Cubic Communications CTX-5000 CTX-5000 (5 KW) SOLID STATE TRANSMITTER User Manual CTX 5000

Cubic Communications Inc CTX-5000 (5 KW) SOLID STATE TRANSMITTER CTX 5000

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CTX 5000

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TECHNICAL MANUAL
CTX-5000 SYSTEM MANUAL
CTX-5000 (5 KW)
SOLID STATE TRANSMITTER
Cubic Communications, Inc.
9535 Waples Street
San Diego, California 9212I-2953
Telephone: (619) mssoo TeleIax: (619) msaoe
Manual Part No. 224546201
ISSUE 2.0 12 February 1999
QCUBIC-CDMMUNICATIONS CTX-5000 SYSTEM MANUAL
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RECORD OF CHANGES
CHANGE DATE TITLE OF BRIEF DESCRIPTIONS ENTERED BY
2/12/99 Update foldouts and figures to include AC line filter, pet DCR
#727825 .
QCUBIGCDMMUNICATIQNB CTX-5000 SYSTEM MANUAL
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FOREWORD
SCOPE
This manual contains information for the installer and operator to obtain best performance from the (TX-5000 Solid State
Transmitter. The infomiation includes: a general description, preparation for use and installation instructions, operating
instructions, general theory of operation. maintenance instructions, and preparation for reshipment.
Module level maintenance is not included in this manual. Refer to the individual equipment manuals for specific maintenance
information. Component level maintenance should be performed in the designated maintenance depot or the factory.
WARNING
Do not apply power to the equipment until the installation procedures in Chapter 2 have been successfully completed,
PROPRIETARY DATA
The information in this manual is the property of Cubic Communications Incorporated. Disclosure to a third party, either wholly
or in part. without written consent from Cubic Communications Incorporated is prohibited.
CORRECTION NOTICE
The information in this manual is believed correct at publication date. If a difference is noted between the information in this
manual and the equipment, contact the factory for clarification. Current and future editions will be corrected as necessary,
FCC COMPLIANCE
This device complies with FCC Pan [SB and 87, EMC Testing.
RIGHTS RESERVED
Cubic Communications Incorporated reserves the right to change the specifications. design, and fabrication methods of
equipment at any time without notice.
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TABLE OF CONTENTS
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1 GENERAL DESCRIPTION ................................................................... 1-1
1-1 INTRODUCTION.
1-2 SYSTEM DESCRIP’I'IO
1-21 PowerSupply
1-242 T4180Exciter .
1-23 Splitter. . . .
1-244 Controller .
1-2.4.l HardwareDe rp n.
1-244] Software Description
1-25 PA-5050A ............
]~2,6 Combiner/Directional Coupler .
1-2.7 Circuit BreakerPonels H
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71.3 EQUIPMENT FURNISl-[EDT
|4 STORAGE DATA ...........
1-5 TOOLS AND TEST EQUTPMENT
1-6 SAFETY PRECAUTTONS .......
z PREPARATION FOR USE AND INSTALLATION INSTRUCTIONS ........................... 2.1
21 INTRODUCTION. . . . 4 2-1
2-2 INSTALLATION 2.1
2-3 CONNECTIONS . . . 2.2
24 INITIAL POWER SUPPLY SETTINGS . . . 2-5
3 OPERATING INSTRUCTIONS ........................................................... 3.1
3.1 INTRODUCTION .. .
3-2 OPERATION . . _
3-2.1 CIX System peralton . .
3-22 Software Upload Procedures 4
3-2,2.1 T4180 Upload Procedure . .
3- 242 Controller Upload Procedure
34.2.3 PA-5050A Upload Procedure .4
3-3 POWER ON APPLICATION & STANDARD OPERATION PROCEDURES A
3-11 Power On Application . . .
3-31 Standard Operation . .
3-4 EMERGENCY OPERATION
3-4TI PA-5050A Failure . . . .
34.2 PA-5050A Module Failure .
3-5 CI'X T4180 EXCITER DIFFERENC
3-5.l Secondary Softkey Difi‘erence: .
3-5.l.1 STORE . . H
12 RECALL.
1.3 PAPOW .
1.4 PAST/IT .
.l.5 PAGAIN . ..
3-52 Remote Operation T
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PARTS LIST ........................................................................... 4-1
I INTRODUCTION .............
»2 REPLACEABLE PARTS LIST . .
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LIST OF ILLUSTRATIONS
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CTX-5000 Front View . . 1-5
CTX—5000 Rear View . . . _ 2.4
CTX T4180 Secondary Soft Key Flow Diagram t . 3-5
CTX 5000 Block Diagram ......... . FP-l
CTX 5000 Interconnect Diagram . . , Fp,2
CTX 5000 Replaceable Parts Locator Diagram ........................ , Fifi—4
LlST OF TABLES
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CTX 5000 Specifications .......................... 1-6
Items Furnished t . . . _ 1.7
Rear Panel Connecu'o . 2-2
Controller Upload Cable . 4 3»2
PA-SOSOA Upload Cable . . . 3-3
PA-SOSOA Failure Output Power ....... , 3.4
CTX T—4180 Exciter Command and Status Messages . . 3-8
CTX-5000 Replaceable Parts List .......................... 4-1
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1-1
CHAPTER 1
GENERAL DESCRIPTION
INTRODUCTION. The CIX-SOOO (5 kW) figure 1~1 is a high powered solid-state HF Transmitter designed to
provide 100% continuous-duty operation. This transmitter is based on field-proven 1 kW Amplifiers combined in a
conservative, no—compromise, high-powered configuration.
Complete coverage of the entire HF frequency spectrum from 2 to 30 MHZ is provided in symthesized 1 Hz steps.
Low level signals are generated by the T4180 Exciter. The Exciter incorporates Digital Signal Processing to derive
all standard operating modes (LSB, 1.5ch, LSch. USB, USch, USch, 1513, AM, FM, FMfax, CW, & FSK.)
This also assures the linearity and spectral purity needed for advanced modes such as Link 11, AN'DVT, ALE.
frequency hopping, high speed data and future waveforms. For more infomtation to the T4180, refer to the
T—4150/80 Technical Manual.
The CTX-SOOO Transmitter can operate locally or remotely. Complete status and control is available from the front
panel and via remote control over RS-232 or RS-422 interfaces. This includes full remote monitoring and diagnosis
of critical functions for each system component including the amplifier modules. Onboard monitoring and control
system provides early detection of faults and adjustments of imbalances to prevent system failure. Individual
defective PA modules can be either automatically or manually taken “offline" with only an incremental reduction in
total output power. Harmonic and spurious radiation have been minimized through the use of high performance
filters in each 1 kW amplifier module. In addition, the T4180 Exciter includes a built—in postselector to reduce
wideband noise generation.
The heart of the CTX»5000 Transmitter is the T4180 HF Exciter which incorporates Digital Signal Processing
(DSP). The DSP technology enables the technician to easily upload new software. This can be done by disk or
remotely in the field via E-Mail.
SYSTEM DESCRIPTION. This section describes the major components that make up the CTX-SOOO System.
1-2.1 Power Supply. There are 2 power supplies used in the CTX-SOOO. Each power supply provides power to three
PA-SOSO power amplifiers. Additionally, the outputs of all power supplies are diode summed to provide power to the
controller and the combiner fans. In the event of a power supply failure, the system is still operational at a reduced
output power level (800 watts maximum).
Each power supply provides 28 volts at up to 330 amps. These are high efficiency switch-mode power supplies which
run off 208 V, 3-phase AC input power (other voltages available). A 3-phase, 80 amp/phase EM] filter conditions
and filters the AC input to the power supplies. The power supplies are fully protected against excessive load current
(including short circuits) and over-temperature conditions. They also incorporate an over-voltage shutdown function
which protects the power amplifiers in the event of a failure in the power supply which causes the output voltage to
rise. Meters are provided on the front panel of each power supply to monitor the output voltage and current. Cooling
is provided by fans built into the power supplies.
1-2.2 T4180 Exciter. The T—4180 is a multi-mode digital signal processing (DSP) exciter with a frequency range
from 2 to 30 MHz. The RF output from 13 of the T—4180 is routed to the Splitter.
The exciter is conu'olled by a 19-button keypad and main adjustment knob used to select the exciter parameters. Five
"soft keys" work in conjunction with the vacuum fluorescent digital display immediately above the soft keys. In
addition to soft key selections, the vacuum fluorescent digital display provides a variety of data including channel,
modulation mode, frequency, bandwidth, gain, local/remote control, an RF level meter, and an AF level meter.
Additional information is displayed depending on soft key selections.
By proper selection of parameters, the exciters can generate a wide variety of signals. These include: on/off keyed
(CW ). amplitude modulation (AM), upper sideband (USB), upper sideband - full carrier (USch), upper sideband -
partial carrier (USch), lower sideband (LSB). lower sideband - full carrier (LSch), lower sideband - partial carrier
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(LSch), independent sideband (ISB) (suppressed carrier and independent), frequency shift keyed (FSK), frequency
modulation (FM). and frequency modulation facsimile (FMfax).
The selected audio input is provided on a 600 ohm balanced line. Normal and alternate (LSB audio when ISB is
selected) audio are simultaneously input on separate 600 ohm balanced lines.
A MIC/KEY jack on the front panel provides for connection of an external microphone or CW key. The audio level
is automatic. The audio is automatically applied to the correct modulator depending on the modulation mode.
However, when ISB modulation is selected, microphone audio is directed to the normal audio channel only.
The exciter may be remotely controlled by any suitable bus controller using either an 1254232 or RS—422 serial
interface bus. As an option. the exciter can be placed in a location different than that of the CTX chassis. If this
option is desired, additional cable lengths and a empty half rack chassis, to replace the current location of the exciter,
will need to be manufactured, see table 1-2.
Refer to the T4150/80 Technical Manual for more details.
l-2.3 Sglitier. The RF signal from the exciter is applied to the Splitter module The Splitter module provides six
equal RF outputs to each of the PA-SOSOA power amplifiers.
l-2.4 Controller. The controller consists of an embedded 80386 processor, a communications interface logic and
signal processing board, DC power supply, indicators and various external connectors. The heart of the controller is
centered around the 80386 processor It has two primary functions: Provide communications between the T4180
exciter and the six PA-SOSOA amplifiers and manage control of the system as a whole.
1»2A.1 Hardware Description The controller's main hardware is the processor and the interface board. the following
paragraphs discuss these components
Processor: The 80386 embedded processor is supported by l megabyte of RAM, a 12 hit, 8-channel AID converter,
two RS-422 serial ports and a 24 bit I/O data and control interface. The processor mns at 20 MHz and supports
Flash Memory for storing executable code. The AID converter is used to sample the system level forward and
reflected output power and temperature sensors in the external system power combiner. The RS-422 serial ports
provide the communications between the T4180 exciter and the controller and between the controller and the six
PA-5050A’s. Software is loaded into flash memory via one of the serial ports when a reset of the processor is
performed and a special upload cable is attached. There are two LED indicators on the processor board. One is a
green power indicator and the other is a red general purpose LED. The red LED can be used under software control.
The processor requires +5 and +/— 12V for normal operation. This is externally provided through a DC-DC
converter.
Interface Board: The interface board is used to condition signals going to and from the T4180 and the six PA-
5050A’s. It also accepts reduced system level RF power and temperature inputs from the external power combiner
These RF input signals are convened to a voltage suitable for output to the AID converter on the processor board
through the use of a log amplifier circuit. The interface board has a DC-DC converter that converts +28V to +5 and
+/- 12V required by the interface board and the processort
RS-422 Serial inputs and outputs are routed through the interface board to the processort The RS-422 serial data
destined for the six PA-SOSOA's originates out of COM2 of the processor and is routed to the designated PA by
control logic on the interface board. This control logic first converts the RS-422 differential levels to standard
5Vlogic levels, routes them through a multiplexer and then converts the 5V logic level back to 125—422 differential
levels. The communication interface between the PA-5050A’s and the processor operates half duplex. The
processor‘s 24-bit l/O interface is used to control the multiplexer and signal direction logic on the interface board.
The system enables two methods of communications to the PA's. Under normal operating conditions, the command
commUnications to each PA is addressed separately. Additionally, a broadcast control line, under software control,
can be used to send commands simultaneously to all PA’sr However, responses can only be received separately.
The transmit key coming from the T4180 is also routed through the interface board to the processor 24-bit1/0 port.
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It supports a SV pull up resistor on the input key line. The processor interprets this key line and provides separate
software controlled key lines back to all the PA‘s through the interface board.
The RF forward and reflected power inputs coming from the system power combiner are representative of the total
system power output, reduced by 60db. These are fed into a log amplifier circuit that converts the RF forward and
reflected power to a DC voltage prior to being routed to the processor AID converter The analog temperatme inputs
coming from the system power combiner are for themtal protection of the combiner. These are routed to the
processor AID converter for sampling,
The interface board accepts +28V from an extemal power source and routes it to the DC-DC converter. The
resulting output of +5V and +/- 12V is used on the interface board and routed to the processor board through an on
board connector.
The interface board also provides outputs for three, front panel mounted, indicator LED lamps. The LED's indicate
— the status of DC power, data communications between the controller and the PA‘s, and a general—purpose error
indicator
There are no manual, externally controlled user interfaces. All status information, with the exception of the front
panel LED‘s, is retrieved through the T4180 PA status screen.
1-2A.2 SoMare Descrign'on A software program specifically designed for this application controls the processor. It
was written using the C programming language and compiled using Boriand" C 4152. The software tasks include, but
are not limited to, serial communication and message processing, system power level management, system status
infomiation retrieval and processing, and progressive system shutdown in the event of a failure. The software
functions are described in the following paragraphs.
The main function is a loop that services the foreground tasks. These include checking for incoming messages from
the T4180, controlling the transmit key line, updating the forward and reflected power readings, updating the
temperature readings, interrogating each PA for status and taking corrective action for any detected errors.
The background routines primarily consist of the interrupt service routines for each communication interface going to
and from the controller, PA's and the T4180 These routines are interrupt driven and notify the foreground routine
only when a serial message has been received. The serial interfaces operate at a speed of 19200 bits per second, with
the line parameters set at 8 data bits, 1 Stop bit and No Parity bit.
The communications between the T4180 and the controller works on a polled basis whereby the controller responds
to commands and replies to queries only when requested by the T4180. This places the T4180 in charge of the
RS422 data line between the T4180 and the controller. It is operated in the half-duplex mode.
The communications between the controller and the six PA-5050’s works on a polled basis. Each PA responds to
commands and replies to queries only when requested by the controller. This places the controller in charge of the
RS422 data line between the controller and the PA~5050A's. It is operated in the half—duplex mode. The controller
to PA serial update rate is set near maximum for the given 19200 bits per second baud rate. This means that the
controller can receive status from each PA approximately twice a second, giving a system level update of one every
500 milliseconds.
1»2.5 Fifi-5050.4. There are six PA-SOSOA linear power amplifiers Each is a solid state unit that provides 1 kilowatt,
reduced to approximately 900W. power amplification of RF signals between 2 and 30 MHZ. The unit contains 4
independent power amplifier (PA) modules. If one or more of the PA modules fail, the CTX system will still operate
with reduced power out.
The front panel contains a PWR LED with each PA module containing an individual PWR and FLT LED, and a
multifunction display. input power to the PA-5050A is derived from a separate +28V DC power supply providing
five separate +28V DC outputs Four independent modular PA modules provide the four stages of amplification.
Each PA module is identical and interchangeable When an individual PA module‘s gain is less than +10 dB, the
circuitry turns on the FLT LED, The individual module can then be removed and replaced.
The rear panel contains connectors for the transmitter/exciter low power RF input. high power RF output to the
Combiner/Directional Coupler RF input, DC power input and serial interface.
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Sixteen internal fans per PA-SOSOA provide cooling across the heatsinks of the unit.
Refer to the PA-5050A Technical Manual for more detailed information
l-2.6 Combiner/Directional Coupler. The six PA-SOSO outputs are applied to the six inputs of the combiner. The six
inputs are combined to produce the 5 kW final output. The combiner has a maximum insertion loss of 0.35 dB.
therefore, the maximum required input power for 5 kW out is approximately 5.4 kW or 900 watts per input.
To protect the combiner from excessive power dissipation (due to mismatched inputs or a high VSWR load), three
thermistors are located at various points within the combiner to sense the temperature. These themlistors are
monitored by the controller and if an excessive temperature is detected, the input power to the combiner is reduced to
protect the combiner from damage.
The output of the combiner is applied to a dual directional coupler. The coupler provides two RF outputs that are
proportional to forward and reflected power. The coupling ratio is 60 dB. The forward output is used by the
controller to monitor the output power during the power setting process. The reflected output is used by the controller
to sense the presence of a high VSWR load so that the controller can reduce the power into the combiner and protect
it from damage. The measured forward and reflected output power values are also sent by the controller to the
T4180 where they are displayed in the PASTAT screen.
1-2.7 Circuit Breaker Panels Two circuit breaker panels, each containing three sets of five circuit breakers are used
to protect the internal modules and components of each PA-SOSOA. Circuit breakers 1—4 are 30 amp breakers that
protect modules 1-4 in each PA-SOSOA. The 5m circuit breaker is a 10 amp Auxiliary circuit breaker used to protect
the auxiliary internal components of the PA»5050A. The Control 10 amp circuit breaker, located on the far right of
the circuit breaker panel protects the Combiner and the two fans located in the Combiner/Directional Coupler.
1-3 EQUIPMENT FURNISHED. Table 1-2 lists the items furnished with the system
1-4 STORAGE DATA. Refer to the T-4180/50 and PA»5050A Technical Manuals for individual equipment storage
data. The CTX system should be stored indoors. the humidity should be no greater than 95% (storage & operation) with a
storage temperature range of -40° to +55“ C, (0° to 50° C operating.)
1-5 TOOLS AND TEST EQUIPMENT. Refer to the specific manuals for the T4180 Exciter and PA-5050A
Power Supply. There are no special tools or test equipment required.
1-6 SAFETY PRECAUTlONS. Safety precautions are presented in this manual preceded by the word
WARNING or CAUTION just before the point where the hazard is likely to be encountered. Warnings and cautions
are defined as follows:
Refers to a procedure or practice that, if not correctly followed,
could result in injury. death. or long term health hazard.
Refers to a procedure or practice that, if not correctly followed,
could result in damage to, or destruction of equipment.
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PS1 p52
BLANK PANEL
COMBINER EXCITER AND
AND CONTROLLER
DIRECTIONAL
COUPLER
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BREAKERS
PM PA4
pAz PAS
PA3 PAS
LEFT SIDE R‘GHT SEDE
FRONT V‘EW
Figure 1-1 CTX 5000 Front View
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OGUBIQCQMMUNICATIDNB CTX 5000 SYSTEM MANUAL
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Table 1-1 CTX-5000 s- clflcatlons.
Speclticatlon
ELECTRICAL
REQUIREMENTS
Frequency Range 2 - 300 MHz
Power Output 5 kW 2 1 dB PEP and average. Rated for 100% continuous duty Adjustable
from 0 lo 60 dB in 1 dB steps“
Intermodulation Distortion <30 dB below PEP Ci"1 order) ‘
Band 1: 2,313.34 Band 5: 1040-1442
Filter Bands (in MHZ) Band 0: 2.02.31 Band 4: 6494—1040
Band 2: 3344.81 Band 6: 1442-2048
Band 3: 4.81-694 Band 7: 208-300
Output VSWR Full power output up to 2:1. Gradual power shutdown above 500W reflected
power. Protected from short and open circuits.
man-wean —
Input Voltage 190-250 VAC. three phase with a maximum of 65 amps/phase, 47-63 Hz, 24 kVA,
Ratio of real power to apparent power (power factor) is 09
GENERAL _
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Spurious -60 dBc within 20 kHz, otherwise -80 dBc or better
Thermal Monitoring Temperature sensing is provided in all PA modules, the power supplies, and the
combiner to protect the system components from excessive temperature rise
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Table 1-1 CTX—5000 S ' officer/ans.
Specmcatlon
INTERFACE
CONNECTORS On Chassis Mates With
5/16" Threaded studs (Located on AC line filter)
CTX-SOOO: 525“ high x 45.5" Wide x 30.75" deep (One double Wide 19" rack)
CTX«5000: Approximately 900 lbs 7 7
s 1 a
El
Table 1-2 Items Fumlshed.
Part No.
2245-1101-1
Nomenclature
Circuit Breaker Panel (Left side)
Circuit Breaker Panel (Right side)
2245-1101-2
118097
118»
2245-1101-1
2«way Combiner/Directional Coupler
2-way Combiner/Directional Coupler
Controller, 5 KW
Controller, 10 KW
IIIIIIl
2245-1101-2
‘ 2600-1000—1 Half Rack Chassis, Empty (Optimal, used only ilT-4l 80 is located in
' m an lvmy from the on chassis.)
2241-1000—X Power Amplifier; PA-SOSOA
275-014 Power Supply: 28V 330 Amp
1 18-098
1 18-XXX
2245-1020]
2607- l 0004 0
2241-102 I~3
6-way Splitter
12-way Splitter
CTX-SOOO System Manual
T4180 MF—HF Transmitter/Exciter, 20-100 milliwatts PEP
Technical Manual. Operation and Maintenance Instructions,
POWER AMPLIFIER, PA-SOSOA (FCC Version)
2607—1021-1 Technical Manual, Operation and Maintenance Instructions.
EXCITER, DIGITAL SIGNAL PROCESSING SINGLE
MF—HF T—41 50/80
Antenna system and attaching cables
(Required but not supplied)
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CHAPTER 2
PREPARATION FOR USE AND INSTALLATION INSTRUCTIONS
2-1 INTRODUCTION. This chapter contains inspection, installation, connections, and initial alignment
procedures for the PA-SOSOA.
2-2 INSTALLATION. The crx-sooo hardware is designed as a rack cabinet mounted system. it should
be operated in a relatively dust free environment with an ambient temperature range between 0 and
+50°C.
ll Pro-drill anchor bolt holes into the floor/deck where the CTX—5000 is to be placed.
’ NOTE
This is an optional procedure. Anchoring is mandatory only if the
CTX cabinet is to be located in an unstable platform. There are a
maximum of 16 anchor bolt holes (eight/cabinet) that can be used for
anchoring the CTX cabinet to the floor/deck, Two anchor bolt holes
are located in each comer of a cabinet,
2. Secure the eight eye-bolts to the top of the cabinet if not already installed.
3. Align the from four eye-bolts so that a pipe or metal bar can be slid through the eyelets. Align the four
rear eye~bolts in the same manner.
4. Slide a strong pipe or metal bar through the front and rear set of eyelets.
Insure the pipe or metal bar is capable of handling the weight of the
cabinet. The material used should be either capped on each end or be
long enough so as not to allow the cabinet to slide off.
5. Using a forklift or other similar device, lift the cabinet and move in place, As an option, rollers can be
placed under the cabinet for movement.
When lifting the cabinet, use all eight eye-bolts to distribute the load
evenly throughout the cabinet. Failure to use all eight eye-bolts may
stress the cabinet beyond its limitations.
6. Attach power cable (not supplied) to the AC line filter. located in the bottom of the cabinet.
Severe injury or DEATH can result if bodily contact is made with an
ungrounded chassis should high leakage current or a short-circuit
condition occur, Insure the system is grounded
7. Secure the CTX~5000 to the floor using anchor bolts (not supplied.)
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2-3 CONNECT|0NS. Refer to the Interconnect Diagram F0-3, for cable connections. Figure 2-1 shows the
CTX 5000 system rear view Table 2-1 provides a brief description of the rear panel connections on each major
piece of hardware that makes up the CTX-SOOO.
stI -1 Hear Panel Connectlans.
Matin : T - - Descri -tion
T4180 Refer to the T-4150/80 Technical Manual
Controller
9-D Sub (F) Control interface to T-4180, Serial Data
T4180 CTRL
PAl - FAG CTRL
9»D Sub (M)
9»D Sub (M)
' 28V POWER AMP 2060614 AMP 206060—1
(320-411) (320—413)
9-D Sub (M)
9-D Sub (5 Control interface to PA-SOSOA, Serial Data
+28VDC & GND. 1 amp maximum.
* COMBINER Themiiswr sense lines & fan power
9-D Sub (F)
BNC (F) BNC (M) Forward RF sense in from directional coupler
REV RF BNc (F) ENC (M) Reverse RF sense in from directional coupler
COM BNC (F) BNC (M) RF in from 114180 exciter output
RF [0 PA-SOSOA RF inputs
BNC (F) BNC (M)
PA-5050A Refer to the PA-SOSOA Technical Manual
Power Supply
3/3" Hole (2) 3/3" Bun/Lug (2) Negative output of zsv power supply
(J 1) 25-0 Sub (F) 25-D Sub (M) Current monitor lines to controller
w OUT 3/3" Hole (2) 3/8" Boll/Lug Positive output onSV power supply
AC lN 1/4" Studs (4) 1/4" Lugs (4) AC Power from AC line filter
AC Llne Filter
'<
Line 5/16" Studs (4) 5/16" Lugs (4) AC Power in, 190 ~ 250 VAC. 47 - 63 HZ, 3 Phase
Load 5/16" Studs (4) 5/16” Lugs (A) AC Power to power supplies
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Table 2-1 Rear Panel Connections.
Type Mating Type Descrlptlon
can-Mm _
RF lN (J 1 - 16) Type N (F) Type N (M) RF Input, Appmximaiely 900 Walls
RF OUT (37) LC (B LC (M) RF Output 5000 watts, 2-30 MHz 5
FWD (18) BNC (F) BNC (M) RF signal at -60 dB Relative Io Forward Power
REV (19) BNC (F) BNC (M) RF signal a! -60 dB Relative to Reflecled Power
FAN POWER 8: 9-D Sub (M) 9-D Sub (M) +28 VDC for combiner fans and lhermislor sense lines.
THERMISTORS
(110) 7, ; ,,,,,— 7 ”—
lssue 2.0 2-3
OCUBIGGOMMUNICATIDNS
Amummmwwum
FREQUENCY REF |N-\
/ RF OUTPUT
P52
EXCITER _.‘>
CONTROLLER
PA4
PAS
PAS
AC INPUTS
Issue 2.0
RIGHT SLDE
Larr SIDE
REAR VIEW
Figure 2-1 crx-saaa Rear View
CTX-SOOO SYSTEM MANUAL
P51
COMBINER
AND
DtRECTIONAl
COUPLER
PM
PAZ
PA)
2-4
GCUBIG COMMUNICATIONS CTX-SOOO SYSTEM MANUAL
Amwumwmum
2-4 INlTlAL POWER SUPPLY SETTlNGS. The power supply voltage and current output settings are factory
set and should not be changed. However, if the power supply setting should differ than the factory setting, use the below
procedures to reset the power supply to the initial factory setting.
It Set Voltage to 28 Volts
- Loosen nut on the Output Voltage Control
- Adjust the potentiometer CW or CCW until 28 Volt readout is obtained on the meter
- Tighten nut
2. Set Current to 330 amps
- Loosen nut on the Output Current Control
- Adjust the potentiometer fully CW to set the current limit to maximum
- Tighten nut
3, Set the Over Voltage Protection potentiometer to maximum (CW)
Issue 2.0 2-5
QCUBIQCQMMUNICATIUNS CTX-5000 SYSTEM MANUAL
Amum-mmmfiyumm.
3-1
3-2
CHAPTER 3
OPERATING INSTRUCTIONS
INTRODUCTION. This chapter contains operating instructions for the CTX~5000 System.
OPERATION.
3-2.1 CTX System Ogeratimr. Operation is performed using the front panel controls and indicators on the
T4180 and the PA-SOSOA, Refer to the T-4150/80 and PA—SOSOA Technical Manuals for information on the front
panel controls and indicators and their functions. Refer to section 3-3, of this manual for Power Application and
Standard Operation Procedures, Refer to section 3—4. of this manual. for a description of the CTX T4180
differences. The CTX PA-SOSOSA operates as described in the PA—SOSOA manual
3-212 Sugar: Upload Procedures. There are three pieces of equipment that can be updated with new
software. These are the T4180. the Controller, and the PA»5050A's. Software updates are only necessary if
problems are occurring or if changes are being made to your system CCI will provide the necessary software
upon
32.2.1 T4180 Upload Procedure, Refer to the T—4150/80 Technical Manual.
3-222 Controller Upload Procedure. Perform the following procedures:
1, Build a Controller Upload Cable in accordance with the description provided in table 3-1.
2. Power off the CTX system.
3, Disconnect cable from the T4180 Control on the back of the Controller.
4. Connect the Controller Upload Cable from the COM port 2 on the PC to the T4180 Control connector on
the back of the Controller.
St Run “PROCOMM” or equivalent.
a, Press “Ctrl” and “E“ to set the program to echo key strokes on the monitor
h. Set the serial bus parameters to 8 bits, 1 stop bit, no parity, 192k baud, and COM 2
6. Power on the CTX System.
7. Observe on the monitor that the system is in the upload mode.
8. Follow the directions on the screen.
9. After completing the upload, disconnect the Controller Upload Cable from the CTX system
10,Reconnect the T4180 Control Cable to the back of the Controller.
1 LPower off the CTX system
12.Power on the Cl'X system.
NOTE:
Steps 10 and l I reset the CTX system to the normal
mode of operation. If these steps are not perfomied
the CTX system will remain in the Upload mode.
Issue 2.0 3-1
©0UBIC¢CDMMUNICATIDN5 CTX-5000 SYSTEM MANUAL
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3—223 PA-5050A 1121an Procedure. Perform the following procedures:
. Build a PA-SOSOA Upload Cable in accordance with the description provided in table 3—24
2. Power off the CTX system
3. Disconnect cable from the PA-SOSOA 15 Serial Remote connectort
4. Connect the PA»5050A Upload Cable from the COM port 2 on the PC to the PA-SOSOA 15 Serial Remote
connector.
5. Run “PROCOMM” or equivalent.
a. Press “Ctrl” and “E“ to set the program to echo key strokes on the monitor
,, b, Set the serial bus parameters to 8 bits. 1 stop bit. no parity, 19,2k baud. and COM 2
6. Power on the CTX System
7. Observe on the monitor that the system is in the upload mode.
Si Follow the directions on the screen.
94 After completing the upload, disconnect the PA-SOSOA Upload Cable from the 15 Serial Remote connector
on the PAASOSOA.
10. Reconnect the PA—SOSOA Cable to 15 Serial Remote connector.
ll.Power off the CTX system
12.Power on the CTX system.
NOTE:
Perform steps 10 and l 1 if uploading to all the PA-SOSOA's and you
desire to reset all the PA's atone time. Otherwise, you can
individually reset a PA by powering it down at the circuit breaker
paneli Performing the reset procedure places the PA('s) in the normal
mode of operation. If a reset is not performed the PA-SOSOACs) will
remain in the Upload mode.
Table 3-1 Controller Upload cable
Pin # on a 25 Pin Pint! on a 9 Pin Female
Female Connector Connector
(T4180 side)
—;
TXD
CTS
Nole: Pin 7 a 5 are Jumpered
Issue 2.0 3-2
QGUBIQCOMMUNICATIONI CTX-5000 SYSTEM MANUAL
Amummmmwmm
Pin # on a 25 Pin ' Pin# on a 25 Pin Male
Female Connector Connector for 224140003
(PAvSOSOA side)
3-3 POWER ON APPLICATION & STANDARD OPERATION PROCEDURES
3—31 Power Qn Application. To tum on, and initially set-up the CTX-5000 System. perform the following
V!“
9”
procedures:
Apply input power to the equipment from the power supply (Tum the POWER switch to ON (up) on
both power supplies.)
Apply input power to the T4180. (Turn the POWER switch ON (up))
Observe PW'R LED on each PA-SOSOA chassis, and all four PA modules light.
The CTX System is remotely controlled using an RS-ASS bus connected to the exciter.
NOTE:
Refer to the section 3-51 for the
appropriate Exciter Commands and Status
Messages.
During operation, press the DISPLAY STATUS button on the front panel to cycle through the different
status messages on the front panel display.
Observe that the FLT LED on each PA module does not light during transmission.
To shut down the PA~5050A remove input power. (Turn the POWER switch to OFF (doum) on both
power supplies.)
3-32 Standard Operation. Prior to transmitting. the CTX System must be tuned for the particular frequency.
The following procedure explains how to tune the CTX System.
PPR“:—
|SSU8 2.0
Select the frequency on the exciter.
Select PAPOW on the T4 180 exciter.
Select the appropriate power setting. refer to the para 36.1.3.
If operating remotely, send the PAP command, refer to table 3-4.
if changing frequency >IO% or crossing the filter bands, the PA must be re-tuned.
The PA gain for each PA can be stored into channel memory to enable a return to that channel without
re-tuning. refer to para 3-5.1.1.
Other power levels besides SkW, 2.5kW. and ”(W may be manually adjusted by selecting the SET softkey.
3-3
®=UBIGQOMMUNICATIDNB CTX-5000 SYSTEM MANUAL
Amwdlm mmwdmumv
3-4 EMERGENCY OPERATION. The CTX System is designed to continue operation, at a reduced power, if
a partial system failure should occur to a PA-SOSOA or any of its modules, or if a power supply failsl A power
supply failure is the same as losing three PA-SOSOA'S. Refer to table 3-3 for the CTX System output power should
a PA or multiple PA failure occurl The controller will automatically compensate for the loss of 1 to 5 PA<5050A's
by reducing the output power. The following procedures explain how to operate in a reduced mode.
3-4ll PA-5050A Failure. In the event of a complete failure of a PA-5050A, power will need to he removed
from the unit. To remove power from a particular PA-SOSOA and replace the unit with a working PA-SOSOA,
conduct the following procedures,
1. Locate the associated circuit breaker switches for the failed PA»5050A at the circuit breaker panel.
2, From the circuit breaker panel, pull all five circuit breakers.
This procedure only removes the DC power to the unit RF power
may still be present, especially if the CTX System is transmitting.
Opening the circuit breakers only prevents further damage from DC
power. DO NOT attempt removing the PA-SOSDA from the CTX
System unless the power has been secured from the two power
supplies. As a secondary precaution, remove the main AC power
cables from the AC power source.
be
After all power has been removed from the CTX System, detach all rear cables to the PA»5050A,
4. Swap out the unit with a working unit.
The working unit must be a PA-SOSOA that has been tuned and
aligned for a CTX System, A standard PA-SOSOA may not be
properly phased matched. Using a standard PA-SOSOA may cause
severe damage to the unit and the CTX System.
Reattach all rear panel cablesr
Close all circuit breakers to the associated PA—5050A.
Apply power to the CTX System.
$9?"
Table 3-3 PA-5050A Failure Output Power
Issue 2.0 3-4
QCUBIGCOMMUNIGATIONB CTX-5000 SYSTEM MANUAL
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3-42 PA-5050A Module Failure. In the event of a module failure in a PA-5050A, the module can either be shut
off or swapped out with a working module while the CTX System is in an operational mode. Perform the
following procedures to shut down a particular module or swap a module out with a working module.
11 From the circuit breaker panel, pull the circuit breaker for the particular PA module to be replaced.
NOTE:
Opening a circuit breaker to a specific module will deactivate that
module. Once deactivated the CTX System will transmit at a reduced
power out. The module does not have to be swapped out
immediately.
2. Remove and replace the PA module in accordance with Chapter 5 of the PA-SOSOA Operation &
Maintenance Manual.
3. Close the circuit breaker for the particular module that was replaced.
3-5 CTX T4180 EXCITER DIFFERENCES. The purpose of this section is to explain the on T4180
Exciter differences as compared to a stand alone T4180 Exciter described in the T-4150/80 Technical Manuals
When operating the CTX T4180 Exciter a different Secondary Soft Key menu is displayed as shown in figure 3-1.
Additionally, the function of certain CTX T—4180 Exciter Command and Status Messages operate differently.
- For a complete explanation on setting or changing the T4180 Exciter parameters, refer to the T-4180
Technical Manual section 3-7.
- For a complete explanation of all serial buss messages used to remotely control the T4180 Exciter, refer to
section 3-87 of the T-4180 Technical Manual
3-5.1 Secondary Sufi/(ex Diflerences, The T4 l80 Exciter displays a different Secondary Softkey menu when
—— connected to the CTX System. The specific differences are the PAPOW, PASTAT, and PAGAIN
softkeys. Figure 3-1 and the menus shown below explain the operation of these keys
economy son KEV MEN —————————————————————————————————————————————— —
-HEcAu. PAFOW ”star PAGAIN
L-msAaLEo; Whm punn ma Primary Soft Key man. u ulsplnyod.
Figure 3-1 CTX T4180 Secondary Soft Key Menu Flow Diagram
Issue 2.0 3-5
@ CUBIC. COMMUNICATlONS CTX-SOOO SYSTEM MANUAL
Amummamwumm-
3-5.l.l STORE This function stores all current exciter parameters in a selected memory channel. All exciter parameters
are first entered using the keypad and/or main adjustment knob. The memory channel is then selected and all data is copied
to the memory channelr
The following parameter settings may be stored in each memory channel: frequency, power level, exciter modulation
mode, audio source, bandwidth, hop rate, dwell time, and PA gain for all PA‘s. Refer to the T4150/80 technical manual
for a detailed description and operation.
3-5tlt2 RECALL There have been no changes to this Soft Key. Refer to the T4150/80 technical manual for its detailed
description and operation.
3-5.1.3 PAPOW. This function allows RF power selection for the CTX-System power amplifiers
f STORE RECALL
Soft Ke Menut
‘—-
Press the PAPOW key to show the power selections. The following menu appears.
PAPOW Soft Ke Menut
NOTE:
When any of the above soft keys are pressed (except CANCEL or SET), the exciter and
PA-SOSOA's are automatically keyed. The attenuator in each PA-SOSOA is automatically
adjusted to produce the selected RF power level output
Press the desired soft key to set the RF power output level.
Press the SET key to manually set other power output levels. The following menu appears.
Issue 2.0 3-6
©GUBIC-COMMUNIGATIDNS CTX-SOOO SYSTEM MANUAL
Amummwmmmnyumm
PAPOW—SEI‘ Soft Ke Menu
Use the numeric keypad to enter the desired power output level in watts or rotate the knob on the front panel of the T4180
Exciter. A range of 100W to SkW can be selected. Press the ENTER soft key to activate the output. Use the BKSP (backspace)
key to correct an entry.
3-5.1.4 PASTAT. This function causes the current slalus of all the PA~5050A power amplifiers to be displayed.
Press the PASTAT key to show the ctment status of all PA»5050A power amplifiers. The following menu appears,
PASTAT Soft Ke Menuo
Pressing the MORE key provides additional infon-nation on the display regarding the status of all PA's. The following
information is displayed by pressing the MORE key.
- Initial Displayed Information: System level information regarding Frequency, Forward & Reverse power,
SWR, & Combiner temperature registered from each thermistor.
- Press MORE 1" time: Forward & Reverse power, SWR, & Attenuation in each PA
- Press MORE 2"‘1 time: Gain fault status of the Driver module & the four PA Modules in each PA
- Press MORE 3'd time: Temperature fault status of Driver module & the four PA Modules in each PA
- Press MORE 4"' time: Displays system level faults of the controller and the 6 PA's in text format. Same
as the ER? command. refer to table 3-4.
Press the CLRERR (Clear Error) button to clear all the indicated faults from the display.
3-5.l.5 PAGAIN. This function has been disabled in the (“fix System When selected the operator is retumed to the Primary
Soft Key Menu.
Issue 2.0 3-7
OCUBIG-EOMMUNICATIONS CTX-5000 SYSTEM MANUAL
Ammummbmmmwmm.
3-52 Remote Operations The T-4180 may be optionally operated under remote control using a serial bus and a suitable
controller. To communicate with the T4180 remotely' the operator uses ASCII encoded messages. Each message that can be
sent from the bus controller is listed in section 3-87 of the T4150/80 manual. Command Status Messages listed in table 3—4
below define the messages that are particular to the CTX System. Messages that are similarly listed in section 3-8.7 of the
T-4150I80 manual are non-operational in the CTX System
Table 3-4 CTX T4180 Exciter Command and Status Messages
Reply 7” Descrlption 7 7 j
ER? ER000 000 000 000 The first 000 contains errors specific to the controller followed by each PA, 1
000 000 000 through 64
Each 000 may contain a value from 0 to 256 where the value represents a binary
flag for specific errorsr These values are:
= No error
Serial Communications Error
SWR Error
Gain Fault Error
Temperature Fault Error
Combiner Temperature Error (Valid for the first error value only)
Minimum Attenuation Fault ( A unit failed the minimum output power
dtn-ing a power set command.
1 64 Reserved
5 1 28 Reserved
TEM?
Nmth-‘O
u—
TEM000 000 000 Where: 000 represents the Temperature of the three sensors in the combiner in
degrees C. These are used for protective shutdown should the combiner
overheat.
IDP? CTX»5000 Ver This is the product 1D response including S/W version and date
thx
MM/DDIYYYY Note The PA's now support this command also
PA? PAF, FWD, REV, Request poweer amplifier status messages This will reply with a complete status .
SWR, ATN, TEM, message of all settings ad described below:
& KEY PAF = PAannnnnn (frequency in 10's of HZ)
FWD = nnnn nnnn nnnn nnnn nnnn nnnn nnnn where:
The 1“ set of n's is the total Forward power in watts
2'“ thru 7‘" set of n's are the Forward power, in watts, for each PA
REV = REVnnn nnn nnn nnn nnn nnn nnn where:
The 1“ set of n's is the total Reverse power in watts
2"‘1 thru 7m set of n's are the Reverse power, in watts, for each PA
SWR = SWRnn nn nn nn nn nn nn where:
The I“ set of n's is the total Standing Wave Raito
2” thru 7‘“ set of n's are the Standing Wave Ration for each PA
ATN = ATNnnn nnn nnn nnn nnn nnn where:
Each set of n's is the dB for each PA
= TEMnnn nnn nnnwhere:
Each set of n's is the temperature in °C for each themtistor in the
combiner
KEY = KEYnnnnnnn where n is “i " or “0" (l=keyed, 0=unkeyed):
The 1“ n represean the total CTX System
2"" thru 7‘“ n represents each PA
PAPXXXX Where XXXX is a value of 100 to 5000 in watts,
For 100 Watts <-> PAP100 -
For 5000 Wa_ > PAPSOOO _
Issue 2.0 3—8
OGUBICJ=OMMUNICATIDNS CTX-5000 SYSTEM MANUAL
Amummmmumpm
CHAPTER 4
PARTS LIST
4~1 |NTHODUCT|ON. This chapter contains the parts list for replaceable pans at the operational maintenance level,
4—2 REPLACEABLE PARTS LIST. Table 4-1 lists the replaceable parts for the unit (See figure F0-3 for
locations.)
Table 4-1 CTX 5000 Replaceable Parts List.
Description Qty
Panel, Blank. 19". IU 3
Combiner, 6-Way, with Directional Coupler
Circuit Breaker Panel in (Left Side)
Front Filler Panel
PA-SOSOA, Final Assembly 6
Power Amplifier Module 2241 l l l l~1 24
Circuit Breaker Panel #2 (Right Side) 2245-1101 2
u.
Panel, Blank. 19"
Control Unit
mm,
Power Supply 0-30V. 330A 2
Panel, Vent, 19" Rack, [U 2
Splitter, PWR 6—Wny, l-175 MHZ 118-098
L:
AC Line Filter 077-026
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FO-Z. CTX-SUM Replacement Parts Locate! Diagrar
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