351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Instruction and Maintenance Manual COM5000-8 HF-SSB 5-kW Linear Power Amplifier THIS DOCUMENT CONTAINS DATA WHICH IS PROPRIETARY TO, OR A TRADE SECRET OF, CUBIC DEFENSE APPLICATIONS, INC. THIS DOCUMENT AND THE DATA CONTAINED THEREIN SHALL NOT BE USED, DUPLICATED, DISCLOSED OR ALTERED WITHOUT THE EXPRESS WRITTEN CONSENT OF CUBIC DEFENSE APPLICATIONS, INC.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Instruction and Maintenance Manual COM5000-8 HF-SSB 5-kW Linear Power Amplifier THIS DOCUMENT CONTAINS DATA WHICH IS PROPRIETARY TO, OR A TRADE SECRET OF, CUBIC DEFENSE APPLICATIONS, INC. THIS DOCUMENT AND THE DATA CONTAINED THEREIN SHALL NOT BE USED, DUPLICATED, DISCLOSED OR ALTERED WITHOUT THE EXPRESS WRITTEN CONSENT OF CUBIC DEFENSE APPLICATIONS, INC.
51804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Revisions/Updates REV Date 100 1/30/15 Description Initial release. Approval E.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL TABLE OF CONTENTS Section Description ...............................................................................................................................Page GENERAL ................................................................................................................................................. v CONFIGURATION .........................................................................................................................
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 5.4 5.4.1 5.4.1.1 5.4.1.2 5.4.1.3 5.4.1.4 5.4.1.6 5.4.1.7 5.4.2 5.4.3 5.4.3.1 5.4.3.2 5.4.3.3 5.4.4 MODULE AND SUBASSEMBLY MAINTENANCE ............................................................... 31 PA Module Maintenance ....................................................................................................... 32 Harmonic Filter Assembly Maintenance................................................................................
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351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL GENERAL This manual describes the 5 kW Linear Power Amplifier that is part of a 5 kW Transmitter. The 5 kW Transmitter comprises the COM5000-8 power amplifier with the T-4180 Exciter as pictured above. This manual provides a basic description of Transmitter operation. For detailed operation of the Exciter, refer to the T-4180 manual. CONFIGURATION The 5-kW Transmitter (351800-1) comprises the following modules: System Controller module 1638-1000-12 1.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 5-kW TRANSMITTER PERFORMANCE SPECIFICATIONS (*) Frequency Range: 2 to 30 MHz Power Output: Nominal 5000 watts average and PEP RF Input Power: + 21 dBm nominal (from T-4180 Exciter) Gain Flatness: +/-0.5dB over 2.0 to 30 MHz (4455 - 5610 watts) with T-4180 Exciter Intermodulation: Two-tone 3rd order IM products 32dB below PEP (26dB below each tone) or better.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL SCOPE OF MANUAL This Manual is intended for use by experienced technicians familiar with similar equipment. The information it contains is current as of the printing date. Subsequent engineering changes are described in supplementary Instruction Manual Revisions issued as needed. The applicable schematic diagram is updated and the changes are described in a revision column on the diagram.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL In addition, do not operate this equipment near electrical blasting caps or in an explosive atmosphere. All equipment must be properly grounded according to installation instructions for safe operation. Compressed air used for cleaning purposes shall not exceed 30 psi (207 kPa) and then shall be used only when goggles or face shields are used for personnel eye protection. CAUTION This equipment contains electrostatic discharge sensitive (ESDS) devices.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL CHAPTER 1 DESCRIPTION 1. INTRODUCTION 1.1 GENERAL The COM5000-8 transmitter is comprised of four 1.25kW PA Modules, a 3-phase power supply module, a 4-Way Combiner module, a System Controller module and a T-4180 exciter module. The modules are enclosed in a standard 19” rack cabinet. The COM5000-8 is capable of delivering a nominal output power of 5000 watts over the frequency range of 2 to 30 MHz. 1.2 FEATURES a) Continuous duty cycle voice operation.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL CHAPTER 2 INSTALLATION 2.1 GENERAL 2.1.1 Government Regulations Ensure that the use of the 5-kW Transmitter satisfies government regulation. In most countries, radio transmitters may be adjusted only by persons holding a suitable government license or by personnel working under their immediate supervision.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 2.1.4 Rack Cabinet Installation Install the Transmitter by first installing the rack cabinet in its intended location. It may be necessary first to remove modules from the rack cabinet in order to reduce cabinet weight or to fasten the cabinet to the floor. 2.1.4.1 Module Removal WARNING: The rack cabinet must be stable while removing modules.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 2.1.4.2 Rack Cabinet Mounting Prior to installation of the rack cabinet, the location must be prepared to accept mounting bolts in the locations shown in figure 2.1.4.2A. All external cables are routed through the large cable entry brush strip opening at the lower rear of the cabinet. To access the bolt-down brackets, remove the 3 floor plates near the bottom inside of the cabinet.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 21.9 31.6 Pivot radius = 2.75 Slot size = 1.2 x 0.4 Typical Bolt Hole Pattern 28.7 24 Bolt-down brackets can be rotated 360° 0 All dimensions are in inches Figure 2.1.4.2A. Rack Cabinet Mounting Hole Locations 5 23.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 2.25” (5.7cm) Lifting Eyes (4X) Blank Panel (2U) 4-Way Combiner Module (3U) System Controller Module (3U) T-4180 Exciter Module (3U) 1.25 kW PA Module #1 (6U) 1.25 kW PA Module #2 (6U) 83.1” (211cm) 1.25 kW PA Module #3 (6U) 1.25 kW PA Module #4 (6U) Power Supply Module (7U) 23.7” (60.2cm) Figure 2.1.4.2B.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 2.1.4.3 Reconnecting Cables To Modules The connections are shown on the Transmitter Interconnect Wiring Diagram in schematic form (see figure 5.1). Cables are secured to cable retractors and are ready to be connected to modules except for the following large coax cables: a. PA Module RF output coax cables (qty.4) are connected between the PA modules and the Combiner module. b. Combiner output coax is connected between the Combiner and the Antenna connector.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 2.1.4.3.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 2.1.4.3.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 2.1.4.4 External Connections to the Transmitter All connections are routed through the cable entry brush strip located below the rear door. AC LINE Input Connection The External AC Line power cable connects to the terminal block inside a junction box at the bottom inside floor of the cabinet. The recommended minimum wire size is #6 AWG (16mm2). The terminals will accept up to #4 AWG (25mm2) wire.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL CHAPTER 3 OPERATION 3.1. INTRODUCTION This section describes the controls and indicators available to the operator. Basic operation of the Power Amplifier is also described. For a description of the exciter controls and display refer to the T-4180 manual. 3.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Figure 3.2.1.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 3.2.2 PA Module Figure 3.2.2 shows the PA Module front panel. The indicators are described below: Indicator Function POWER LED, (green) When lit, indicates that bias is enabled in the PA module. FAULT LED, (red) When lit continuously, indicates a fault in the PA module. 3.2.3 System Controller Module Figure 3.2.3 shows the System Controller Module front panel.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Figure 3.2.2.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Figure 3.2.3.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 3.2.4 T-4180 Exciter Module Refer to T-4180 manual. 3.3 TRANSMITTER SYSTEM OPERATION 3.3.1 General The COM5000-8 power amplifier can be considered an "extension" of its model T-4180 exciter. Transmitter operation is described in the T-4180 Manual.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL STDBY mode: The Transmitter enters STDBY mode if the System Controller, the T-4180 and the 50VDC Power Supply module is turned ON. Serial data communication must also have been established between the T-4180 and the System Controller to enter STDBY mode. The transmitter remains in STDBY mode under certain fault conditions.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL In addition to the System Controller and PA module LED display, the T-4180 Status display will show operational parameters and specific fault conditions. The first of two T-4180 status screens is evoked as follows: From the T-4180 default screen press [NEXT] On the new screen press [PASTAT] The first of two status screen appears T-4180 Status screen #1: FREQ: 29.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Fault definition: PX A 0 0 0 Bit 0 Bit 1 Bit 2 Bit 3 350W AMP 1A 350W AMP 1B 350W AMP 2A 350W AMP 2B Bit 0 Bit 1 Bit 2 Bit 3 Critical Supply Temperature Filter Bit 0 Bit 1 Bit 2 Bit 3 NA FAN Driver VSWR 350W AMP 1A 350W AMP 1B 350W AMP 2A 350W AMP 2B 1.25 kW PA module front view.
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351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL LED FAULT DISPLAY 1.25kW PA Module: 1. PA Module Temperature Fault: A temperature (TEMP) fault is declared when the 350W AMP heatsink temperature exceeds approximately 100°C. The transmitter response is to disable bias from the affected 350W AMP and reduce system power output as needed to continue operation. With a temperature fault in a PA module, the System Controller and PA module LED display is as shown below. 1.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 3. PA Module Harmonic Filter Fault: a. Filter relay faults are declared whenever the selected filter relay pair current is above or below specific hardware set limit. b. The loss of RF signal through the filter selected also results in a filter fault. The Transmitter response is to disabled bias from the affected PA Module and reduce system power output as needed to continue operation.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL The LED display will only show that a PA module has faulted. The specific fault condition is indicated on the T-4180 Module Status screen #2. When the fault condition disappears, the fault LED’s will turn OFF on the next key – or in case of a critical fault – the power has been turned OFF and ON again. Power Supply Module: The 50VDC supply voltage is monitored by the microprocessor in the System Controller module.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL When the FAN fault condition disappears, the AIR FLOW fault LED will turn OFF on the next key. It takes approximately 10 seconds of transmission for this fault to be cleared. (Note: Momentary flashing of a fault LED does not indicate a fault. The LED must be on continuously to indicate a fault.) When the Temperature fault condition disappears, the TEMP fault LED will turn OFF. Combiner faults are also indicated on the T-4180 Module Status screen #1.
1804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL CHAPTER 4 FUNCTIONAL DESCRIPTION 4.1 INTRODUCTION This chapter starts with a functional description of the COM5000-8 power amplifier followed by a description of the individual modules comprising it. These modules are: 1.25kW PA Module (4 each) Combiner Module System Controller Module Power Supply Module 4.2 COM5000-8 SYSTEM A block diagram of the COM5000-8 Amplifier System is shown in figure 4.2.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL PA module #1 PA module #2 Combiner Module PA module #3 Antenna PA module #4 RF #1 RF #2 RF #3 RF #4 PA Control I/O Driver/Splitter/ALC PCB assembly VF VR Controller PCB assembly System Controller module RF Exciter Control I/O Supply monitor/control T-4180 Exciter System Control I/O’s 50VDC Figure 4.2.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 350W AMP 350W AMP 350W AMP 350W AMP Figure 4.3. 1.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 4.4 COMBINER MODULE The Combiner module receives signals from the four 1.25kW PA modules and combines the signals, in-phase, to yield the 5kW output signal. The output signal is routed through a VSWR Detector (located inside the combiner module) to provide forward and reflected power information for the System Controller. 4.5 SYSTEM CONTROLLER MODULE A block diagram of the System Controller module is shown in figure 4.5.
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351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 4.6 POWER SUPPLY MODULE The Power Supply consists of 3 invertors with the AC inputs and DC outputs connected in parallel. Each invertor is rated for 5 kW (50 VDC at 100 A). Total output power of the Power Supply is 15 kW (50 VDC at 300 A). The 3-phase AC input is applied to the invertors through a 3-pole circuit breaker mounted on the front panel. This circuit breaker also serves as the AC power switch.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL CHAPTER 5 MAINTENANCE 5.1 INTRODUCTION The maintenance chapter contains a list of recommended test equipment, and instructions for mechanical disassembly, for verifying the performance of the amplifier, for routine adjustments, and for aligning the Transmitter. For maintenance refer to the Transmitter Interconnect Wiring diagram 351803, figure 5.1. 5.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 5.4.1 PA Module Maintenance For 1.25kW PA Module maintenance refer to the PA Module Interconnect wiring diagram shown in figure 5.4.1. The 1.25kW PA Module comprises the following assemblies: 1 ea. 2 ea. 1 ea. 1 ea. 1 ea. 1 ea. 2 ea. PA/Driver/Splitter (heatsink) PA (heatsink) PA/Combiner (heatsink) Harmonic Filter PA Controller PCB Fan Interface plate assembly 1.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Figure 5.4.1A. 1.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 351293-1 FAN FAN 351293-1 1.25 kW COMBINER 351285-1 350W Amp #1A L163209-1 PA CONTROLLER 350W Amp # 1B 351280-1 FAN INTERFACE 351289-1 FRONT TOP VIEW Figure 5.4.1B. 1.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 350W Amp #2B 350W Amp #2A 351275-1 DRIVER/SPLITTER Line Flattener FRONT BOTTOM VIEW Figure 5.4.1C. 1.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 5.4.1.1 Harmonic Filter Assembly Maintenance See figure 5.4.1A To gain access to the Harmonic Filter PCB assembly, loosen the six captive screws that secure the filter assembly cover to remove the cover. CAUTION: RF HAZARD ALIGNMENT OF THE HARMONIC FILTER VSWR DETECTER CAUSES EXPOSURE TO RF Adjustments: The following adjustments should only be performed when a PCB assembly has been repaired in the field. All PCB's are factory aligned prior to shipment.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 5.4.1.2 350 W Amp Assembly Maintenance To gain access to the bottom two 350 W Amp's remove the bottom cover. To gain access to the top two 350 W Amp's proceed as follows: 1. Loosen the two "captive" screws that secure the Filter assembly to the 1.25kW PA Module front panel. 2. Carefully move the filter module up to past its vertical position and make sure that it "leans back" onto its back stops. 3. For location of the 350 W Amp's see figure 5.4.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 5.4.1.3 PA Controller PCB Assembly Maintenance To gain access to the PA Controller PCB, proceed as follows: 1. Loosen the two "captive" screws that secure the Filter assembly to the 1.25kW PA Module front panel. 2. Carefully move the filter module up to past its vertical position and make sure that it "leans back" onto its back stops. 3. For location of the PA Controller PCB see figure 5.4.1B.
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351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 50 Ohm Load “T” connector (direct at Wattmeter) 1.25kW PA Module RF OUTPUT Wattmeter Connector 50 Ohm Load h) Starting with a low RF output level from the RF Signal Generator increase the generator level until the forward power reading is 500W. i) Measure the voltage on U20-1 (VF). Adjust VR5 so the voltage measured on U20-7 is equal to the voltage at U20-1. j) Measure the voltage on U20 pin 7.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 5.4.1.4 Driver/Splitter Maintenance To gain access to the Driver/Splitter, remove the 1.25kW PA Module bottom cover. The location of the Driver/Splitter is shown in figure 5.4.1C. Adjustments: The following adjustments should only be performed when a PCB assembly has been repaired in the field. All PCB's are factory aligned prior to shipment.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Driver Gain adjustment (1.25kW PA Module gain): The DRIVER/ALC gain adjustment, using potentiometer R2, is performed to set the 1.25kW PA Module gain equal to approximately 47 dB at 29.9 MHz. a) Operate the PA Module as a “stand alone” Amplifier – while still part of the Transmitter - as described in section 5.4.1 above. b) Turn ON the System. Select a T-4180 operating frequency of 29.9 MHz. c) Set the RF Signal Generator output level to +12 dBm.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 5.4.2 Combiner Module Maintenance Adjustments: See System Controller operational adjustment in section 5.4.3.3. 5.4.3 System Controller Module Maintenance For System Controller maintenance, refer to the System Controller Interconnect wiring diagram shown in Figure 5.4.3. The System Controller module comprises the following assemblies: 1 ea. Driver/Splitter/ALC PCB 1 ea. System Controller PCB 1 ea. Power Supply Assy. 1 ea.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 21000044 Fan 1638-2001-1 1638-2000-1 System Controller Driver/Splitter/ ALC L162087 Power Supply Front Figure 5.4.3A: SYSTEM CONTROLLER TOP VIEW 5.4.3.1 Driver/Splitter/ALC PCB Maintenance To gain access to the Driver/Splitter/ALC PCB proceed as follows: 1. Remove the 4 retaining screws that secure the System Controller module to the rack cabinet. Pull the module slowly out all the way. 2.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL c) Adjust VR1 for 1.0 VDC measured on U13 pin 8 on the Driver/Splitter/ALC PCB. This sets the normal input drive level to the microprocessor. If more than 22 dBm is applied to the RF input connector of the System Controller, the overdrive protection will engage. d) 5.4.3.2 Adjust VR2 for 0.55 VDC measured on U13 pin 14 on the Driver/Splitter/ALC PCB. System Controller PCB Maintenance To gain access to the System Controller PCB proceed as follows: 1.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Measure resistance between: Verify values: U29 pin 3 and GND U29 pin 5 and GND U30 pin 1 and 2 U30 pin 6 and 7 U41 pin 1 and 2 U41 pin 6 and 7 U41 pin 10 and GND U41 pin 12 and GND 2.2 – 2.4 K ohm 2.2 – 2.4 K ohm 2.6 – 2.8 K ohm 1.7 – 1.9 K ohm 1.6 – 1.8 K ohm 1.6 – 1.8 K ohm 4.3 - 4.7 K ohm 1.5 – 1.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 5 kW Transmitter T-4180 Exciter Audio (J6) PA Control (J5) Output (J3) DVM Variable Attenuator RF Signal Generator Exciter Interface (J3) RF INPUT (J5) System Controller module RF OUTPUT ≤12”coax Directional Coupler J4 50 Ohm Termination COM5000-8 RFIN J3 208 VAC Wattmeter Sensor 50 Ohm, 4 kW Load/ Attenuator T Spectrum Analyzer 50 Ohm Load, 10 kW Figure 5.4.3.3.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Setting System Controller potentiometers, Forward Power a. Set up per figure 5.4.3.3. Command the Transmitter to operate on a frequency of 15 MHz, CW mode. Set the variable attenuator for maximum attenuation. Key the Transmitter. b. Using the variable attenuator, slowly increase the power. Observe the Transmitter power output level on the wattmeter. Increase the power output to 4000W.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Setting System Controller potentiometers, output power (ALC level) adjustment: a. With a CW power output of 5000W, adjust the System Controller PCB potentiometer VR2 clockwise until the power drops to 4750W. Un-key the system. b. Change the T-4180 mode to ISB. Select “TONE” as modulation source with a modulation frequency of 500 Hz. c. Key the system. While observing the PEP output power, readjust VR2 to obtain 5000W of PEP output power. Un-key the system.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Transmitter J3 ≤ 5 feet coax Directional Coupler J4 Wattmeter 4381 50 Ohm, 4 kW Load/ Attenuator w. Blower 8929-300 T 50 Ohm Load, 10 kW Bird 8931 d. Key the system and observe the Wattmeter reading. The forward power should be close to 2000W and the reflected power close to 200W. By varying the RF drive level with the variable attenuator, adjust the reflected power read on the Watt-Meter for 200W - the forward power reading should be close to 2000W.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL f. Observe the forward power reading on the wattmeter. Adjust VR5 clockwise until the power drops to 1750W - or if no power reduction is observed - adjust VR5 fully clockwise. g. While observing that the power output remains below 2750W, reduce the attenuation on the Variable Attenuator in small increments until the attenuation is zero. It may be necessary to readjust VR5 to keep the power output below 3500W.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 5.5 SPARE MODULES AND ASSEMBLIES Spare Modules: Description QTY Per COM5000-8 PART NUMBER System Controller 1 1638-1000-12 1.25 kW Power Amplifier 4 351270-2 Power Supply 1 351830-2 Output Combiner 1 L163145-1 T-4180 Exciter 1 1644-1000-4 Spare Assemblies: Description QTY Per COM5000-8 PART NUMBER Part of PA/Driver heatsink assembly 4 351275-1 1.25kW PA Module PA heatsink assembly 8 351280-1 1.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Figure 5.1.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Figure 5.4.1.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Figure 5.4.3.
351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Figure 5.4.4.