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351804-1 Rev. 100

COM5000-8 TECHNICAL MANUAL

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Typical Bolt Hole Pattern

Bolt-down brackets

can be rotated 360°

Pivot radius = 2.75

Slot size = 1.2 x 0.4

All dimensions

are in inches

Figure 2.1.4.2A. Rack Cabinet Mounting Hole Locations

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Summary of Contents for COM5000-8

Page 1: ...ISCLOSED OR ALTERED WITHOUT THE EXPRESS WRITTEN CONSENT OF CUBIC DEFENSE APPLICATIONS INC NO RIGHT TITLE OR INTEREST IS GRANTED EXPRESSLY OR BY IMPLICATION IN OR TO ANY DATA CONTAINED HEREIN BY VIRTUE OF ITS DISCLOSURE TO OR USE BY THE HOLDER RECIPIENT DISCLOSURE MAY NOT BE MADE TO ANY THIRD PARTY FOR ANY PURPOSE ALL STATUTORY AND COMMON LAW RIGHTS ARE HEREBY RESERVED Cubic Defense Applications In...

Page 2: ...ISCLOSED OR ALTERED WITHOUT THE EXPRESS WRITTEN CONSENT OF CUBIC DEFENSE APPLICATIONS INC NO RIGHT TITLE OR INTEREST IS GRANTED EXPRESSLY OR BY IMPLICATION IN OR TO ANY DATA CONTAINED HEREIN BY VIRTUE OF ITS DISCLOSURE TO OR USE BY THE HOLDER RECIPIENT DISCLOSURE MAY NOT BE MADE TO ANY THIRD PARTY FOR ANY PURPOSE ALL STATUTORY AND COMMON LAW RIGHTS ARE HEREBY RESERVED Cubic Defense Applications In...

Page 3: ...351804 1 Rev 100 COM5000 8 TECHNICAL MANUAL i Revisions Updates REV Date Description Approval 100 1 30 15 Initial release E Wise ...

Page 4: ...onnections 7 2 1 4 3 2 System Controller Module Connections 8 2 1 4 3 3 Additional Module Connections 9 2 1 4 4 External Connections To The Transmitter 10 CHAPTER 3 OPERATION 11 3 1 INTRODUCTION 11 3 2 CONTROLS AND DISPLAYS 11 3 2 1 Power Supply Module 11 3 2 2 PA Module 13 3 2 4 T 4180 Exciter Module 16 3 3 TRANSMITTER SYSTEM OPERATION 16 3 3 1 General 16 3 3 2 Operating The Transmitter 16 3 3 3 ...

Page 5: ... Controller PCB Assembly Maintenance 38 5 4 1 4 Driver Splitter Maintenance 41 5 4 1 6 1 25 kW Combiner Maintenance 42 5 4 1 7 Fan Interface Maintenance 42 5 4 2 Combiner Module Maintenance 43 5 4 3 System Controller Module Maintenance 43 5 4 3 1 Driver Splitter ALC PCB Maintenance 44 5 4 3 2 System Controller PCB Maintenance 45 5 4 3 3 System Controller Operational Adjustment 45 5 4 4 Power Suppl...

Page 6: ...351804 1 Rev 100 COM5000 8 TECHNICAL MANUAL iv FRONT VIEW OF TRANSMITTER ...

Page 7: ...80 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 25 kW Power Amplifier module Qty 4 ea 351270 2 Power Supply module 351830 2 Output Combiner module L163145 1 T 4180 Exciter ...

Page 8: ...Bc Impedance 50 Ohm nominal Load Mismatch Unit capable of operating into load VSWR up to 3 1 reduced output survive open and shorted load Stable with any load Operating Mode Class AB Cooling Forced Air Dimensions HxDxW 85 5 x 31 6 x 23 7 217 x 80 3 x 60 2 cm Weight 775 pounds 352 kg approximately Temperature range 0 to 40 degree C Operating 40 to 70 degree C Storage Relative Humidity 0 to 95 opera...

Page 9: ...t when the power control is in the OFF position due to charges retained by capacitors To avoid severe shock or injuries always remove power and ground a circuit before touching it DO NOT SERVICE OR MAKE ADJUSTMENTS ALONE Under no circumstance should any person reach into the enclosure for the purpose of servicing or making adjustments to the equipment except in the presence of someone who is capab...

Page 10: ...ded 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 Special handling methods and materials must be used to prevent equipment damage ...

Page 11: ...ystem 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 b Gradual reduction of output power in case of failure in a PA module c Extensive BIT d FCC Part 87 and Part 15 certified FC...

Page 12: ...se Applications Inc 9333 Balboa Avenue San Diego CA 92123 USA Office 858 505 2130 FAX 858 277 1878 2 1 3 General Installation Select the mounting location for convenience of access for electrical connections and for maintenance Keep the antenna cable as short as possible to minimize losses The selected location should be clean dry and well ventilated Do not locate the Transmitter in close proximit...

Page 13: ... screws slowly pull out the module until the rack slides are fully extended and locked in this position c Disconnect all the cables coaxial and control cables and ground wires from the rear panel of the module see para 2 1 4 3 d Disengage the locking mechanism on both of the slides by pushing in the locks Then pull the module slowly out and away from the slides e When removing a PA module weight 7...

Page 14: ... Note that the bolt down brackets can be rotated to different positions if desired Air exhaust for the rack cabinet is at the rear through the perforated door When the rack cabinet is secured to the floor the floor plates plinth base covers and modules can be installed Install the modules starting with the bottom module and proceed towards the top module Work only with one module at a time make su...

Page 15: ...CHNICAL MANUAL 5 0 31 6 0 23 7 19 28 7 21 9 24 Typical Bolt Hole Pattern Bolt down brackets can be rotated 360 Pivot radius 2 75 Slot size 1 2 x 0 4 All dimensions are in inches Figure 2 1 4 2A Rack Cabinet Mounting Hole Locations ...

Page 16: ...re 2 1 4 2B Rack Cabinet Module Location Power Supply Module 7U 1 25 kW PA Module 4 6U T 4180 Exciter Module 3U System Controller Module 3U 4 Way Combiner Module 3U Blank Panel 2U 1 25 kW PA Module 3 6U 1 25 kW PA Module 2 6U 1 25 kW PA Module 1 6U 2 25 5 7cm Lifting Eyes 4X ...

Page 17: ...escribed below 2 1 4 3 1 Power Supply Module Connections Connections to the Power Supply module rear panel terminal block are shown below L3 L2 L1 The AC LINE Input is connected as follows L1 Line 1 black L2 Line 2 red L3 Line 3 blue Ground green The System Controller and Exciter module AC Line inputs connect to J2 of the Power Supply module through a splitter cable The 50V DC NEG connections from...

Page 18: ...RF INPUT J1 BNC RF Output J6 3 BNC PA module 3 RF INPUT J1 BNC RF Output J6 4 BNC PA module 4 RF INPUT J1 BNC RF INPUT J5 BNC T 4180 Exciter OUTPUT J3 BNC Supply Control J8 9 pin DSUB Power Supply Module J4 9 pin DSUB Combiner Control J1 9 pin DSUB Combiner module Control J6 9 pin DSUB PA Control J7 37 pin DSUB PA module 1 2 3 and 4 PA Control J3 15 pin DSUB Exciter Interface J3 15 pin DSUB T 4180...

Page 19: ... J6 N Combiner RF IN RF IN J3 N RF Output PA module 3 J6 N Combiner RF IN RF IN J4 N RF Output PA module 4 J6 N Combiner RF IN RF IN J5 N Combiner Module Combiner module Connector Label Combiner module Connector Type Connected to Connector Label Connector Type RF OUT J1 C Antenna connector NA LC T 4180 Exciter Module Exciter module Connector Label Exciter module Connector Type Connected to Module ...

Page 20: ...ded via an RS 232 RS 422 interface on the rear of the T 4180 exciter at J4 See the T 4180 manual for details Audio Connection Two balanced 600 ohm audio inputs are provided on J6 of the Exciter rear panel A microphone input with PTT push to talk is also available on the front panel of the exciter See the T 4180 manual for details External Reference An external 10 MHz reference input is provided on...

Page 21: ...e 3 2 1 shows the Power Supply Module Front Panel The controls and indicators are described below Control Indicator Function AC ON PS 1 LED yellow When lit indicates that internal power supply invertor 1 is on and operating normally AC ON PS 2 LED yellow When lit indicates that internal power supply invertor 2 is on and operating normally AC ON PS 3 LED yellow When lit indicates that internal powe...

Page 22: ...351804 1 Rev 100 COM5000 8 TECHNICAL MANUAL 12 Figure 3 2 1 Power Supply Module Front Panel ...

Page 23: ...ously indicates that the antenna VSWR exceeds approximately 4 1 SPLY Fault LED red When lit continuously indicates there is a DC supply voltage fault AIRFLOW Fault LED red When lit continuously indicates failure of one or more FANS in a PA module or in the Combiner module AMP OFF status LED red When lit indicates that the 50VDC supply voltage is not present and or communication with the T 4180 Exc...

Page 24: ...351804 1 Rev 100 COM5000 8 TECHNICAL MANUAL 14 Figure 3 2 2 PA Module Front Panel ...

Page 25: ...351804 1 Rev 100 COM5000 8 TECHNICAL MANUAL 15 Figure 3 2 3 System Controller Module Front Panel ...

Page 26: ...ting to conditions as they change key dependent evaluated on the next PTT or latched in d Faults and BIT responses are reported to the T 4180 The information can be accessed and read on the T 4180 front panel display or on an external computer See section 3 3 4 below 3 3 2 Operating The Transmitter To turn ON the Transmitter proceed as follows a Turn ON the System Controller module b Turn ON the T...

Page 27: ...ondition Note The Transmitter may enter the OPER status even if faults have been detected Operation is permitted at reduced power under many fault conditions In the OPER mode the 50VDC Power Supply module green DC ON LED is turned ON The Transmitter system is now ready to be keyed PTT For detailed operation instructions refer to the T 4180 manual 3 3 3 Transmitter External Control Protocol The T 4...

Page 28: ...s are as follows a On screen 1 if a fault is detected OK will change to FLT b COMS show status of serial communication with the PA module If communication with a PA module is lost OK will change to FLT c FLTS show PA module faults in HEX format The definition is shown below o A critical fault requires the 50V supply voltage to be turned OFF and then ON to reset the fault o Most other faults are re...

Page 29: ...ing of faults The two Status screens may be used with the LED indicators on the PA module and the System Controller module to locate a fault Note The FWD and REV power readings on T 4180 Status screen 1 indicate the power measured at the output connector of the Combiner The power reading is for reference only and may not match the reading of an external wattmeter especially when operating into hig...

Page 30: ...OK OK OK FAULT 2 OK OK FAULT OK 3 OK OK FAULT FAULT 4 OK FAULT OK OK 5 OK FAULT OK FAULT 6 OK FAULT FAULT OK 7 OK FAULT FAULT FAULT 8 FAULT OK OK OK 9 FAULT OK OK FAULT A FAULT OK FAULT OK B FAULT OK FAULT FAULT C FAULT FAULT OK OK D FAULT FAULT OK FAULT E FAULT FAULT FAULT OK F FAULT FAULT FAULT FAULT Right Digit A VSWR Driver Fan NA 0 OK OK OK Not used 1 OK OK OK Not used 2 OK OK FAULT Not used ...

Page 31: ... will return to normal Note Momentary flashing of a fault LED does not indicate a fault The LED must be on continuously to indicate a fault 2 PA Module Fan Fault A fan fault is declared if the fan speed is below a specific hardware set limit The Transmitter must be keyed in order to detect a fan fault and it takes approximately 10 seconds for the fault to be detected With a fan fault in a PA modul...

Page 32: ... the T 4180 Module Status screen 2 When selecting a frequency in another filter band and transmitting the filter fault will be cleared and transmission at full power restored on that filter and the remaining good filters 4 PA Module Gain Fault Gain reduction or complete loss of gain in a 1 25kW PA Module may have a number of causes 350W AMP protection fuse s blown Driver output transistor failure ...

Page 33: ...PA Module LED s System Controller FAULT LED s PWR FAULT TEMP VSWR SPLY AIR FLOW Exceeding limits OFF OFF OFF OFF ON OFF When the fault condition disappears the fault display is cleared on the next key Note The Power Supply module will start current limiting at approximately 325A and enter constant current mode of operation Excessive current draw does not necessarily indicate a failure of the 50VDC...

Page 34: ...PLY AIR FLOW VSWR OFF OFF OFF ON OFF OFF The transmitter will continue to operate with reduced output power If a new operating frequency is selected following a VSWR fault the power will remain low and only slowly increase to a normal value if the VSWR condition has improved Transmitter rack cabinet system a The Operational Interlock connection Cabinet Interlock is monitored by the System Controll...

Page 35: ...in phase Combiner Module The Combiner output is routed to the antenna Control and monitoring functions are provided by the System Controller Module The COM5000 8 is powered by a 3 phase Power Supply Module rated at 15kW DC out 50V 300A 4 3 1 25KW PA MODULE A block diagram of the 1 25kW PA Module is shown below in figure 4 3 The RF output signal from the System Controller module is applied to the R...

Page 36: ...F VR RF Exciter Control I O Supply monitor control System Control I O s 50VDC Figure 4 2 COM5000 8 Block Diagram PA module 1 PA module 2 PA module 3 PA module 4 Combiner Module System Controller module Driver Splitter ALC PCB assembly Power Supply module Controller PCB assembly T 4180 Exciter ...

Page 37: ...351804 1 Rev 100 COM5000 8 TECHNICAL MANUAL 27 350W AMP 350W AMP 350W AMP 350W AMP Figure 4 3 1 25 kW PA module Block Diagram ...

Page 38: ...e following functional groups A Combiner Control and monitoring circuitry provides ON OFF switching of the Combiner FAN and receives information on the Combiner heatsink temperature Voltages proportional to the forward VF and reflected VR power are routed to the Fault Sensing circuitry and to the Meter Drivers VF and VR are also applied to the automatic level control ALC circuitry to maintain cons...

Page 39: ...biner module control and monitoring circuitry Meter driver circuitry Serial communication circuitry Driver Splitter ALC PCB assembly Microprocessor controlled Fault sensing control and multiplexing circuitry PA module control and monitoring circuitry Power Supply module control and monitoring circuitry Front Panel LED drivers System Controller power supply Input level detection circuitry 1 2 3 4 ...

Page 40: ...utput of the invertors is routed through 8 circuit breakers on the front panel There are 2 circuit breakers for each 1 25 kW Power Amplifier module The DC output is also applied to the Accessory connector J4 through a 3A circuit breaker Two of the AC input lines are routed to an auxiliary AC output connector J2 on the rear panel This output is protected by a 5A 2 pole circuit breaker mounted on th...

Page 41: ...er Agilent model N9320B Oscilloscope Tektronix model TDS2012C DVM Fluke model 77 Uses 230VAC blowers For 115VAC change 230 to 115 in model number Note Equivalent equipment may be substituted 5 3 PERIODIC MAINTENANCE The only items that require regular maintenance are the air filters The filters should be removed and cleaned periodically at a frequency determined by the operating environment The fi...

Page 42: ...kW PA Module assemblies is described in this section Unless otherwise noted reassembling is done in the opposite order of disassembly To perform alignment of the 1 25kW PA Module it is necessary to operate the module as a stand alone Amplifier while still part of the Transmitter as follows The 1 25kW PA Module is pulled out of the Transmitter rack cabinet to gain access to subassemblies The 50V Po...

Page 43: ...351804 1 Rev 100 COM5000 8 TECHNICAL MANUAL 33 Figure 5 4 1A 1 25kW PA Module Subassembly Location ...

Page 44: ...v 100 COM5000 8 TECHNICAL MANUAL 34 351293 1 351293 1 351285 1 351280 1 L163209 1 351289 1 FRONT TOP VIEW Figure 5 4 1B 1 25kW PA Module 1 25 kW COMBINER 350W Amp 1A 350W Amp 1B PA CONTROLLER FAN FAN FAN INTERFACE ...

Page 45: ...351804 1 Rev 100 COM5000 8 TECHNICAL MANUAL 35 351280 1 351275 1 Line Flattener FRONT BOTTOM VIEW Figure 5 4 1C 1 25kW PA Module 350W Amp 2B 350W Amp 2A DRIVER SPLITTER ...

Page 46: ...ove b Turn ON the Transmitter Select an operating frequency of 16 MHz and key the system c Adjust the signal generator level to obtain a power output of 1000 W at a frequency of 16 MHz c Measure the DC voltage at J2 pin 4 VR d Adjust C4 for a dip minimum reading The voltage should be less than 0 5 VDC e Note the position of trimmer capacitor C4 as indicated by the position of the silver plating 1 ...

Page 47: ...50 W Amp module to be adjusted If necessary temporarily remove the auxiliary 50VDC connection to eliminate its effect on the current reading This is the thin red wire going to the Fan Interface Board Pre adjust the bias adjust potentiometer R44 47 60 and 64 to their fully counter clockwise position Note R42 is not used and should be left in its approximate midpoint position b Turn ON the 5 kW Ampl...

Page 48: ... Amplifier and Harmonic Filter adjustments have been completed Adjustments to perform U3 Vref voltage VF VFL and VR Nominal Power output 50 Ohm 1000 W 2 1 VSWR Power output 500 W DRVR Q1FLT Window Comparator Initial potentiometer setting Potentiometers may be preset by measuring resistance and adjusting as shown below Note The purpose of presetting the potentiometers is to avoid drastic misalignme...

Page 49: ...t a T 4180 operating frequency of 16 MHz c With the 1 25kW PA Module terminated in a 50 ohm load key the 5 kW Amplifier system Adjust the RF Signal Generator level to obtain a power output of 1000 W Wait for the initial drift in power to settle in order to get a reasonably stable 1000 W power d Proceed to perform this adjustment on the PA Controller PCB Assembly with 1000 W power output VF Set VR6...

Page 50: ...red on U20A pin 1 VFL Set VR8 for a reading of 1 00 V measured on U2 pin 3 DRVR Q1FLT Window Comparator This adjustment requires the Driver bias current adjustment to have been completed See paragraph 5 4 1 4 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 With the system un keyed measure and record the...

Page 51: ...34 R35 R36 and R37 to their counter clockwise position for minimum bias in Q1 and Q4 c Q1 bias is turned ON by shorting R30 to ground do not key the system to apply bias Note the residual current It should be 70 90 mA Slowly turn R36 clockwise for a current reading of 230 mA above the residual current Then turn R37 slowly clockwise until the total current reads 460 mA above the residual current e ...

Page 52: ...1 6 1 25 kW Combiner Maintenance To gain access to the 4 Way Combiner 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 1 25 kW Combiner PCB see Figure 5 4 1 B Adjustments No adjustmen...

Page 53: ...assemblies is shown in Figure 5 4 3A To perform alignment of the System Controller Module it is necessary to operate the Transmitter as follows The System Controller Module is pulled out of the Transmitter rack cabinet to gain access to subassemblies All Control connections from the T 4180 are in place to permit normal operation of the Transmitter The T 4180 RF Output connector is terminated into ...

Page 54: ...6 screws on the side of the System Controller to remove the top cover The Driver Splitter ALC PCB is located as shown in figure 5 4 3A 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 Detected RF IN level adjustment a Turn ON the System Controller module Do not key the system b Connect ...

Page 55: ... can be performed without operating the Transmitter The following System Controller adjustments may be performed without operating the Transmitter D A Converter U2 reference voltage adjustment Turn on the System Controller module Adjust VR1 of the System Controller PCB for a voltage of 2 0 VDC measured on U2 pin 3 VREF 5 4 3 3 System Controller Operational Adjustment System Controller operational ...

Page 56: ... 1 5 1 7 K ohm VR2 for 1600 Ohm To perform operational adjustment of the System Controller Module it is necessary to operate the Transmitter as follows The System Controller Module is pulled out of the Transmitter rack cabinet to gain access to subassemblies All Control connections and the RF drive signal connection from the T 4180 are in place to permit normal operation of the Transmitter The Tra...

Page 57: ... operational adjustment Exciter Interface J3 RF INPUT J5 System Controller module RF OUTPUT COM5000 8 Variable Attenuator Wattmeter Sensor 50 Ohm 4 kW Load Attenuator Spectrum Analyzer Oscilloscope DVM T 4180 Exciter Audio J6 PA Control J5 Output J3 RF Signal Generator 50 Ohm Load 10 kW 50 Ohm Termination Directional Coupler J4 J3 T ...

Page 58: ...r output level on the wattmeter Increase the power output to 4000W If it is not possible to obtain the 4000W there may be a number of reasons 1 The ALC may be engaging adjusting VR2 counter clockwise releases the ALC 2 The Input Overdrive ALC Splitter PCB may be set wrong c With 4000W output power 1 Measure the DC voltage at the junction of R95 and L2 and verify that the voltage is 2 95 3 05 V 2 T...

Page 59: ...variable attenuator is set for maximum attenuation The T 4180 is set to operate in CW mode of operation at 100 power at a frequency of 15 MHz Key the transmitter system and observe the output power Change the attenuation on the Variable Attenuator in small increments until the output power reaches 2000W b Un key the system To prevent the microprocessor from reducing the power during this alignment...

Page 60: ...t possible to obtain the 200W there may be a number of reasons 1 The VSWR ALC may be engaging too early VR5 2 Actual fault conditions e With 200W reflected power Measure the DC voltage at the junction of R96 and L1 and verify that the voltage is 1 27 1 31 V If not there may be a problem in the Combiner module Then if necessary 1 Adjust VR3 for 1 16 VDC U31 pin 11 2 Adjust VR9 for a System Controll...

Page 61: ...able attenuator adjust VR5 for a forward power of 2750W i Un key the system Remove the clip lead short from the junction of R118 and C93 to ground Replace the 2 1 VSWR Load with a 50 Ohm Load 5 4 4 Power Supply Module Maintenance The Power Supply module provides 50 VDC at 300 A maximum to the Transmitter system The Power Supply is a switch mode supply operating from a 3 PHASE AC Line input For Pow...

Page 62: ...embly 8 351280 1 1 25kW PA Module PA Combiner heatsink assembly 4 351285 1 1 25kW PA Module Harmonic Filter assembly 4 L163184 1 25kW PA Module PA Controller PCB 4 L163209 1 1 25kW PA Module Fan Interface Plate assembly 4 351289 1 1 25kW PA Module 1 25kW PA module Fan 8 351293 1 1 25kW PA Module ALC Splitter PCB 1 1638 2001 2 System Controller Module System Controller PCB 1 1638 2000 2 System Cont...

Page 63: ...351804 1 Rev 100 COM5000 8 TECHNICAL MANUAL 53 Figure 5 1 Transmitter Interconnect Wiring Diagram ...

Page 64: ...351804 1 Rev 100 COM5000 8 TECHNICAL MANUAL 54 Figure 5 4 1 PA Module Interconnect Wiring Diagram ...

Page 65: ...351804 1 Rev 100 COM5000 8 TECHNICAL MANUAL 55 Figure 5 4 3 System Controller Interconnect Wiring Diagram ...

Page 66: ...351804 1 Rev 100 COM5000 8 TECHNICAL MANUAL 56 Figure 5 4 4 Power Supply Interconnect Wiring Diagram ...

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