ATRAD ST-40 User manual

DESIGN AND MANUFACTURE OF ATMOSPHERIC RADAR SYSTEMS
ST-40
SYSTEM OPERATION
MANUAL
 Copyright by ATRAD 2007
All Rights Reserved
ATRAD Pty Ltd
ABN 72 112 121 801
Thebarton SA 5031
1/26 Stirling Street
Australia
P/No: 15-05004 Issue 2 1
ATRAD

P/No: 15-05004 Issue 2 2

Table of Contents
1 ST-40 SYSTEM................................................................................... 5
1.1 OVERVIE ........................................................................................................................ 5
1.2 RACK LAYOUT.................................................................................................................5
2 SUB-RACK - DC POWER SUPPLY................................................... 8
2.1 OVERVIE ...................................................................................................................... 8
2.2 PS CONTROLLER...........................................................................................................9
2.3 PS RECTIFIER...............................................................................................................10
3 SUB-RACK – ST-20.......................................................................... 11
3.1 OVERVIE ...................................................................................................................... 11
3.2 PA DRIVER......................................................................................................................14
3.3 PA MODULE................................................................................................................... 16
3.4 PA CONTROLLER......................................................................................................... 20
3.5 RF DISTRIBUTION MODULE.....................................................................................23
4 SUB-RACK - RF POWER COMBINER............................................. 25
4.1 OVERVIE ...................................................................................................................... 25
5 ST-40 SYSTEM ASSEMBLY............................................................ 28
5.1 MECHANICAL ASSEMBLY....................................................................................... 28
5.2 ELECTRICAL ASSEMBLY......................................................................................... 28
5.3 RF CABLE ASSEMBLY................................................................................................28
6 REFERENCES.................................................................................. 2
P/No: 15-05004 Issue 2 3

List of Pictures
Picture 1. ST-40 Rack (Front View) 7
Picture 2. ST-40 Rack (Rear View) 7
Picture 3. Valere, L Series Compact Shelf, DC Power Supply 8
Picture 4. Valere, L Series Compact Shelf, DC Power Supply 8
Picture 5. Controller Display 9
Picture 6. Rectifier Insertion/Extraction 10
Picture 7. VHF PA Driver (Top View) 15
Picture 8. VHF PA Driver (Bottom View) 15
Picture 9. VHF PA Module (Top View) 17
Picture 10. VHF PA Module (Bottom View) 18
Picture 11. PA Controller (Front View) 19
Picture 12. PA Controller (Rear View) 19
Picture 13. RF Power Combiner (Rear View) 25
Picture 14. RF Power Combiner (Rear View) 25
List of Block Diagrams
Block Diagram 1. ST-40 Rack (Front) 6
Block Diagram 2. ST-40 Rack (Rear) 6
Block Diagram 3. ST-20 System 11
Block Diagram 4. ST-20 Sub-Rack (Rear) 12
Block Diagram 5. ST-20 Sub-Rack (Front) 12
Block Diagram 6. Tx Trigger Pulse 13
Block Diagram 7. VHF PA Driver 15
Block Diagram 8. VHF PA Module 17
Block Diagram 9. PA Controller 19
Block Diagram 10. VHF PA Controller (Front Panel Connectors) 20
Block Diagram 11. RF Distribution Module 22
Block Diagram 12. RF Distribution Module (Front Panel Connectors) 23
Block Diagram 13. ST-40 RF Power Combiner 24
P/No: 15-05004 Issue 2 4

1 ST-40 System
1.1Overview
Hardware Specifications
Operating Frequency Range 30-60 MHz
Peak Envelope Power 40 KW PEP (minimum)
VSWR(Input/Output) 1.5:1 (minimum)
Maximum PRF Dependent on pulse width and maximum Duty Cycle
Pulse Shape Gaussian Square
Maximum Duty Cycle 10 % Gaussian 12% Square
Output Spurious and Harmonics Better than –60 dBc
Impedance (Input/Output) 50Ω
Output Level Adjustable from 0 to 100%
Power Supply 50V DC (typical) 10KW (for max. Duty Cycle)
Ambient Temperature +5 to +35 oC
Sub-Rack Temperature +65 to +95 oC (60 oC rise for max. Duty Cycle)
Sub-Rack Mounting 19” rack mount
Cooling Forced air-cooled
1.2Rack Layout
The ST-40 VHF Transmitter is composed of a number of sub-systems here referred to as sub-racks. The
three main sub-racks are
1. DC Power Supply (x2)
2. RF Power Combiner (x1) and
3. ST-20 (x2) ( which is itself a VHF Transmitter).
Other components of the ST-40 include a Circuit Breaker/Distribution Panel Ethernet Switch and a Medium
Power 2-1 RF splitter. Please refer to Block Diagrams 1 & 2 for the front and rear view of these sub-racks in
the ST-40 cabinet.
Modularity is an important feature of the ST-40 design and as such critical sub-racks are modular. In
particular the ST-20 is composed of [1-6] RF PA Modules also a RF PA Driver Controller and Fan
module. The DC Power Supply is composed of a Controller module and [1-4] Rectifier modules. The
benefits of this modularity include:
1. Scalability in RF Output Power. From 4 KW to 40KW in steps of 4 KW.
2. Scalability in Duty Cycle. 0-10% with 4 Rectifier modules installed i.e 2 Rectifiers per ST-20 sub-
rack. With reduced PEP then operation with a Duty Cycle > 10% may be possible.
3. Maintenance upgrades & repairs.
4. Easy of Transport.
Please refer to the various sub-rack sections for module installation instructions also see Block Diagram [1-
2] and Pictures [1-4].
P/No: 15-05004 Issue 2 5

(5 RU)
(3 RU)
(1 RU)
(2 RU)
(1 RU)
(9 RU)
(1 RU)
(3 RU)
(1 RU)
(9 RU)
(1 RU)
(2 RU)
(1RU)
Blanking Panel /
Ethernet Switch
Circuit Breaker &
Distribution
Vent Panel
DC Power Supply
Vent Panel
ST-20
Vent Panel
RF Power Combiner
Vent Panel
ST-20
Vent Panel
DC Power Supply
Vent Panel
Block Diagram 1. ST-40 Rack (Front) Block Diagram 2. ST-40 Rack (Rear)
P/No: 15-05004 Issue 2 6

Picture 1. ST-40 Rack (Front View) Picture 2. ST-40 Rack (Rear View)
P/No: 15-05004 Issue 2 7

2 Sub-Rack - DC Power Supply
2.1 Overview
Picture 3. Valere, L Series Compact Shelf, DC Power Supply [4]
Picture 4. Valere, L Series Compact Shelf, DC Power Supply
The Valere Compact DC Power System (L Series Compact Shelf) accepts an AC Voltage between 180 and
264 VAC 47 to 63 Hz and produces a regulated output of 42-56 VDC capable of delivering a maximum of
200 Amperes (depending on the number of deployed Rectifiers i.e 50 Amperes per rectifier) in an ambient
operating temperature range of -40oC to +75oC. It boasts a typical conversion efficiency of 92%. Picture 5
shows the front panel of the DC Power System there are five modules. Two Rectifier modules fitted two
blank modules (which can be up replaced/upgraded with additional rectifiers) and a Controller module is to
the far left.
There is a Compact DC Power System associated with each ST-20 sub-rack. The Supply requirements for
the ST-20 will be dependent on user defined Duty Cycle. Typical power requirements for a 20 KW (PEP) RF
pulse set at 5% duty cycle is 2000 W (50V@40A). Typical power requirements for a 20 KW (PEP) RF pulse
set at 10% duty cycle is 4000 W (50V@80A).
For the AC and DC connection details please refer to [3]. The DC supply connection interface to the ST-20
is via 4 Powerpole Pak Connectors [5] on the rear of the ST-20 with a separate 6U panel dedicated and four
panel receptacles. Each Powerpole Pak Connector is capable of passing 50V@90A.
P/No: 15-05004 Issue 2 8

2.2 PS Controller
Picture 5. Controller Display [4]
This section refers to the BC Series Controllers menu's and
configuration options. In particular there are three menu
levels
1. Basic
2. Main
3. Administrator.
We will restrict ourselves to the Basic and Main menu as it is
recommended that the controller settings are not altered
without consultation care should be exercised in using the
Administrator menu. Appendix A of [4] contains the complete
menu tree for the controller. Further Navigation is via the
Controller's Front Panel and three button keypad (DN
MENU UP).
Basic Menu
After Power ON the controller should display “System OK”. The controller is now at the Basic menu level.
You can use the DN/UP buttons to view the basic plant parameters. The parameters of interest for the ST-20
sub-rack include- DC output voltage DC output current and internal temperature.
Main Menu
Hold the MENU button (on the Controller's front panel) down for 5 seconds the Main menu can now be
accessed.
By scrolling to the “Review” field and pressing the MENU button all the Power Supplies parameters can be
viewed (refer to the menu tree for navigation details Appendix A of [4]).
Within the Main menu by scrolling to the “Log In” field and pressing the MENU button the Administrator
Level is accessed (refer to the menu tree for navigation details Appendix A of [4]). The default password is
5001.
Please Note: It is recommended that the controller factory equipped default
settings are not altered without consultation
P/No: 15-05004 Issue 2 9

2.3 PS Rectifier
The modular plug-n-play nature of this Power Supply makes diagnostics and repair very easy. The rectifiers
are hot swappable modules which can be removed while the system is running without effecting operation.
Rectifier Model: V2500A Series 2:14 Input: [200-240 VAC 0-15A 50/60Hz] Output: [42-56 VDC 0-
50A].
PS Rectifier Installation
Picture 6. Rectifier Insertion/Extraction
To extract a rectifier push the “latch button” on the front of
the module and pull the “latch” open. This will remove the
rectifier from the back plane and disconnect it from the
system.
To insert a rectifier with the latch open and push the rectifier
into position. Once in position push the rectifier latch closed
as shown in Figure 8.
P/No: 15-05004 Issue 2 10

3 Sub-Rack – ST-20
3.1Overview
PA ModulePA Module 6
PA ModulePA Module 5
PA ModulePA Module 4
PA ModulePA Module 3
PA ModulePA Module 2
PA ModulePA Module 1
RF Backplane
(RF & 50V Power
Di tribution)
VHF PA Driver Module
Plugin
RF Input (100mW PEP)
RF Ouput (4KW PEP)
PA Driver
(1KW PEP)
Controller Backplane
(Control, Fan & DC Power)
Plugin
RF Ouput (4KW PEP)
RF Ouput (4KW PEP)
RF Ouput (4KW PEP)
RF Ouput (4KW PEP)
RF Ouput (4KW PEP)
uController+CPLD
DC-DC
RF Modulator
PA Controller
RF In
RF Drive
Trigger In
Trigger Out
Ethernet
Aux
Fan Module
Control
Debug
1-6
Splitter
Block Diagram 3. ST-20 System
The ST-20 is the heart of the ST-40 Transmitter. When fully loaded the ST-20 is capable of delivering 20
KW at 10% duty cycle. A Block Diagram of the ST-20 is shown above. As can be seen the system consists
of four types of modules
1. VHF PA Controller Module
2. VHF PA Driver Module
3. VHF PA Module
4. Fan Module
The ST-20 is designed to be modular with a eurocard fit a maximum of 6 PA modules per ST-20 cabinet.
The PA modules are designed for a 19 inch rackmount system with overall dimensioned – 9RU (400mm) by
14 HP (70mm) by Eurocard length (220 mm). Each module weighs less than 3 Kg (6.6 lb). To sustain a
maximum rise in temperature of 60oC the minimum airflow to the unit shall be greater than 100 cfm.
Modules are fitted into the cabinet as depicted in Block Diagrams [4 5]. Please note that the Blank panels
and the DC Power Input panel are designed to be fixed in place. The Fan Module can be extracted from the
cabinet for maintenance and replacement.. The other modules ( PA Controller PA Driver and PA Modules )
have card guides to help with their insertion and alignment to the internal backplanes.
Please note that none of the ST-20 modules are hot pluggable. Please turn off the main power before
attempting to insert or extract any of the modules.
P/No: 15-05004 Issue 2 11

(3 RU)
(6 RU)
Block Diagram 4.
ST-20 Sub-Rack (Rear)
Panel Description
Panel A-6RU: DC Power Input
Panel B-6RU: VHF PA Controller
Panel C-6RU: Blank
Panel ABCD-3RU: Blank
Panel D-6RU: VHF PA Driver
Panel E-3RU6RU: Fan Module
A
(10 HP)
B
(10 HP)
C
(8 HP)
D
(14 HP)
E
(42 HP)
(9 RU)
Block Diagram 5.
ST-20 Sub-Rack (Front)
Panel Description
Panel A-9RU: VHF PA Module
Panel B-9RU: VHF PA Module
Panel C-9RU: VHF PA Module
Panel D-9RU: VHF PA Module
Panel E-9RU: VHF PA Module
Panel F-9RU: VHF PA Module
A
(14 HP)
B
(14 HP)
C
(14 HP)
D
(14 HP)
E
(14 HP)
F
(14 HP)
P/No: 15-05004 Issue 2 12

Transmitter Power Ramping
The PA is switched off when not transmitting that is the Transistor Bias (Vbias) is set to << Threshold Bias
voltage (Vth). A “Trig In” signal is required to be fed into the PA Controller Module which Module then
distributes this control signal to the various RF Modules. As mentioned the trigger pulse controls the Power
Amplifier transistor bias voltages effectively turning the transistors on only during an active pulse phase. The
relationship between the Tx Trigger Pulse and the RF Pulse is depicted in Block Diagram 6 below.
T
doff
T
don
Tx Trigger RF Pul e
Block Diagram 6. Tx Trigger Pulse
Tdon is the delay time between the rising edge
of the Tx trigger signal and the start of the RF
pulse signal.
Tdoff is the delay time between the falling edge
of the Tx trigger signal and the end of the RF
pulse signal
Transmitter RF Output
The RF output of the ST-40 was captured via a Tektronics Digital Oscilloscope (TDS3052B) as is displayed
in Figure 1 below. The equipment required for this test included: the ST-40 a RF Signal Generator (51 Mhz
@ +13dBm) Trigger Pulse Generator (1usec pulse@ 1KHz) RF Sniffer and a High Power Load (50 ohms
@ 1KWavg). Please note that for the figure below the RF sniffers attenuation has been compensated for
hence the full 4000V peak-to-peak voltage (i.e 40KW PEP).
-2 -1 0 1 2 3
-2500
-2000
-1500
-1000
-500
0
500
1000
1500
2000
2500
Time (u ec)
Voltage (Volt )
Figure 1. ST-40 RF Output - 1 usec gaussian pulse width.
P/No: 15-05004 Issue 2 13

3.2 PA Driver
Hardware Specifications
Operating Frequency Range 30-60 MHz
Peak Envelope Power 150 W PEP (per channels)
Number of Channels 6 equal Amplitude 0o phase
VSWR(Input/Output) 1.5:1 (minimum)
Maximum PRF Dependent on pulse width and maximum Duty Cycle
Pulse Shape Gaussian Square
Maximum Duty Cycle 10 % Gaussian 12% Square
Output Spurious and Harmonics Better than –60 dBc
Impedance (Input/Output) 50Ω
Output Level Adjustable from 0 to 100%
Power Supply 50V DC (typical) 200W (for max. Duty Cycle)
Ambient Temperature +5 to +35 oC
Sub-Rack Temperature +65 to +95 oC (60 oC rise for max. Duty Cycle)
Cooling Forced air-cooled
Physical Details Eurocard 6RU 14HP & 220mm Card Depth
Weight 1 Kg
Module Monitoring Forward/Reverse RF Power Power Supply Temperature.
External User Interfaces
Connector Details Direction Notes
BNC RF Input Input Level: 40 mW typical (4 Vpp)
Internal Back Plane Interfaces
Connector Details Direction Notes
110 PIN ERNI Connector
(S/N044766 ERmet type
A female connector)
http://www.erni.com/
DC Power Supply Input 50 V @ 4 A.
DC Power Supply Input 15 V @ 0.5A
DC Power Supply Input 5 V @ 0.5 A
Health Monitor - Output Multiplexer Analog Bus
Health Monitor - Input
3 bit address 1 select. i.e 8
Tx Trigger Input 1 bit input +15V
VSWR Bus Output VSWR protection
Monitor LED Indicators
1. Supply LED – Controller Module must be present
2. RF LED – will be active when the RF output power is within 10 dB of the maximum (i.e optimal)
output power. It indicates that substanital RF power is being produced by this module.
P/No: 15-05004 Issue 2 14

RF Input
(100mW PEP)
1:6 RF Power Divider
(1KW PEP)
DC Power
RF Power Monitor
Temperature Monitor
DC Power Monitor
VSWR Monitor
MRF151G Bia Control
110 PIN Connector (ERNI:110PIN_EG044.766)
BNC Type Connector
PD55015 Block
MRF151G Block
PD55015 Bia Control
Block Diagram 7. VHF PA Driver
Picture 7. VHF PA Driver (Top View) Picture 8. VHF PA Driver (Bottom View)
P/No: 15-05004 Issue 2 15

3.3 PA Module
Hardware Specifications
Operating Frequency Range 30-60 MHz
Peak Envelope Power 4 KW PEP (minimum)
VSWR(Input/Output) 1.5:1 (minimum)
Maximum PRF Dependent on pulse width and maximum Duty Cycle
Pulse Shape Gaussian Square
Maximum Duty Cycle 10 % Gaussian 12% Square
Output Spurious and Harmonics Better than –35 dBc
Impedance (Input/Output) 50Ω
Output Level Adjustable from 0 to 100%
Power Supply 50V DC (typical) 800W (for max. Duty Cycle)
Ambient Temperature +5 to +35 oC
Sub-Rack Temperature +65 to +95 oC (60 oC rise for max. Duty Cycle)
Cooling Forced air-cooled
Physical Details Eurocard 9RU 14HP & 220mm Card Depth
Weight 2.5 Kg
Module Monitoring Forward/Reverse RF Power Power Supply Temperature.
External User Interfaces
Connector Details Direction Notes
N RF Output Output Level: 4 KW typical (1260 Vpp)
Internal Back Plane Interfaces
Connector Details Direction Notes
110 PIN ERNI Connector
(S/N044766 ERmet type
A female connector)
http://www.erni.com/
DC Power Supply Input 50 V @ 16 A.
DC Power Supply Input 15 V @ 0.5A
DC Power Supply Input 5 V @ 0.5 A
Health Monitor - Output Multiplexer Analog Bus
Health Monitor - Input 3 bit address 1 select. i.e
Tx Trigger Input 1 bit input +15V
VSWR Bus Output VSWR protection
Monitor LED Indicators
1. Supply LED – Controller Module must be present
2. RF LED – will be active when the RF output power is within 10 dB of the maximum (i.e optimal)
output power. It indicates that substantial RF power is being produced by this module. Do not
disconnect RF Output Cable while the RF LED is active.
P/No: 15-05004 Issue 2 16

MRF151G Block
MRF151G Block
MRF151G Block
MRF151G Block
RF Output
(4KW PEP)
1:4 RF Power Divider
(120W PEP)
1:4 RF Power Combiner
(4KW PEP)
DC Power
RF Power Monitor
Temperature Monitor
DC Power Monitor
VSWR Monitor
MRF151G Bia Control
110 PIN Connector (ERNI:110PIN_EG044.766)
N Type Connector
RF Input
(120W PEP)
Block Diagram 8. VHF PA Module
Picture 9. VHF PA Module (Top View)
P/No: 15-05004 Issue 2 17

Picture 10. VHF PA Module (Bottom View)
P/No: 15-05004 Issue 2 18

3.4 PA Controller
Block Diagram 9. PA Controller
Picture 11. PA Controller (Front View) Picture 12. PA Controller (Rear View)
P/No: 15-05004 Issue 2 19
RS232
DC Power
+12 V Regulator
RS232 PHY
Interface
Ethernet PHY
Interface
Interface
Atmel uP
110 PIN Connector (ERNI:110PIN_EG044.766)
RJ45
BNC
BNC
BNC
BNC
Mini-Con-X
Maxi-Con-X
uP SRAM
uP JTAG
CPLD JTAG
CPLD
DAC SRAM
DC Power
+5 V Regulator
Interface
RF Modulator
(RF In)
(RF Drive)
(Trig In)
(Trig Out)
(Control)
( Auxiliary )

External User Interfaces
Details
Debug
Connectors
RS232
Notes
Microprocessor Debug port.
Ethernet RJ45 Control & Monitor using the ARC Protocol.
LED's DC Power Trigger and Alarm Indicators
Trig In BNC PA Trigger Input Signal. TTL level pulse.
Trig Out BNC PA Trigger Output Signal.
RF In BNC RF carrier into the modulator (+13dBm typ.).
RF Drive BNC RF output to the PA Driver module/s.
Control Mini-Con-X RS422 user control
(Mini-Con-X 8 Pin Connector (Part No. 7282-8PG-
300) [Conxall http://www.conxall.com/ ])
Auxiliary Maxi-Con-X Custom interface to monitor external Atrad
Tx accessories such as the ST-40 12:1 Com-
biner the Combiner/Splitter/TR-Switch.
(Maxi-Con-X 18 Pin Connector (Part No. 14282-
18PC-300) [Conxall http://www.conxall.com/ ] )
Block Diagram 10. VHF PA Controller (Front Panel Connectors)
Internal Interfaces
Connector Details Direction Notes
110 PIN ERNI Connector
(S/N044766 ERmet type
A female connector)
http://www.erni.com/
DC Power Supply Input 50 V @ 1 A.
DC Power Supply Output 15 V @ 2A
DC Power Supply Output 5 V @ 2 A
Health Monitor - Analog Input Multiplexer Analog
Health Monitor - Digital Output 3 bit address 1
Tx Trigger Output 1 bit input +15V
VSWR Bus Input VSWR protection
Fan Health Monitor Input Fan Speed
P/No: 15-05004 Issue 2 20
VHF PA Contr olle r