Comtech EF Data XPA-200 User Manual

r
XPA-20
Solid-State High Power Amplifie
Installation and Operation Manual
Part Number MN/XPA200.IOM Revision 2

Errata A

Comtech EFData Documentation Update
Subject:
Date: Document:
Part Number: Collating Instructions:
Comments:
The following changes provide updated information. This information will be incorporated into the next revision.
Various Changes
February 28, 2003 XPA200-7984-I-OPT1, X-Band SSPA Installation and Operation Manual, Rev. 2
Attach these pages at the beginning of the manual.
Change Specifics:
1. Section 3.3.2.1 should be amended to include (amendments or changes in bold):
. . . EXT mute on from external J4 control (see section 1)
ON muted by M&C control or via remote control
2. Section 5.8.2.2 should be amended to include (amendments or changes in bold):
. . . Confirmation: >DEV/MUT_xxx’cr’lf’]
Note: On Status queries, the ‘MUT’ command may also return EXT (mute on from external J4 control) or INH (mute on or inhibited by Mitec 2723B via J5).
3. Section 5.8.3.1 should be amended to include (amendments or changes in bold):
. . . TX_nnn’cr’ Transmit ON/OFF/EXT/INH . . .
Filename: XPA200-7984-I-OPT1_Errata_a.doc 1
4. Section 5.8.3.5 should be amended to include (amendments or changes in bold):
. . . +10_2_xx’cr’ +10 PS#2 Fault
SHTD_xx’cr’ Thermal Shutdown
. . .
Note: A temperature fault is indicated if the unit is less than ­20C or more than 85 degrees C. This creates a summary fault and will cause the unit to mute itself and switchover to the back-up unit. However, the 10V supply to the FET transistors will remain on until the unit reaches the thermal shutdown temperature of 90 degrees C or above. For protection reasons, the unit will shutdown the 10V supply to the power transistors at temperatures at or above 90 degrees C.
5. Section 5.8.3.8 should be amended to include (amendments or changes in bold):
. . . Confirmation: >DEV/PACRCS_aabcde'cr''lf']
where: aa = # of 0.25 dB steps in HEX above 0dB (0to120) b = 1 if Amplifier ON, 0 if OFF
c = 1 if Tx ON, 0 if OFF, 2 if external mute
command, 3 if external inhibit command
d = 1 if unit ONLINE, 0 if OFFLINE
e = 1 if Auto Recovery enabled, else 0
6. Section 5.8.3.9 should be amended to include (amendments or changes in bold):
. . . iii = RF forward pwr, .1 dBm steps above 26.0 dBm in Hex jjj = RF reverse pwr, .1 dBm steps above 19.0 dBm in Hex
7. Section 5.8.3.12 should be amended to include (amendments or changes in bold):
. . . Confirmation: >DEV/PACRAS_abcdefghijkl'cr''lf'] . . . . . .
g = 1 if +10 PS#2 Fault, else 0
h = 1 if TEMP Fault, else 0 i = 1 if Thermal Shutdown, else 0 j = 1 if FAN 1 Fault, else 0 k = 1 if FAN 2 Fault, else 0 l = 1 if PROC Fault, else 0
Filename: XPA200-7984-I-OPT1_Errata_a.doc 2
Note: A temperature fault is indicated if the unit is less than ­20C or more than 85 degrees C. This creates a summary fault and will cause the unit to mute itself and switchover to the back-up unit. However, the 10V supply to the FET transistors will remain on until the unit reaches the thermal shutdown temperature of 90 degrees C or above. For protection reasons, the unit will shutdown the 10V supply to the power transistors at temperatures at or above 90 degrees C.
Filename: XPA200-7984-I-OPT1_Errata_a.doc 3
XPA200-7984-I-OPT1, X-Band SSPA Policy

POLICY

WARRANTY
This COMTECH Product is warranted against defects in material and workmanship for a period of one year from the date of shipment. During the warranty period, COMTECH will, at it's option, repair or replace products which prove to be defective. For warranty service, the product must be returned to COMTECH, all shipping charges prepaid by the buyer. COMTECH will pay shipping charges to return repaired, or replaced, products shipped by normal surface delivery within the continental U.S..
The information within this document is subject to change without notice. Contact the COMTECH Customer Service Representative, 1-(480)333-4357, for information updates that apply to this product.
LIMITATIONS of WARRANTY
The foregoing warranty shall not apply to defects resulting from improper installation or maintenance, abuse, unauthorized modification, or operation outside of the environmental specifications for this product, or, for damages that occur as a result of improper repackaging of equipment for return to COMTECH.
No other warranty is expressed or implied. COMTECH specifically disclaims the implied warranties of Merchantability and Fitness for Particular Purpose.
EXCLUSIVE REMEDIES
The remedies provided herein are the buyer's sole and exclusive remedies. COMTECH shall not be liable for any direct, indirect, special incidental, or consequential damages, whether based on contract, tort, or any other legal theory.
XPA200-7984-I-OPT1, Rev.2
XPA200-7984-I-OPT1, X-Band SSPA Preface

Preface

Manual
This manual describes the installation, operation and maintenance for the XPA200-7984-I 200 watt X-Band Solid State High Power Amplifier (SSPA).
Intended Users
This is a technical document intended for satellite earth station engineers, technicians and operators responsible for the installation, operation and maintenance of the XPA200-7984-I X­Band SSPA.
Organization of Manual
This manual includes the following chapters:
! Section 1 - describes the purpose, function,
description, options and systems specifications of this product.
! Section 2 - describes the unpacking, installation and
and brief operating instructions for use with the Mitec 2723B Variable Phase Combiner and Redundancy Switching System.
! Section 3 - describes the system operation.
! Section 4 - describes the redundant system operation.
! Section 5 - describes the remote control operation.
! Section 6 - describes the maintenance and
troubleshooting procedures.
XPA200-7984-I-OPT1, Rev.2 i
XPA200-7984-I-OPT1, X-Band SSPA Preface
Manual Revision Numbering Scheme
The following table identifies the revision numbering scheme utilized for the COMTECH Operation and Maintenance Manuals, Addenda and Supplements:
Part Number Description
XPA200-7984-I-
2nd edition of the Manual.
OPT1, REV.2
Reporting Comments or Suggestions Concerning This Manual
Comments and suggestions regarding the contents and design of this manual will be appreciated. To submit your Comments, please contact the COMTECH Customer Service Representative, 1-(480)333-4357.
Safety Notice
This equipment has been designed to minimize exposure of personnel to hazards. The operators and technicians must:
! NEVER TURN ON THE UNIT WITHOUT PROPER RF TERMINATIONS.
! Know how to work around, with and on high voltage and
high RF power level equipment.
! Exercise every precaution to ensure personnel safety.
! Exercise extreme care when working near high
voltages/high RF power level equipment.
! Be familiar with the warning presented in this manual.
! CAUTION - Disconnect the power supply cord before
servicing the SSPA.
! Lithium Battery Replacement - CAUTION: There is a
danger that the Lithium battery on the M&C assembly
XPA200-7984-I-OPT1, Rev.2 ii
XPA200-7984-I-OPT1, X-Band SSPA Preface
will explode if the battery is incorrectly replaced. Replace only with the same or equivalent type battery recommended by the manufacturer. Dispose of used batteries according to the Lithium battery manufacturer’s instructions.
Returning a Product
The following information applies to a COMTECH equipment
product being returned for repair or replacement service:
NOTE: An item is considered “out-of-Warranty” if the warranty
period (as determined by the original purchase) has expired; or the equipment has been damaged or otherwise made unusable as a result of an accident or unreasonable use, neglect, improper or unauthorized service, repairs or modifications, or other causes not arising out of defects in design, material, or workmanship.
To return a COMTECH product for repair or replacement:
1. Request a Return Material Authorization (RMA)number from the COMTECH Customer Service Representative, 1-(480) 333-4357, FAX 1-(480)333-2500.
2. Provide the Customer Service Representative with the following information:
a. Model number. b. Serial number. c. Description of the problem. d. Description of action taken to identify the
problem.
e. Name and telephone number of the company
contact.
3. The product being shipped should be packed in it's original shipping container with proper packing material to prevent possible shipping damage.
XPA200-7984-I-OPT1, Rev.2 iii
XPA200-7984-I-OPT1, X-Band SSPA Preface
4. Ship the product, prepaid, to COMTECH. Provide the following address on the shipping label, with the RMA number clearly marked on the label and the shipping container:
COMTECH EF Data Corp. 2114 W. 7th Street Tempe, Arizona 85281 U.S.A. Attention: Customer Service Department, RMA Number:
For more information regarding the COMTECH warranty policy, please refer to the policy page located on the back of the title page.
Product Application, Upgrading or Training Information
To obtain product application, upgrade or training information, Please contact theCustomer Service Representative at the numbers above.
XPA200-7984-I-OPT1, Rev.2 iv
XPA200-7984-I-OPT1, X-Band SSPA Table of Contents

Table of Contents

Section Description Page No.
1 Introduction 1-1
1.1 Scope 1-1
1.2 Functional Description 1-1
1.3 Specifications 1-3
1.4 Prime Power Input 1-4
1.5 Physical Dimensions 1-4
1.6 Environmental specifications 1-4
1.7 Front Panel Controls 1-4
1.8 Front Panel Indicators 1-5
1.9 Front Panel Display 1-7
1.10 Front Panel Test Point Samples 1-7
1.11 Rear Panel Connections 1-7
1.12 Prime Power Switch 1-11
2 Installation/Operation with Mitec 2723B
2.1 Unpacking and Inspection 2-1
2.2 Rack Mount Installation 2-1
2.3 Combined/Redundant System Operation 2-4
and Setup
3 System Operation 3-1
3.1 General 3-1
3.2 Switching Power On 3-1
3.3 Operation 3-3
3.3.1 SSPA Commands 3-9
3.3.2 Configuration Menu 3-10
3.3.3 Monitor Status Menu 3-11
3.3.4 Current Faults Menu 3-11
3.3.5 Stored Faults Menu 3-12
3.3.6 Utility Menu 3-13
XPA200-7984-I, Rev.1 i
XPA200-7984-I-OPT1, X-Band SSPA Table of Contents
Section Description Page No.
4 Redundant System Operation
4.1 General 4-1
5 Remote Control 5-1
5.1 General 5-1
5.2 Electrical Interface 5-1
5.2.1 RS-232C 5-1
5.2.2 RS-485 5-1
5.3 Physical Interface 5-1
5.3.1 Connector 5-2
5.3.2 Pin-Out 5-2
5.3.3 Cables 5-3
5.4 Protocol 5-4
5.4.1 Transmission Mode 5-4
5.4.2 Baud Rate 5-4
5.4.3 Format 5-4
5.4.4 Character Set 5-4
5.4.5 Response Timeout 5-5
5.4.6 Bus Inactivity Requirement 5-5
5.5 Access Methods 5-5
5.6 Addresses 5-5
5.6.1 Physical Address 5-5
5.7 Message Structure 5-6
5.7.1 Start Character 5-6
5.7.2 Device Address 5-6
5.7.3 Command 5-6
5.7.4 Confirmation Response 5-7
5.7.5 Error Response 5-7
5.7.6 End of Message 5-7
5.8 Command/Response Pairs 5-8
5.8.1 Utility Commands 5-8
5.8.2 Configuration Commands 5-11
5.8.4 Status Commands 5-12
5.8.5 Stored Alarm 5-17
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XPA200-7984-I-OPT1, X-Band SSPA Table of Contents
Section Description Page No.
5.9 Error Processing 5-18
5.9.1 General Errors 5-18
5.9.2 Configuration Errors 5-18
5.9.3 Time Outs 5-18
Remote Command Summary Sheet 5-19
6 Maintenance and Troubleshooting 6-1
6.1 General 6-1
6.2 Maintenance Testing 6-2
6.2.1 Test Point Samples 6-2
6.3 Troubleshooting 6-2
6.3.1 SSPA Faults 6-2
6.3.1.2 DC Power Supply Module 6-3
6.3.1.3 Temperature Fault 6-4
6.3.1.4 Monitor & Control Board 6-4
6.4 Returning the SSPA to COMTECH 6-5
6.4.1 Return Material Authorization (RMA) 6-5
6.4.2 Shipment to COMTECH 6-5
6.5 Product Application, Upgrading or Training
Information 6-6
7 Addendum 7-1
7.1 General 7-1
7.2 Additional Troubleshooting Helps 7-1
7.3 Wiring Diagram 7-5
7.4 Parts List 7-6
XPA200-7984-I, Rev.1 iii
XPA200-7984-I-OPT1, X-Band SSPA Introduction
Section 1

Introduction

1.1 Scope
This manual provides instructions on the installation, operation and maintenance of the XPA200-7984-I X-Band Solid State High Power Amplifier manufactured by COMTECH COMMUNICATIONS Corp.
1.2 Functional Description
The XPA200-7984-I X-Band High Power Amplifier (SSPA) is designed for use in communication systems, or in satellite up­link data systems. The SSPA operates over the RF input frequency range of 7900 to 8400 MHZ. The RF power output is 53.0 dBm minimum at 1 dB compression. A functional block diagram is shown in Figure 1-1.
The SSPA is designed to be hard mounted in a standard 19­inch rack or cabinet, or to be rack mounted using COMTECH slide mechanisms provided with the SSPA to allow it to be serviced without its removal from the rack. Two internally mounted exhaust fans are mounted on the chassis for cooling. An AC power connector, with an on/off switch, is located on the rear on the chassis.
All operator controls, indicators and displays for local and remote operation as well as the RF Input and Output sample test ports are located on the front panel of the SSPA. Connectors for the external interface connections are located on the rear of the SSPA chassis.
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XPA200-7984-I-OPT1, X-Band SSPA Introduction
Prime Power Input
PS # 2 28Vdc
FAN1
FAN2
PS #1 10Vdc
PS #2 10Vdc
-5Vdc Interlock
AUX. PS & SWITCH CONTROL
AS/0206
+12V -12V CONTROL
& MONITOR
MONITOR & CONTROL
-5V
AS/0200
+5V
+10Vdc
RF INPUT RF OUTPUT
POWER AMPLIFIER
AS/0558
Figure 1.1 FUNCTIONAL BLOCK DIAGRAM
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XPA200-7984-I-OPT1, X-Band SSPA Introduction
1.3 Specifications
The following are the design, operating and environmental specifications
for the XPA200-7984-I X-Band Solid State High Power Amplifier (SSPA).
Output Front Panel
Frequency 7.900-8.400 GHz Display 24 x 2 LCD Power 53.0dBm min. @ 1dB Comp. Data Entry Cursor Control Keypad
Mute -80dB Input Sample Type N,50 Ohms,-20dBc VSWR 1.25:1 Max. Connector CPR-112G Waveguide Flange
Gain Remote Control
Linear 62dB min, 67dB typ. Comm Port RS-485 or RS-232C Adjust 20dB in 0.25dB Steps Protocol Comtech ASCII or Emul. Per 500MHz + Per 40 MHz + +0 - +50C +
Third Order Intermod. Tx ON Yellow
Intercept +60.5dBm Min.,+62.0dBm Typ. Online Yellow
Products -30dBc typ., -25dBc max @ Remote Yellow
AM to PM Conversion Height 12.25 inches
2.0 degrees typ., 3.0 max @ rated output Width 19 inches
(see Note 1) Output Sample Type N,50 Ohms,-40dBc
.75dB .25dB Alarms
0.50dB @ center Freq. Summary Fault Form C
±1.00dB @ full band
3 dB total back off (two tones,
ªf= 1MHz)
LED
Power Green Fault Red Stored Fault Red
Mechanical
Depth 24 inches Weight 100 lbs.
Group Delay
Linear + Parabolic + Ripple 1.0ns Peak-to-Peak (See Note 1)
Spurious 0-100% Noncond. Stor.
Carrier Related -65dBc Shock Normal Commercial Line Related -50dBc Shipping & Handling
Input
Impedance 50 Ohms Power Requirements Noise Figure 10dB Typ.,15dB Max. 115 VAC, 47-63 Hz, 2600 VA VSWR 1.25:1 Max. Connector Type N
Note 1: P1dB only guaranteed 0 to 40C. Operation above 40C not recommended.
0.03ns/MHZ Environmental
0.003ns/MHz
2
Temperature 0 to +50C Operation
Humidity 10-95% Noncond. Oper.
-40 to +70C Storage
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XPA200-7984-I-OPT1, X-Band SSPA Introduction
1.4 Prime Power Input
The power input requirements for the XPA200-7984-I X-Band SSPA
are as follows:
! 115 volts AC. ! 47 to 63 Hz. ! 2600 VA (approx. 1800W) nominal
1.5 Physical Dimensions
! Width: 19 inches. ! Height: 12.25 inches. ! Depth: 24 inches. ! Weight: 100 lbs.
1.6 Environmental Specifications
! Temperature: 0 to +50 degrees C operating.
(Note: P1dB guaranteed only 0 to 40C. Operation above 40C not recommended).
! Humidity: 10 to 95% noncondensing operation.
1.7 Front Panel Controls
The front panel contains a User Interface Key-Pad which is used by a local operator to input commands to the SSPA. The key-pad is used to select the configuration for operating and monitoring the status of the SSPA. In conjunction with the front panel two line, twenty four character, LCD display, the key-pad allows the operator to select one of five configurations. The configuration functions are "Configuration Menu", "Monitor Status Menu", "Currents Faults Menu", "Stored Faults Menu" and "Utility Functions Menu".
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XPA200-7984-I-OPT1, X-Band SSPA Introduction
1.7 Front Panel Controls (Continued)
The key-pad has six keys: Enter, Clear, Right Arrow, Left
Arrow, Up Arrow and Down Arrow. Each key has a logical function:
! Enter Key: (ENT)
Used to select a display function, or to execute a command to change the configuration of the SSPA.
! Clear Key: (CLR)
Used to cancel a selection, or to cancel a
configuration change which has not been executed using the "Enter" key. After pressing the "Clear" key the display will return to the previous selection.
! Right and Left Arrow Keys:
/
These keys are used to select or change an operating mode within a function, or to input or change the
configuration input data (numbers).
! Up and Down Arrow Key:
/
These keys are used to move to the next operation
mode, or to move the cursor to select a specific parameter or digit within an operating mode selected.
1.8 Front Panel Indicators
There are six LED indicator lights on the front panel which indicate the status of the SSPA and provide summary fault information. The indicators are defined as follows:
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XPA200-7984-I-OPT1, X-Band SSPA Introduction
1.8 Front Panel Indicators (continued)
Faults:
C Fault (Red):
Indicates that a fault condition exists when the LED light is on.
C Stored Fault (Red):
Indicates that the fault has been logged and stored When the LED light is on. The fault may, or may not, be active.
Status:
C Power (Green):
Indicates that power is applied to the SSPA when the LED light is on.
C Tx ON (Yellow):
Indicates that the transmit function of the SSPA is on when the LED light is on. The indicator light reflects the actual condition of the transmit function.
C On Line (Yellow):
Indicates that the SSPA is operating on-line to transmit data.
C Remote (Yellow):
Indicates that the SSPA is being operated in the remote control mode where commands and data are transferred via an RS-485 (RS-232C is optional) serial communications link.
XPA200-7984-I-OPT1, REV.3 1-6
XPA200-7984-I-OPT1, X-Band SSPA Introduction
1.9 Front Panel Display
The front panel display is a two line by twenty-four character, LCD display. Each configuration function, or operating mode, is shown on the display when the operator enters a command into the key-pad on the front panel.
1.10 Front Panel Test Point Samples
Two test point connections are located on the front panel for monitoring the RF input and the RF output. A type N female connector is provided for the RF sample test points.
1.11 Rear Panel Connections
The following is a list of the connectors on the rear panel:
! Connector J1: SSPA RF Input (RF in).
! Connector J2: SSPA RF Output (RF output).
! Connector J3: AC Prime Power Input (AC in).
! Connector J4: Cust. Discrete Control (Discrete Control).
! Connector J5: Combiner Interface.
! Connector J6: COM1 Port (RS-232C/RS-485) (COM1).
! AC Power On / Off Switch.
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XPA200-7984-I-OPT1, X-Band SSPA Introduction
1.11.1 RS-485/RS-232C Interface (COM1), Connector J6
The RS-485/RS-232C Interface connector, J6, is a 9 pin "D" type DB9F connector socket. The pin-out specifications are contained in Table 1-1. The mating connector is a DB9M.
Table 1-1.
J6, COM1 connector Pin-Out
Pin # RS-232C RS-485 4-Wire RS-485 2-Wire
1 no connect GND; Ground GND; Ground
2 TD; Transmit Data no connect no connect
3 RD; Receive Data no connect no connect
4 no connect +TX; Signal +RX/TX; Signal
5 GND; Ground -TX; Signal
Complement
6 DSR; Unit Ready -
no connect no connect
always high.
7 RTS; Request to
no connect no connect Send. Looped to CTS
8 CTS; Clear to
+RX; Signal +RX/TX; Signal Send
9 no connect -RX; Signal
Complement
-RX/TX; Signal Complement
-RX/TX; Signal Complement
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XPA200-7984-I-OPT1, X-Band SSPA Introduction
1.11.2 Customer Discrete Control, Connector J4
The Customer Discrete Control connector, J4, is a 19 pin circular connector, type MS3112E14-19S. The pin-out specifications is contained in Table 1-2. The mating connector is a MS3116F14-19P.
Table 1-2.
J4, Customer Discrete Control Connector Pin-Out
Pin Signal Name Description
A External Mute
Cmd
B External Mute
External Mute Command. TTL input “high” mutes the unit.
External Mute Common.
Common
G Local Online
Local Online Status Common.
Common
H Local Online
Tied to pin G when Online, else open.
NO
N Summary Fault
Summary Fault Status Common.
Common
P Summary fault
Open when Faulted, else tied to Pin N.
NO
Note: All other pins are unused.
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XPA200-7984-I-OPT1, X-Band SSPA Introduction
1.11.3 Combiner Interface, Connector J5
The Redundant Loop interface connector, J5, is a 19 pin circular connector, type MS3112E14-19S. The pin-out specifications is contained in Table 1-3 The mating connector is a MS3116F14-19P.
Table 1-3.
J5, Combiner Interface Connector Pin-Out
Pin # Description Pin # Description
A Inhibit Command L not used
B VPC A+B->Antenna M not used
C not used N not used
D not used P not used
E VPC Output Common R not used
F VPC A(B)->Antenna S Local SumFlt Common
G not used T Local SumFlt NO
H Inhibit Common U not used
J not used V not used
K not used
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XPA200-7984-I-OPT1, X-Band SSPA Introduction
1.11.4 AC Prime Power Input Connector, J3
The AC prime power input connector, J3, is a 3 pin circular connector, type CA3102E20-19PB FMLB A. The ground connector, pin A, is of the first make, last break type. The pin-out specifications are contained in Table 1-4. A mating connector of type CA3106E20-19SB is included for the customer.
Table 1-4.
J3, AC Prime Power Input Connector
Pin # Description
A Ground
B Neutral
C Line
1.12 Prime Power Switch
The on/off prime power switch is located on the rear of the chassis adjacent to the prime power input connector. The circuit breaker is rated for 40 Amps.
XPA200-7984-I-OPT1, REV.3 1-11
XPA200-7984-I-OPT1, X-Band SSPA Installation
Section 2
Installation/Operation with
Mitec 2723B
Variable Phase Combiner and
Redundant Switching System
2.1 Unpacking and Inspection
This section is intended to give a brief explanation on how to setup and operate two Comtech XPA200 SSPAs with the Mitec 2723B Variable Phase Combiner and Redundant Switching System. More detailed explanations on operation of the SSPA are contained in later sections of this manual. More detailed operating instructions for the Mitec Combiner and redundant switching system can be found in it’s associated manual.
Inspect the shipping container for damage. The shipping container and packing materials should be retained for possible re­shipment. Check to determine that all parts, materials and documentation have been shipped with the SSPA. The SSPA should be inspected for possible damage, and then tested for proper operation.
If the shipment is incomplete, or there is mechanical damage, or the SSPA does not operate properly, notify the COMTECH Customer Service representative immediately. If there is damage to the shipping container, notify the carrier, and retain all shipping materials for inspection by the carrier.
2.2 Rack Mount Installation
2.2.1 XPA200 Installation
The XPA200-7984-I X-Band SSPA is designed for installation to mount in a standard 19 inch rack cabinet or enclosure. The SSPA chassis requires 12.25 (7RU) inches of panel height space.
Adequate air ventilation should be provided to the rack mounted equipment. Cool air is taken in through the front panel and
XPA200-7984-I-OPT1, Rev.2 2-1
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