the amplifier solidly to the chosen platform Six 5 clearance mounting slots three each side are provided to allow fixing from above Suitable load spreading washers should be used to protect the amplifier from damage during the mounting process Suitable locking nuts and or locking washers should be used to prevent the amplifier from working loose under vibration and shock conditions that each installation may impose This is especially important for mobile applications The amplifier should be positioned so as to avoid the direct entry of rain water into the ventilation slots The amplifier is provided as standard with an air inlet cowl the normal orientation of which is pointing towards the base of the unit to avoid the direct entry of driving rain When used with this arrangement the unit should not be mounted closer than 42 mm from any flat surface to avoid choking of the forced air cooling system see figure 1 143 mm MIN FLAT SURFACE Figure 1 Mounting distance from a flat surface cowl fitted HBN63xx 1 Issue 8 Page 8 Circular duct adaptors and alternative cowl orientations are discussed further in section 3 3 2 If the amplifier is to be installed where a second
22. MHz corresponding to an RF output frequency range 13 75 to 14 5 GHz The block upconverter comprises four main elements as shown in the block diagram below this modularity gives design flexibility allowing gain and frequency variants to be accommodated All modules are fully integrated within the standard package outline with the amplifier control system providing all power and control interfaces The L band input signal should be connected to the N type socket labelled RF IN The external 10 MHz locking reference input is fed into the unit modulated onto the L band input signal This 10 MHz signal is split from the L band input within the amplifier converted to 50 MHz and used to phase lock the frequency of the DRO The L band input is fed to the mixer where it is combined with the LO and subsequently fed to the bandpass filter The waveguide filter is used to remove the LO and other mixer products it gives excellent rejection performance with low loss and a flat response The output of the filter is connected to the input of the solid state amplifier fixed gain or digital electronically variable attenuator version An out of lock alarm signal is fed from the upconverter to the amplifier control system see note 1 this in turn is processed and provided as an advisory upconverter fault alarm signal available from the 41 pin user interface connector see sections 5 and 6 and note 2 HBN63xx 1 Issue 8 Page 18 4 5
23. SCII non printable characters are enclosed thus lt gt final character in each example is the checksum 6 4 1 Simple Command Message no return of data Command ASCII Hex Enable manual redundancy mode b 3b Enable auto redundancy mode 6 36 This HPA to antenna 7 37 This HPA to load 8 38 Enable RF E 45 Helix record top of file F 46 Go to local L 4 Inhibit RF N 4E Off O AF Remote enable R 52 Standby S 53 Transmit X 58 Gen lt STX gt address 5 lt ETX gt checksum ASCII lt STX gt 5S lt gt g Hex 0235 53 03 67 Response Gen lt ACK gt address S lt ETX gt checksum ASCII lt ACK gt 5S lt ETX gt c Hex 06 35 53 03 63 6 4 2 Command Messages Requesting Data Command ASCII Hex Warm up time G 43h Next Ihlx record G 47 Helix current H 48 Elapsed hours J 4A Forward power P 50 Attenuator U 55 High power alarm V 56 Low power alarm W 57 Command Gen lt STX gt address lt ETX gt checksum ASCII lt STX gt 5H lt ETX gt Hex 02 35 48 03 7C Response Gen lt ACK gt address xx xmA lt ETX gt checksum HBN63xx 1 Issue 8 Page 36 ASCII lt ACK gt 5H 12 4mA lt ETX gt M Hex 06 35 48 31 32 2E 34 6D 41 03 4D 6 4 3 Universal Command Messages Requesting Data Command ASCII Hex HPA type 0 30h Command Gen lt STX gt address 0 lt ETX gt checksum ASCII lt STX gt 50 lt ETX gt lt EOT gt Hex 02 35 30 03 04 Response Gen lt ACK gt address 0 mmmmnn lt ETX
24. TWT too hot bit 1 fan 2 fault bit O fan 1 fault 6 4 4 Command messages requesting longer data strings The command J elapsed hours returns longer data strings than other commands The format is as follows Command ASCII Hex Elapsed hours J 4A HBN63xx 1 Issue 8 Page 38 6 4 5 6 4 6 Command lt STX gt address J lt ETX gt checksum Response ACK address J Tnnnnn Xnnnnn Snnnnn Onnnnn lt ETX gt checksum where Tnnnnn total elapsed hours Xnnnnn elapsed hours in transmit mode Snnnnn elapsed hours in standby mode Onnnnn elapsed hours in off mode Command Messages Passing Parameters Command ASCII Hex Set low power alarm A 41h Set high power alarm B 42h Set attenuator D 44h Set address Y 59 Set baud rate Z bA Command Gen lt STX gt address A nnn lt ETX gt checksum ASCII lt STX gt 5A 150 lt ETX gt Hex 02 35 41 3D 31 35 30 03 7C Response Gen lt ACK gt address A lt ETX gt checksum ASCII lt ACK gt 5A lt ETX gt q Hex 06 35 41 03 71 The alarm setting is sent as nnn where nnn is in watts leading zeros not required The alarms are disabled by setting to zero A 0 B 0 The attenuator setting is sent as 2 nnn where nnn is in nominal units leading zeros not required If the is omitted the command will be considered invalid and a acknowledge response sent 1 not Response To An Invalid Command Message Command messages will be classed as in
25. ary rain cover is used the air inlet cowl may be removed and the amplifier mounted closer to a flat surface see figure 2 106 mm MIN L T TU IET FLAT SURFACE Figure 2 Mounting distance from a flat surface no cowl When designing the installation a space of approximately 162 mm should be allowed for the disconnection and the bend radius of connection cables see figure 3 162 mm NOM LIT S Figure 3 Interface connector and cable space allowance HBN63xx 1 Issue 8 Page 9 3 2 RF Connections RF input is via an N type connector mounted on the end of the amplifier RF input signals applied to this connector must be within the frequency range and below the maximum RF input power levels given in the specification see section 8 and summarised in the table below Ensure a suitable grade of cable is used externally Product type number Maximum RF input drive level RF input frequency range N63xx and N63xxD 10 mW 13 75 to 14 5 GHz N63xxC 1W 13 75 to 14 5 GHz N63xxUA and N63xxDUA 1 mW 950 to 1450 MHz N63xxUB and N63xxDUB 1 mW 950 to 1700 MHz RF output is via a waveguide connection on the end of the amplifier Waveguides type WG17 or WR75 may be used The waveguide flange type 154 IEC UBR 120 with 4 tapped holes 6 32 UNC requires four screws 6 32 UNC 2A x L inch fully threaded as supplied If the amplifier is to be used in
26. ax non operating 5 12km 40 000 ft max Vibration MIL STD 810E common carrier and field transportation Shock EC Publication 68 2 27 Part 2 Test Ea 25 g for 11 ms half sine Electromagnetic compatibility EMC Directive 89 336 EEC Safety 2 Low Voltage Directive 73 23 EEC 8 4 Characteristics This amplifier meets the requirements of INTELSAT EUTELSAT for TWTAs in the Ku band Full details are shown on the appropriate data sheet 9 RELATED DOCUMENTS Data Sheets A1A N6312 A1A N6315 or A1A N6318 HBN63xx 1 Issue 8 Page 44 APPENDIX Dual Amplifier Redundant Configuration using N6143 Controller If the requirement is for a two amplifier redundant system the following wiring can be used A personal computer can be used in place of the N6143 controller commands and protocols are detailed in this manual CMS Gad LMS Gad Wld M 96L SHOLSIS3H SNILVNIINH3 L ALON AGL H L 193135 SS3udav a t coco 0 tc d l 114 S 4 _a EH b 3SN3S HOLIMS d GND Su mu ZMS LMS um 1 174 E i 6 1 mL sng Vis _ ee mm P p XH SH mm g SH sna viuas 2 XLSH L1 M7 N 2 v
27. butor for further assistance Fault experienced No cooling air flow Fans operate but amplifier fails to respond to user port control inputs No RF output exhaust air is cool No RF output exhaust air is warm BASEPLATE OVER TEMPERATURE condition TWT OVER TEMPERATURE condition COOLING FAN 2 fault COOLING FAN 1 fault HEATER FAULT fault Possible cause Mains connector not connected Mains supply not present at amplifier input check all external trips fuses breakers and cabling User port connector not connected External control system fault Control cable damaged severed Transmit mode not selected No or low RF input Damaged severed external RF cable Internal gain adjust is set to minimum only on units fitted with DEVA option RF Inhibit facility active Check external RF inhibit circuitry If external RF inhibit circuit is not used check user interface connector mating half has a link between pins H and P see section 5 2 Inadequate cooling for the amplifier see section 3 3 Obstruction within the cooling airflow sys tem The lower lid is removed or incorrectly fitted External ducting is too long or restrictive see section 3 3 Inadequate cooling for the amplifier see section 3 3 Obstruction within the cooling airflow system The lower lid is removed or incorrectly fitted External ducting is too long or restrictive see section 3 3 Contact your distributor Contact your distribut
28. contact outputs switched to GND pin P on the user interface connector when condition is false Example Unit is operating normally with no fault condition when pin k on the user interface connector is closed to pin P RED FLT O P Part of the redundant switch control facility Indicates that the unit has suffered a low power alarm or a fault condition that has resulted in removal from the XMIT mode This output would normally be connected to the RED FLT I P pin t on the user interface connector of the other amplifier in the redundant switch system Note Only active if an AUTO ENA input has been received by the amplifier HBN63xx 1 Issue 8 Page 22 5 2 3 5 2 4 5 2 5 Analogue Outputs The following analogue outputs are provided to allow the user to implement a simple and cost effective monitoring system these outputs are also available in digital form via the RS 422 or RS 485 serial communications interface see section 6 These outputs are referenced to GND pin P on the user interface connector It is recommended that a screened cable is utilised to avoid RFI effects FWD PW MON Provides a0 to 10 V dc analogue output that corresponds to an RF output power range of 0 to 200 W This output is a linear 20 W V Maximum output impedance 100 HX MON Provides 0 to 10 V dc analogue output that corresponds a TWT Helix current range of 0 to 20 mA This output is a linear 2 mA V Maximum output impedance 100 Co
29. control of the RF by switching on off the power supply to the active RF input components if fitted see section 6 4 1 for details of message format 6 1 7 1 Enable RF Cancels the RF inhibit mode described below 6 1 7 2 Inhibit RF Inhibits the RF output from the unit by removing the power to the active RF input components Helix Current Monitoring The following command messages allow the control monitoring of the built in helix current monitoring and recording feature 6 1 8 1 Helix Record Top of File A simple command message that returns the helix current record pointer to the top of the non volatile historical helix current file detailed below The top of the file corresponds to the earliest record see section 6 4 1 for details of message format 6 1 8 2 Next IhIx Record A command message requesting data that results in a response showing the historical helix current record in mA During operation in the transmit mode the amplifier automatically stores in non volatile memory a reading of helix current every 15 minutes After 50 hours 200 readings an average is taken and stored to the non volatile historical helix current file Each request automatically steps the file pointer to the next entry allowing easy data retrieval Resetting to the top of the file earliest entry is detailed in section 6 1 8 1 above see section 6 4 2 for details of command and response format HBN63xx 1 Issue 8 Page 30 6 1 9 6 1 10
30. ds being initiated Note If the ambient temperature is less than 10 C the warmup timer period is 10 minutes During WARMUP the STBY or XMIT modes can be requested to select the mode that the amplifier will enter at the end of the warmup period Amplifier STBY Standby mode In this mode the TWT cathode is at its operating temperature and is ready to enter the XMIT mode Power is applied only to the TWT cathode heater Unless XMIT mode has been requested the amplifier will enter STBY mode when the warmup is complete Following transmission the STBY mode can be requested to remove the amplifier from the XMIT mode Amplifier XMIT Transmit mode With the amplifier in the STBY mode selecting the XMIT mode results in the application of helix and collector voltages to the TWT allowing RF transmission In the XMIT mode the RF output power and TWT helix current monitor features are operational and the control of gain is possible using the optional Digital Electronically Variable Attenuator Upconverter Operation Products in the antenna mount range which include a UA or UB suffix in the type number e g N6315UA N6318DUB contain an integral block upconverter The UA suffix indicates an upconverter which operates over the RF input frequency range 950 to 1450 MHz corresponding to an RF output frequency range 14 0 to 14 5 GHz The UB suffix indicates an upconverter which operates over the RF input frequency range 950 to 1700
31. e RF input power or increase the internal digital attenuator if fitted and an RF enable request is sent to clear the RF inhibit or ii the high power alarm is disabled see section 6 1 4 2 HBN63xx 1 Issue 8 Page 27 D3 D4 D5 HBN63xx 1 Issue 8 Page 28 high power alarm enabled f set shows that the high power alarm is enabled See section 6 1 4 for details on enabling disabling and operation of the power alarms power too low If set indicates that the low power alarm is set and that the RF output power level is below the alarm level The amplifier will remain in the transmit mode but the fault flag will only clear once either i the RF output power level exceeds the alarm level or ii the low power alarm is disabled see section 6 1 4 1 low power alarm enabled set shows that the low power alarm is enabled See section 6 1 4 for details on enabling disabling and operation of the power alarms RF enabled f set shows that the RF is enabled The RF enabled inhibited commands are accepted in any of the operational modes See section 6 1 7 for details on enabling disabling the RF inhibit feature remote enabled f set shows that the amplifier is in the remote mode allowing control via the serial communications interface See section 6 1 12 for details on enabling disabling the remote mode heater current If set indicates that the amplifier has seen an internal heater fault trip The amplifier will
32. e2v e2v technologies N63xx Series Ku Band Antenna Mount Amplifier Product Range Operation Manual O 2003 e2v technologies limited This work must not be copied in whole or in part without the prior written permission of e2v technologies limited e2v technologies Waterhouse Lane Chelmsford Essex CM1 2QU UK Telephone 44 0 1245 493493 Fax 44 0 1245 492492 Internet www e2vtechnologies com Holding Company e2v holdings limited HBN63xx 1 Issue 8 July 2003 This Operation Manual covers the following am plifier type numbers N6312 N6312C N6312D N6312DUA N6312DUB N6312UA N6312UB N6312W N6312DW N6315 N6315C N6315D N6315DUA N6315DUB N6315UA N6315UB N6315W N6315DW N6318 N6318C N6318D N6318DUA N6318DUB N6318UA N6318UB N6318W N6318DW A SAFETY NOTES The following warnings and precautions are for your safety and the prevention of injury Please read them carefully and observe at all times when installing or operating a Stellar Travelling Wave Tube Amplifier Hazard warning signs as defined in 55378 Safety Signs and Colours are used on the equipment to highlight any possible hazards Earthing A protective earth must be connected to the amplifier before applying the mains supply This protective earth must only be removed after disconnecting the amplifier from the mains supply The protective earth must be connected to the local system earth point must be capable of carrying 30 A and must c
33. ed copper braid A pin is provided on the connector for the connection of a drain wire if available on the cable For cable runs above 5 m an additional insulated conductor core should be used as a signal return connection Data format The format is 1 start bit 8 data bits with most significant bit sent as EVEN parity 1 stop bit Which can be realised as 1 start bit 7 data bits EVEN parity 1 stop bit Data Rate The default data rate is 9600 baud but other baud rates may be selected using the appropriate command HBN63xx 1 Issue 8 Page 32 6 2 4 6 2 5 Generalised Message Format lt delimiter gt address command data lt delimiter gt checksum delimiter Function ASCII Hex Start of text lt STX gt 2h End of text lt ETX gt 3h Acknowledge lt ACK gt 6h Not acknowledge lt NAK gt 15h address The unique address of the HPA in the range Dec 48 to 111 ASCII 0 to o Hex 30h to 6Fh The HPA will respond only to messages containing this address and will ignore all other messages command A character specifying a particular function for the HPA to perform The character can be in the range ASCII 0 to lt DEL gt Hex 30h to 7Fh data A parameter qualifying a command or data returned in response to a command Characters can be in the range ASCII SP to DEL Hex 20h to 7Fh checksum Bit by bit exclusive OR of all characters in message between and including the delimiters Characters can be in the ra
34. ed panels which are designed to prevent large items of foreign matter from entering and potentially blocking the internal airways A maintenance plan should be developed to check and clean the amplifier slotted panels regularly along with any external filters restrictions The frequency of cleaning will be dependent upon the installation and the environment The maintenance plan should be regularly reviewed and modified according to changes in the environment this can be seasonal e g airborne seed pods can cause regular blockages at certain times of the year The paint used on this product is designed to provide maximum reflection of solar radiation for this reason any exposed faces of the amplifier should be regularly cleaned with soapy water to maintain these reflective characteristics Dirty exposed faces will absorb more solar radiation increase the temperature within the unit and ultimately reduce the reliability and life of the amplifier Do not use detergents or other cleaners without consulting e2v technologies The amplifier must be disconnected from the mains supply before cleaning Maintenance Airways should be checked regularly for blockages see section 2 4 Desiccant should be replaced every 3 to 5 years depending upon environmental conditions The typical life of desiccant is b years in sub tropical conditions assuming that the seal on the lid has not been disturbed HBN63xx 1 Issue 8 Page 7 3 1 3 INSTALLATION
35. enable input r RED SEL redundancy select input S RED FLT I P redundancy fault input t 5 2 User Interface Features 5 2 1 Indicator Outputs Type 1 Normally open relay contact outputs switched to GND pin P on the user interface connector when condition is true Example 1 amplifier in the OFF mode is indicated by pin on the user interface connector closing to pin P Example 2 MUX fault line is at binary 1 when pin X on the user interface connector closes to pin P OFF IND Indicates power is applied and that the unit is in the OFF mode WARMUP IND Indicates the TWT cathode three minute warm up timer is operating and that the unit is in the WARMUP mode STBY IND Indicates the TWT Cathode warm up is complete the unit is in the STDBY standby mode and is ready to enter the XMIT mode XMIT IND Indicates the unit is in the XMIT transmit mode SUM FLT IND Indicates the unit has detected a fault condition MUX 0 MUX 1 Four binary coded discrete lines that indicate the fault conditions the following list gives a breakdown of these fault conditions with a MUX 2 brief description of reset conditions MUX 3 HBN63xx 1 Issue 8 Page 21 5 2 2 Fault Code MUX 3210 Fault Type Reset Code 1101 Upconverter fault 1100 Baseplate over temperature condition M 1011 TWT Collector over temperature condition 1010 Cooling fan 2 fault P 1001 Cooling fan 1 fault P 1000 Heater fault P 0111 HV fault A 0110 D
36. ent signal locking 2 If the wider band 750 MHz UB variant is used with exciter chain equipment that is operating over a narrower band 500 MHz the lowest frequency reference point will be 13 75 GHz resulting in an output frequency range of 13 75 to 14 25 GHz and not the desired 14 0 to 14 5 GHz MIXER BANDPASS FILTER DEMODULATOR 950 TO 1450 1700 MHz S n c TENN INPUT KO ERNE Oo 4 L BAND 110 MHz 50 MHz PHASE amp 10 MHz FREQUENCY LOCKED A i MULTIPLIER 50 MHz OSCILLATOR 13 05 12 80 GHz OUTPUT UPCONVERTER FAULT RF Sample Port Provided as an optional N type female connector mounted at the opposite end of the amplifier to the waveguide flange It allows external monitoring of the output power providing a signal approximately 50 dB lower than the RF output power It is provided with calibration data across the amplifier s frequency range HBN63xx 1 Issue 8 Page 19 5 USER INTERFACES The amplifier is provided with two interfaces that are used to control the amplifier the user port and the serial communications interface RS 485 All interfaces are available on the 41 pin control connector located next to the mains supply connector This section identifies each control connector pin and describes the function of each pin including the electrical specification 5 1 Pin Identification Code Function User interface pin identification OFF IND o
37. f mode automatically prime power must be removed and re applied to reset the trip Redundancy Mode The following simple command messages that do not have an associated return of data allow control of the built in redundancy waveguide switching feature see section 3 6 for details of operation see section 6 4 1 for details of message format 6 1 3 1 Enable Manual Redundancy Mode Cancels the automatic redundant mode described below 6 1 3 2 Enable Auto Redundancy Mode Selects the automatic redundant operating mode In the event of an amplifier failure the waveguide switch will be automatically positioned so as to route the output from the good amplifier to the antenna 6 1 3 3 This HPA to Antenna Selects the appropriate position of the waveguide switch that routes this amplifier to the antenna 6 1 3 4 This HPA to Load Selects the appropriate position of the waveguide switch that routes this amplifier to the load Power Alarms The following command messages allow the control monitoring of the built in high and low power alarms feature The associated fault flags are detailed in section 6 1 2 6 1 4 1 Set Low Power Alarm Allows the low power alarm level to be set in watts or disabled when set to zero see section 6 4 5 for details of passing parameters 6 1 4 2 Set High Power Alarm Allows the high power alarm level to be set in watts or disabled when set to zero see section 6 4 5 for details of passing parameters H
38. ff indicator output A WARMUP IND warm up indicator output B STBY IND standby indicator output C XMIT IND transmit indicator output D SUM FLT IND summary fault indicator output E spare F RF INHIB RF inhibit control input G INV RF INHIB inverted RF inhibit control input H OFF off control input 5 standby control input K XMIT transmit control input L spare M FWD PW MON forward power monitor analogue output N GND ground P EXT INTLK external interlock input R ADD 0 address select 0 5 ADD 1 address select 1 T 15 V 15 V output U ADD SEL address select V CTRL O R control override select W MUX 0 multiplexed fault line 1 indicator output X MUX 1 multiplexed fault line 2 indicator output Y MUX 2 multiplexed fault line 3 indicator output Z MUX 3 multiplexed fault line 4 indicator output a RS TX serial interface b RS TX serial interface Tx C RS RX serial interface Rx d HBN63xx 1 Issue 8 Page 20 Code Function User interface pin identification RS RX serial interface Rx HX MON helix current monitor analogue output f ADD 2 address select 2 g ADD 3 address select 3 h ADD 4 address select 4 i ADD 5 address select 5 j RED FLT O P redundancy fault indicator output k RED SW 1 redundancy RF switch drive 1 this HPA to antenna m RED SW 2 redundancy RF switch drive 2 this HPA to load n RS GND serial interface signal return p SWITCH SENSE redundancy RF switch sense input q AUTO ENA redundancy automatic mode
39. frequency UA DUA variants W variants all other types Input frequency UA and DUA variants UB and DUB variants W variants all other types Typical output power at the output flange N6312 N6315 N6318 Gain at rated power C variants D variants UA UB variants DUA and DUB variants all other types RF input level C variants Seth oes DUA DUB UA and UB variants all other types Prime power voltage frequency power power factor Mechanical Dimensions 19 inch rack width height depth Weight nominal 14 0 to 14 5 GHz 12 75 to 14 5 GHz 13 75 to 14 5 GHz 950 to 1450 MHz 950 to 1700 MHz 12 75 to 14 5 GHz 13 75 to 14 5 GHz 120 W 150 W 165 W 36 dB typical 62 dB typical dB typical 47 dB typical 65 dB typical 30 dBm max 0 dBm max 10 dBm min 10 dBm max 99 to 265 V 47 to 63 Hz 1050 W max 0 95 nom 206 mm 8 1 inch 203 mm 8 0 inch 436 mm 17 2 inch 12 kg 26 Ib HBN63xx 1 Issue 8 Page 43 8 3 Environmental for operation outside these parameters refer to e2v technologies for guidance Operating temperature ee 40to 45 Derating 2 300 m above sea level Storage temperature 5 40to 80 Relative humidity non condensing 100 Altitude operating 5 s s 4 5 km 15 00 ft m
40. ith phase combination to give increased power at the antenna the N6145 controller is required as shown below With the amplifiers connected in this way an RF INHIBIT will be generated as the CRCA waveguide switch changes position HPA A HPA B Eu TO CRCA ga Q OQ 4 63 9 5 1 9 8 3 5 9 8 5 3 AMP INT HPA A HPA B INTERFACE INTERFACE N6143 CONTROLLER N6145 CONTROLLER HBN63xx 1 Issue 8 Page 47 APPENDIX Single Amplifier Configuration with N6143 N6081D Controllers If operating in single amplifier mode the remote interfacing becomes easier to provide A simple RS 485 link is required between the amplifier and the controller to give full func tionality The dual amplifier controller N6143 can still be used in this set up as it is fully configurable to either single or dual amplifier mode of operation The N6081D is a low cost single amplifier controller that also provides the amplifier parameter display it uses the low voltage DC supply from the amplifier so it does not require a mains power connection Examples of the interface wiring for this method of control are as follows HPA USING N6143 N6143 CONTROLLER 120 W USING N6081D Cable screened twisted pair
41. k input that operates as a fault trip If the EXT INTLK input is opened whilst the amplifier is in the XMIT mode the amplifier is automatically placed into the STBY mode In order to return to the XMIT mode the EXT INTLK input must first be closed reset conditions are detailed in section 5 2 1 If the external interlock is open in any other mode the fault condition is indicated but the amplifier mode is not changed If this feature is not required this pin should be linked to GND within the 41 pin user interface connector GND XMIT available Not Connected Inhibit XMIT Control Inputs Type 3 The following control inputs set the modes of operation of the unit They are designed to be linked within the 41 pin user interface connector during equipment installation and therefore do not form part of the everyday control functions of the unit To set the mode the appropriate pins should be linked to 15 V pin U on the user interface connector Maximum external link resistance 10090 Note Although designed to operate using the internally generated 15 V with local links an external supply can be used to remotely set these modes of operation Any external supply should be capable of nominally 15 V 5 mA per pin and should conform to the following requirements Maximum logic 0 voltage s art gt 0 8Vdc Minimum logic l voltage 12Vdc Maximu
42. m logic 1 voltage 30Vdc ADD 0 ADD 1 Six binary coded discrete lines that allow the user to set the ADD 2 address of the unit when using the RS 422 or RS 485 serial communications interfaces this hardware address select mode CPEs is only active when ADD SEL is not connected to 15 V ADD 4 15 V binary 1 Not Connected binary 0 ADD 5 HBN63xx 1 Issue 8 Page 24 The following gives the binary and equivalent hexadecimal code of these discrete lines Address code ADD 543210 Address in Hex 000000 30H 000001 31H 000010 32H 111110 6EH 111111 6FH ADD SEL Allows the user to select the method of setting the serial communications interface The address can be set either in hardware using the ADD to ADD 5 lines above or in software over the serial interface itself see section 6 3 Note With hardware address selection the only valid baud rate is 9600 15 V Software selection Not Connected Hardware selection This feature allows the user to return to a known address in the event of the software losing contact with the unit by simply cutting the ADD SEL to 15 V link The amplifier is supplied with no links hence the interface is set to address 30H baud rate 9600 CTRL O R This allows the user to select the black box mode When selected as soon as the mains supply is applied to the unit the three minute WARMUP mode is initiated and subsequently the unit
43. nd cleaned as necessary When normal airflow is confirmed the amplifier can be taken back into the XMIT mode The amplifier is automatically placed in the OFF mode if the over temperature condition exists for more than 4 minutes The mains supply should be removed and the amplifier isolated before a full inspection is made of the installation cooling system The amplifier should be left for 20 minutes before any attempt is made to re start Following an over temperature condition the TWT OVER TEMPERATURE or BASEPLATE OVER TEMPERATURE fault conditions are set these can be monitored via the user interface or accessed through the serial communications port see section 5 When deciding on the location of the amplifier the following points should be observed It is important not to obstruct the air inlet or the air exhaust In any system prevent hot exhaust air from recirculating to the inlet otherwise the inlet air temperature will increase resulting in potential thermal runaway This is a prime consideration when designing common ducting systems for multiple amplifiers HBN63xx 1 Issue 8 Page 11 3 3 2 3 3 3 In any other instance if there is significant additional obstruction to the air flow then it may be necessary to provide externally forced cooled air to the amplifier Ducting Considerations The amplifier is provided as standard with an air inlet cowl the normal orientation of which is pointing towards the base
44. nd monitoring of switch position and amplifier operation for further details on the N6143 contact your distributor As the amplifiers do not have a master slave relationship the position of the waveguide switch is pre selected by the user either manually via the user interface or from the N6143 control unit The low power alarms on both amplifiers are set if required then both amplifiers are placed into the XMIT mode The automatic mode enable AUTO ENA input is then selected via the user interface or from the N6143 control unit control of the switch is then passed to the amplifiers With both amplifiers operating normally in the XMIT mode and giving gt 1 W of RF output power the waveguide switch will remain as set Each amplifier monitors the status of the other amplifier for potential faults If the amplifier routed to the antenna develops a fault condition or its RF output power drops below the low power alarm setting 1 W minimum low power alarm level the other amplifier takes control HBN63xx 1 Issue 8 Page 15 switching the waveguide switch If the N6143 control unit is used an audible alarm will activate indicating the fault condition to the operator The amplifiers will remain in the automatic mode as before If the faulty amplifier does not recover a fault on the second amplifier will not result in switching of the waveguide switch The waveguide switch coil should be a 24 V type and a tell back switch within the
45. ng Earthing A protective earth must be connected to the amplifier before applying the mains supply This protective earth must only be removed after disconnecting the amplifier from the mains supply The protective earth must be connected to the local system earth point must be capable of carrying 30 A and must conform to the regulations in the British Standard Codes of Practice BS7430 1991 Earthing or equivalent national regulations A supply wiring earth can be connected between the mains supply source and the amplifier rear panel connector Mains Supply Distribution System A mains supply disconnection device must be provided to isolate the amplifier from the mains supply source Either a socket outlet or a two pole isolation switch must be used as the mains supply disconnection device It must be installed near the amplifier and be easily accessible The mains connector must not be used as the mains supply disconnection device It is provided for convenience during installation and for ease of operation It is strongly recommended that the mains supply for the amplifier is fed via a double pole Residual Current Circuit Breaker RCCB The amplifier earth leakage current is 6 mA rms under nominal operating conditions In some circumstances on low voltage 3 phase systems e g 115 V line to neutral and 200 V line to line it may be preferable to operate the amplifier bi phase In this case the amplifier may be connected across an
46. nge ASCII lt NUL gt to DEL Hex Oh to 7Fh Command Message Format lt STX gt address command ETX checksum Command message with no qualifying data lt STX gt address command data lt ETX gt checksum Command message including a qualifying parameter HBN63xx 1 Issue 8 Page 33 6 2 6 6 2 7 Response Message Format All valid command messages are acknowledged in the following forms The address and command characters are a reiteration of those in the command message lt ACK gt address command lt ETX gt checksum Simple acknowledgment lt ACK gt address command data lt ETX gt checksum Acknowledgment with data Any unrecognised or unexecutable commands will be acknowledged in the form shown below lt NAK gt address command data lt ETX gt checksum Not acknowledge with explanation for the command rejection Any command containing a parity framing overrun or checksum error will be ignored and consequently the master must re issue the command Message Timing The maximum time between each character of a message must not exceed 10 ms and a pause of 10 ms minimum should be inserted after a command message to allow units to recognise bus inactivity between commands HBN63xx 1 Issue 8 Page 34 6 3 Summary Of Command Messages Command HPA type Status Enable manual redundancy mode Enable auto redundancy mode This HPA to antenna This HPA to load Set low power alarm Set high power ala
47. ntrol Inputs Type 1 The following control inputs are of the momentary edge triggered type The inputs are internally pulled up to 15 V by 2k7 resistors The input is asserted on the falling edge i e as the input is switched to GND pin P on the user interface connector Only one input should be asserted at a time and should be relinquished for at least 10 ms prior to asserting another type 1 input Note The operation of the XMIT control input is modified while the CTRL O R input is asserted See section 5 2 6 Minimum pull down time y BA SE SR RGB kee heed MS Maximum external switch on resistance 100 Q OFF Selects the OFF mode directly from any of ifie three operating modes WARMUP STBY or XMIT STBY Selects the STBY mode directly from the XMIT mode When selected from the OFF mode the unit is placed into the WARMUP mode for three minutes before automatically entering the STBY mode XMIT Selects the XMIT mode directly from the STBY mode When selected from the OFF or WARMUP modes the XMIT mode is automatically entered after the end of the three minute heater warm up time RED SEL Part of the redundant switch control facility selects the amplifier to be routed to the antenna Control Inputs Type 2 The following control inputs are of the level active type The inputs are internally pulled up to 15 V by 2k7 resistors Maximum external switch on resistance 10090
48. of the amplifier see section 3 1 Additional cowls are available from e2v technologies and can be fitted to the air outlet in a similar orientation to that of the inlet cowl The cowls can be turned through 90 for an alternative amplifier mounting configuration These cowls are designed to avoid driving rain entering the unit if a secondary cover is not utilised The cowls can be removed and replaced with circular duct adaptors which utilise the same fixing holes These circular duct adaptors are available from e2v technologies and are designed to accept 8 9 cm 3 5 inch diameter ducting Any ducting connected to the inlet or exhaust will create additional back pressure reduce the airflow and increase the internal temperature of the amplifier Each amplifier is designed to handle some additional back pressure but this must be minimised When designing ducting systems Keep ducting lengths to a minimum check the amplifier maximum operating temperature derating for the length of duct required Route ducting directly avoid sharp bends and ensure that the minimum bend radius is three times the ducting diameter Use the largest cross sectional area of ducting possible Usesmooth walled ducting avoid corrugated ducting as it is more restrictive to airflow lransitions in ducting sizes should be smooth avoid step changes Do not use ducting adaptors that reduce the internal cross sectional area of the ducting If
49. of two amplifiers the N6143 control unit and a waveguide switch 2 If an AUTO ENA signal is not received by the amplifiers the RED FLT O P will not be enabled Therefore if an external controlling device other than the N6143 is used this must be taken into account if the RED FLT O P is to be used to trigger switch over Alternatively the SUM FLT IND multiplexed fault lines or inverted XMIT IND outputs can be used as the trigger for switch over HBN63xx 1 Issue 8 Page 16 4 1 4 2 4 3 4 3 1 4 BASIC OPERATION OF THE AMPLIFIER Applying The Mains Supply Before applying the mains supply to the amplifier the operator must be satisfied that both the RF input and RF output connections are correctly terminated see section 3 2 safety and cooling requirements are complied with see safety notes and section 3 3 the correct type of mains cable is in use see section 3 4 Once the above has been verified apply the mains supply to the amplifier The fans will be heard to start It is good practice to allow the TWT to cool for three to four minutes after leaving the transmit mode before disconnecting the amplifier from the mains supply Mains Supply Interruptions It is common on some mains or local generator derived supplies for the supply to be temporarily interrupted This section details the behaviour of the amplifier under these conditions when it is transmitting Interrupt lt 30 ms the amplifier will con
50. onform to the regulations in the British Standard Codes of Practice 57430 1991 Earthing or equivalent national regulations Mains Supply A mains supply disconnection device must be provided to isolate this amplifier from the mains supply source Either a socket outlet or a two pole isolation switch must be used as the mains supply disconnection device and it must be easily accessible The mains connector must not be used as the mains supply disconnection device Toxic Material The Travelling Wave Tube TWT within the amplifier contains beryllium oxide Dust created by breakage or fumes from a beryllium oxide fire are highly toxic if inhaled or if particles enter the body via a cut or abrasion Consult e2v technologies and the appropriate national authorities for details regarding the disposal of damaged or old TWTs and amplifiers HBN63xx 1 Issue 8 Page 2 AN High Voltage High voltages in excess of 6 kV are present within the amplifier However the equipment is designed so that personnel cannot come into contact with high voltage circuits unless the covers are removed RF Radiation Exposure of the human body to microwave radiation can constitute a hazard ANSI IEEE C95 1 1992 Personnel must be protected from microwave energy produced by the TWT All RF connectors must be correctly fitted before operation so that there is no leakage of RF energy The amplifier must not be operated unless the RF output connection is
51. onsideration when designing common ducting systems for multiple amplifiers 3 3 4 Commissioning the Installation 3 4 3 4 1 When commissioning the installation the temperature difference across each amplifier should be checked to assess the suitability of the cooling system Temperature measurements should be taken as follows Under the worst case operating conditions with the amplifier in XMIT mode with no RF drive applied beam only and after the amplifier has thermally stabilised typically 2 hours after XMIT has been selected As close to the amplifier inlet and exhaust cowls as possible to reduce the effects of inaccuracies caused by radiation from duct walls As an average across the cross sectional area of the aperture duct to avoid inaccuracies caused by uneven temperature distribution Mains Supply Connection The safety notes at the start of this manual should be read before connecting the amplifier to the mains supply The amplifier can be operated from mains supplies of 99 to 265 V ac without any user adjustments Both the live and the neutral connections on the amplifier are fully rated and isolated for maximum line voltage full transient and noise immunity The amplifier is supplied with one mains plug but no cable Additional mains plugs are available from e2v technologies please contact your distributor The connector details are shown in figure 5 If the amplifier is to be used in applications whe
52. or Contact your distributor HBN63xx 1 Issue 8 Page 41 Fault experienced HV FAULT fault DC BUS FAULT fault PFC FAULT fault EXTERNAL INTERLOCK TRIP fault REFLECTED POWER TRIP fault MEAN HELIX OVER CURRENT TRIP fault PEAK HELIX OVER CURRENT TRIP fault INTERMODULATION PRODUCTS too high out of specification UPCONVERTER fault UPCONVERTER SIGNAL out of lock but no UPCONVERTER fault indication HBN63xx 1 Issue 8 Page 42 Possible cause Contact your distributor Contact your distributor Mains supply lower than the minimum 99 V External interlocks activated code active External interlock cable damaged severed If external interlock is not used check user interface connector mating half has a link between pins R and P see section 5 2 Poor match with external equipment External waveguide incorrectly fitted or damaged Protective bung still fitted to amplifier wave guide output or other foreign object within waveguide including water moisture Contact your distributor Contact your distributor With the upconverter option L band drive level too high see section 4 4 With the upconverter option 10 MHz locking signal not present on L band input of the upconverter check correct connection of L band input cable and correct operation of previous equipment With the upconverter option L band drive level too low see section 4 4 8 1 8 2 8 SPECIFICATION Electrical Output
53. re it is exposed to rain or subjected to condensation all attempts must be made to prevent moisture ingress into the mains connector The mains connector is supplied with a range of cable retention bungs these should be selected to suit the size of cable chosen see section 3 4 1 The cable bungs if correctly selected will seal to the cable and prevent moisture ingress A NEUTRAL B EARTH C LIVE Figure 5 mains connector pin identification Mains Supply Cable Selection Cable size and distribution protection must be determined by the user and will depend on the mains supply voltage to be applied to the amplifier If the amplifier is always used in an environment with a 240 V mains supply then a cable capable of carrying at least 15 A can be fitted HBN63xx 1 Issue 8 Page 13 3 4 2 3 4 3 It is important when using lower mains supply voltage sources of 110 V and 120 V nominal to ensure that the required voltage is available at the input connector of the amplifier under conditions of maximum current demand It is also important to ensure that for any supply selected the mains supply source no load to full load voltage drop is less than 10 V rms On full load the amplifier mains supply voltage must be greater than 99 V Under conditions of a low voltage power source with long power connection leads this may require selecting a cable for low voltage drop and not just basing the selection on a nominal current rati
54. rm Warm up time Set attenuator Enable RF Helix record top of file Next Ihlx record Helix current Input power see note Elapsed hours Go to local Inhibit RF Off UC Forward power Remote enable Standby Reflected power see note Attenuator High power alarm Low power alarm Transmit Set address Set baud rate Type UC user command UC p user command with parameter US user status data request Note Input power and reflected power are not monitored ASCII 0 2 lt RC 30 31 35 36 37 38 41 42 43 44 45 46 47 48 49 4 50 52 53 54 55 56 57 58 59 Type see below US US UC UC UC UC US UC UC US US US US UC UC 4F US UC UC US US US US UC UC4 UC4 UC p UC p UC p rp rp Data requests will be serviced with the HPA in either local or remote mode However for other commands to be executed with the exception of remote enable the HPA must be in remote mode Commands will be rejected as unexecutable with the HPA in local mode HBN63xx 1 Issue 8 Page 35 6 4 Examples Of Command And Response Messages Examples for each command type are given in a generalised ASCII and hexadecimal form using the address 5 35h for the specific examples The expected response message for each command is shown using the same format Note A
55. set conditions will be dependent upon the fault present transmitting set indicates that the amplifier is operating in the transmit mode full details of the operating modes are given in section 4 3 standby If set indicates that the amplifier is operating in the standby mode full details of the operating modes are given in section 4 3 warm up If set indicates that the amplifier is operating in the warm up mode full details of the operating modes are given in section 4 3 off If set indicates that the amplifier is operating in the off mode full details of the operating modes are given in section 4 3 D2 output to antenna When using the redundant switch control feature if set indicates that the amplifier is routed to the Antenna If not set indicates that the amplifier is routed to the Load See section 6 1 3 for details on the operation of the redundant switch control feature auto redundancy f set indicates that the automatic mode for redundant switch control is enabled If not set indicates that the manual mode for redundant switch control is enabled See section 6 1 3 for details on the operation of the redundant switch control feature power too high If set indicates that the high power alarm is set and that the RF output power is above the alarm level The amplifier will remain in the transmit mode but with the RF inhibited until either i the RF output power falls below the alarm level decrease th
56. sponse format Interface Set Up To use the serial communications interface the amplifier must be placed into the remote mode of operation this can only be done over the serial communications interface To send the remote enable command the address and baud rate must be correctly set This can be done either i in hardware on the 41 pin control connector using links see section 5 or ii via the master controlling device by polling all combinations of address and baud Once captured either the address or baud rate can be modified The following command messages allow the set up and control of the serial communications interface feature 6 1 12 1 Set Address Allows the address to be set in nominal units between 48 and 111 48 corresponding to address Hex 30h 111 corresponding to address Hex see section 6 4 5 for details of passing parameters 6 1 12 2 Set Baud Rate Allows the baud rate to be set in nominal units between 1 6 1 corresponding to a baud rate of 600 2 1200 3 2400 4 4800 5 9600 and 6 19200 see section 6 4 5 for details of passing parameters HBN63xx 1 Issue 8 Page 31 6 2 6 2 1 6 2 2 6 2 3 6 1 12 3 Go To Local A simple command message that places the amplifier into the local mode allowing control via the user interface discrete control lines Data requests via the serial communications interface will continue to be serviced in the local mode however commands other
57. than Remote enable will be rejected as non executable see section 6 4 1 for details of message format 6 1 12 4 Remote Enable A simple command message that places the amplifier into the remote mode allowing control via the serial communications interface When in the remote mode the standby and transmit user interface discrete control inputs are disabled all other control inputs and monitor outputs remain active Protocol Interface and Termination RS 485 compatible 4 wire with no receiver biasing option When using this amplifier with the serial communications interface a 120 bus termination should be fitted externally between the Rx pin d and Rx pin e connections of the 41 pin control connector If used in the redundant mode with another amplifier or on a multi drop system the bus termination is only required on one equipment typically the furthest from the master device A screened cable terminated to the backshell of the user interface connector should be used to prevent radio frequency interference from adversely affecting operation when connecting the screen of the cable to the backshell a full 360 electrical connection should be made pig tailed connections should be avoided For short cable runs up to approximately 5 m a suitable data transmission cable would include a twin twisted pair conductor arrangement typical conductor size of 24 to 26 AWG screened in aluminised tape with an overall tinn
58. the standby mode and automatically attempt to reset three times for full reset details see section 5 2 1 6 1 3 D6 case too hot f set indicates that the amplifier has seen an excessive internal case temperature trip The amplifier will revert to the standby mode automatically until the fault condition clears upconverter fault If set indicates that the amplifier has not detected an external 10 MHz locking signal provided multiplexed onto the RF input This flag is only active if the amplifier contains an upconverter module type numbers with a U in the suffix This is an advisory alarm only and will remain set until the fault condition clears the amplifier will remain in the transmit mode D7 baseplate too hot If set indicates that the amplifier has seen an excessive PSU baseplate temperature trip The amplifier will revert to the standby mode automatically until the fault condition clears TWT too hot If set indicates that the amplifier has seen an excessive TWT collector temperature trip The amplifier will revert to the standby mode automatically until the fault condition clears fan 2 fault If set indicates that the amplifier has seen an internal cooling fan fault trip The amplifier will revert to the off mode automatically prime power must be removed and re applied to reset the trip fan 1 fault If set indicates that the amplifier has seen an internal cooling fan fault trip The amplifier will revert to the of
59. the installation dictates restrictive duct systems install additional external fans to provide adequate airflow and counteract the effects of ducting Additional fans should be installed on the air input to the amplifier where the air is at its coolest Equipment Housings All equipment housings including basic flight cases roof mount enclosures cabins and air conditioned rooms have common cooling system design requirements Maintain an adequate supply of air to the inlet a 58 cm 9 inch unimpeded aperture should be provided into any enclosure for each Stellar amplifier The local source and destination of cooling air should ideally be common to avoid back pressure caused by differential pressure effects Housings that are exposed to environmental wind effects should use a common face for inlet and exhaust vents to avoid back pressure caused by differential wind effects Terminations of inlet and exhaust vents should be of a design that prevents direct environmental wind effects whilst avoiding creating additional restriction to airflow f a sealed cooling system with recirculating air conditioners is used an over temperature alarm should be fitted to the cabin to detect air conditioner failures HBN63xx 1 Issue 8 Page 12 In any system prevent hot exhaust air from recirculating to the air inlet otherwise the inlet air temperature will increase resulting in potential thermal runaway This is a prime c
60. tinue to operate normally Interrupt gt 30 ms lt 5 seconds a degradation of RF performance can be expected the amplifier will leave the XMIT mode When the mains supply returns the amplifier will automatically re enter the XMIT mode within 1 second All operating parameters will be as previously set Interrupt gt 5 seconds a degradation of RF performance can be expected the amplifier will leave the XMIT mode When the mains supply returns the amplifier will remain in the OFF mode until the user selects another mode of operation either manually or automatically Functions As the amplifier has no direct human interface for control or monitoring the 41 pin control connector is used to effect control either via the serial communications bus or the discrete control connections This section describes the control functions available to the user Amplifier OFF mode Applying prime power to the unit results in the amplifier entering the OFF mode until another mode is selected In this mode only the Amplifier control auxiliary circuits and fans are operational the main cooling fan operating at half speed Following transmission the OFF mode can be requested to remove the amplifier from the XMIT mode HBN63xx 1 Issue 8 Page 17 4 3 2 4 3 3 4 3 4 4 4 Amplifier WARMUP mode Requesting either the STBY or XMIT mode from the OFF mode will result in the TWT cathode heater power being applied and the warmup timer 180 secon
61. valid if the command is not recognised a parameter is out of range or not numeric or the command cannot be executed For example if a command which is not part of the amplifier command set is used the response will be as follows Command Gen lt STX gt address lt ETX gt checksum ASCII lt STX gt bb lt ETX gt v Hex 02 35 42 03 76 Response Gen lt NAK gt address B D1 lt ETX gt checksum ASCII lt NAK gt 5Bp lt ETX gt DC1 Hex 15 35 42 70 03 11 HBN63xx 1 Issue 8 Page 39 D1 is a byte representing the invalid command code It is defined as follows D1 bit 7 parity bit 6 1 bit 5 1 bit 4 1 bit 3 0 bit 2 0 bit 1 command not executed bit O command data invalid 6 5 Application Notes The following application notes apply to amplifiers with operating software SAMOS issue 1 or higher Before attempting to control the amplifier using the RS 485 4 wire multi drop bus check the following Ensure that the data connector is correctly wired Rx Rx are not reversed etc Check that the amplifier data rate is the same as that of the master should be set to 9600 baud Ensure that the amplifier has a unique address Check that the master has the same data format as the amplifier 1 start bit 7 data bits EVEN parity and 1 stop bit HBN63xx 1 Issue 8 Page 40 7 FAULT FINDING If the amplifier does not work correctly consult the following table before contacting either the helpline or your distri
62. y two lines of the 3 phase system to obtain what is effectively a 200 V single phase source Under these circumstances the neutral of the 3 phase system is not connected to the amplifier With smaller 3 phase generators this may offer a method of partially balancing a number of lower power single phase loads If the amplifier is connected bi phase an external 2 pole protection device must be provided that disconnects both line connections in the event of a fault on either line This equipment has not been designed for connection to an IT power system The mains input surge current for this unit is dependent upon mains voltage The following table shows the t products during the power up phase for 110 120 V and 220 240 V it should be used to determine the rating of any current overload protection devices The half cycle average surge current is less than the maximum running current of the unit therefore typically a 13 A HRC fuse to BS 1362 is adequate for the over current protection of each amplifier this can be reduced to a 10 A HRC fuse to BS 1362 if the unit is to be used on high mains voltage supplies HBN63xx 1 Issue 8 Page 14 3 5 3 5 1 High Line Conditions 220 240 V nominal Time Peak A i to switch on 10 lt 1 to 100 ms 40 lt 5 to 250 ms 8 0 7 Low Line Conditions 110 120 V nominal Time Peak A 121 to switch on 5 lt 0 3 to 100 ms 18 lt 3 5

N63XX Series KU Band Operations Manual

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