Comtech EF Data PCB-4000 User manual

Phase Combiner
IMPORTANT NOTE: The information contained in this document supersedes all previously published
informationregardingthisproduct.Productspecificationsaresubjecttochangewithoutpriornotice.
P/N MN/PCB4000.IOM Revision 0
PCB-4000
Installation and Operation Manual

PCB-4000
Phase Combiner
Installation and Operation Manual
P/N MN/PCB4000.IOM
Revision 0
August 25, 2005
Comtech EF Data is an ISO 9001
Registered Company.

CUSTOMER SUPPORT
Contact the Comtech EF Data Customer Support Department for:
4Product support or training
4Information on upgrading or returning a product
4Reporting comments or suggestions concerning manuals
Contact Customer Support using any of the following methods:
Email: [email protected]
Mail: Comtech EF Data
Customer Support Department
2114 West 7th Street
Tempe, Arizona 85281 USA
Internet: www.comtechefdata.com
Phone: [phone]
(Main Comtech EF Data Number)
480. 333.4357 (Customer Support Desk)
Fax: [phone]
To return a Comtech EF Data product (in-warranty and out-of-warranty) for repair or
replacement:
1. Request a Return Material Authorization (RMA) number from the Comtech EF Data
Customer Support Department.
2. Be prepared to supply the Customer Support representative with the model number,
serial number, and a description of the problem.
3. To ensure that the product is not damaged during shipping, pack the product in its
original shipping carton/packaging.
4. Ship the product back to Comtech EF Data. (Shipping charges should be prepaid.)
For more information regarding the warranty policies, see Warranty Policy, p. vi.

i
Table of Contents
CHAPTER 1. INTRODUCTION..........................................................................................1–1
1.1 Introduction.........................................................................................................................1–1
1.2 Description...........................................................................................................................1–2
1.3 Dimensional Envelope ........................................................................................................1–5
CHAPTER 2. CONNECTOR PINOUTS.............................................................................2-1
2.1 External Connectors .....................................................................................................2-1
2.1.1 System Comm Connector, J1..........................................................................................2-2
2.1.2 SSPA Comm 1 or 2 Connector, J2, J3, or J4 (J4 only for 1:2 systems) .........................2-3
2.1.3 SSPA SW Out, J5 ...........................................................................................................2-4
2.1.4 RF Input Switch, J6.........................................................................................................2-5
2.1.5 RF IN 1, J7......................................................................................................................2-5
2.1.6 RF IN 2, J8......................................................................................................................2-5
2.1.7 SSPA Out 1, J9 ...............................................................................................................2-5
2.1.8 SSPA Out 2, J10 .............................................................................................................2-5
2.1.9 Notes:..............................................................................................................................2-6
CHAPTER 3. THEORY OF OPERATION .........................................................................3-1
3.1 Introduction..........................................................................................................................3-1
3.2 Phase and Gain Equalization..............................................................................................3-2
3.3 System Attenuation..............................................................................................................3-2
3.4 Soft Fail Protection..............................................................................................................3-2
CHAPTER 4. ALIGNMENT PROCEDURES...................................................................4-1
4.1 Introduction..........................................................................................................................4-1

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4.2 LED Operation.....................................................................................................................4-2
4.2 Initial System Setup and Verification................................................................................4-3
4.3 Gain or Amplitude Balance Verification and Alignment.................................................4-4
4.4 Amplitude Alignment (as necessary)..................................................................................4-5
4.5 Phase Alignment...................................................................................................................4-6
4.6 System Online and Transmitting........................................................................................4-6
CHAPTER 5. REMOTE COMMANDS...............................................................................5-1
5.1 Introduction..........................................................................................................................5-1
5.2 RS-485...................................................................................................................................5-1
5.3 RS-232...................................................................................................................................5-2
5.4 Basic Protocol.......................................................................................................................5-2
5.5 Packet Structure...................................................................................................................5-3
5.5.1 Start Of Packet................................................................................................................5-3
5.5.2 Base Address...................................................................................................................5-3
5.5.3 Virtual Address ...............................................................................................................5-4
5.5.4 Instruction Code..............................................................................................................5-4
5.5.5 Instruction Code Qualifier ..............................................................................................5-5
5.5.6 Message Arguments........................................................................................................5-6
5.5.7 End Of Packet .................................................................................................................5-6
5.5.8 Remote Commands.........................................................................................................5-7
APPENDIX A. ASSEMBLY KIT .........................................................................................A-1
A.1 Parts List for Combined 1:1 ODPA X-Band Assembly Kit P/N KT/11344(-1)............A-5

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Figures
FIGURE 1-1. PCB-4000, PHASE COMBINER CONTROL BOX (PCCB)............................ 1–1
FIGURE 1-2. BLOCK DIAGRAM ........................................................................................... 1–3
FIGURE 1-3. DIMENSIONAL ENVELOPE ........................................................................... 1–5
FIGURE 2-1. EXTERNAL CONNECTORS .............................................................................2-1
FIGURE 3-1. COMBINING LOSS VS. PHASE IMBALANCE ............................................. 3-1
FIGURE 4-1. SYSTEM SETUP AND VERIFICATION ......................................................... 4-2
FIGURE A-1. COMBINED 1:1 ODPA X-BAND ASSEMBLY KIT, P/N KT/11344 ............A-3
Tables
Table 2-1. EXTERNAL CONNECTORS ..............................................................................2-1
Table 2-2. SYSTEM COMM CONNECTOR PIN ASSIGNMENTS J1 ...............................2-2
Table 2-3. SSPA COMM 1, 2, 3 CONNECTOR PIN ASSIGNMENTS, J2, J3, J4 ..............2-3
Table 2-4. SSPA SW OUT, J5................................................................................................2-4
Table 2-5. RF INPUT SWITCH, J6........................................................................................2-5
Table A-1. PARTS LIST.......................................................................................................A-5

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ABOUT THIS MANUAL
This manual provides installation and operation information for the Comtech EF Data
PCB-4000, Phase Combiner. This is a technical document intended for earth station engineers,
technicians, and operators responsible for the operation and maintenance of the Phase Combiner.
CONVENTIONS AND REFERENCES
CAUTIONS AND WARNINGS
CAUTION
CAUTION indicates a hazardous situation that, if not avoided, may
result in minor or moderate injury. CAUTION may also be used to
indicate other unsafe practices or risks of property damage.
WARNING
WARNING indicates a potentially hazardous situation that, if not
avoided, could result in death or serious injury.
IMPORTANT
IMPORTANT indicates a statement that is associated with the task
being performed.
METRIC CONVERSION
Metric conversion information is located on the inside back cover of this manual. This
information is provided to assist the operator in cross-referencing English to Metric conversions.
TRADEMARKS
Other product names mentioned in this manual maybe trademarks or registered trademarks of
their respective companies and are hereby acknowledged.

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REPORTING COMMENTS ORSUGGESTIONS CONCERNING THISMANUAL
Comments and suggestions regarding the content and design of this manual will be appreciated.
To submit comments, please contact:
Comtech EF Data Technical Publications Department: [email protected]
SAFETY NOTICE
This equipment has been designed to minimize exposure of personnel to hazards.
The operators and technicians must:
•Know how to work around, with and on high voltage equipment.
•Exercise every precaution to ensure personnel safety.
•Exercise extreme care when working near high voltages.
•Be familiar with the warnings presented in this manual.
CAUTION
A Neutral Fusing -Double pole/ neutral fusing used on the prime
power supply input.

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WARRANTY POLICY
This Comtech EF Data product is warranted against defects in material and workmanship for a
period of 24 months from the date of shipment. During the warranty period, Comtech EF Data
will, at its option, repair or replace products that prove to be defective.
For equipment under warranty, the customer is responsible for freight to Comtech EF Data and
all related custom, taxes, tariffs, insurance, etc. Comtech EF Data is responsible for the freight
charges only for return of the equipment from the factory to the customer. Comtech EF Data
will return the equipment by the same method (i.e., Air, Express, Surface) as the equipment was
sent to Comtech EF Data.
LIMITATIONS OF WARRANTY
The foregoing warranty shall not apply to defects resulting from improper installation or
maintenance, abuse, unauthorized modification, or operation outside of environmental
specifications for the product, or, for damages that occur due to improper repackaging of
equipment for return to Comtech EF Data.
No other warranty is expressed or implied. Comtech EF Data specifically disclaims the implied
warranties of merchantability and fitness for particular purpose.

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EXCLUSIVE REMEDIES
The remedies provided herein are the buyer's sole and exclusive remedies. Comtech EF Data
shall not be liable for any direct, indirect, special, incidental, or consequential damages, whether
based on contract, tort, or any other legal theory.
DISCLAIMER
Comtech EF Data has reviewed this manual thoroughly in order to provide an easy-to-use guide
to your equipment. All statements, technical information, and recommendations in this manual
and in any guides or related documents are believed reliable, but the accuracy and completeness
thereof are not guaranteed or warranted, and they are not intended to be, nor should they be
understood to be, representations or warranties concerning the products described. Further,
Comtech EF Data reserves the right to make changes in the specifications of the products
described in this manual at any time without notice and without obligation to notify any person
of such changes.
If you have any questions regarding your equipment or the information in this manual, please
contact the Comtech EF Data Customer Support Department.

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Chapter 1. INTRODUCTION
1.1 INTRODUCTION
Phase combining is a traditional technique to cost effectively increase the available
output power of an amplifier system. The PCB 4000 (1+1 version), together with 2
SSPAs, form a complete 1+1 phase combined system that doubles the available output
power. The PCB 4000 (1+1) also features a “soft fail” configuration, such that if one
SSPA experiences a failure, the total output power will only be reduced by 3dB, rather
than 6dB.
Figure 1-1. PCB-4000, Phase Combiner Control Box (PCCB)

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1.2 DESCRIPTION
Figure 1-2 is a block diagram that shows the major components of the phase combined
system.
The Phase Combiner Control Box (PCCB) contains a microprocessor based M&C circuit
board to control the system. The PCCB communicates with each SSPA via control
cables that are attached from the PCCB (J2, J3) to each SSPA. It is also through this
connection that the PCCB receives it prime power to operate. A +24V signal from each
SSPA is diode OR’ed to provide redundant operating power for the PCCB. Control of
the waveguide switches is accomplished via a “Y” cable (J5). The user communicates
with the control box via the System Comm. Connection (J1). (In order to avoid
ambiguities, all communication to each SSPA is also accomplished via the control box
M&C.)
The PCCB provides a weatherized housing for the necessary input RF components. An
input RF redundancy switch selects which RF path is directed to the output. It is
controlled via J6. The output RF signal is fed into an in-phase divider, which equally
splits the signal in phase and amplitude to SSPA #1 and SSPA#2 outputs (J9, J10). The
RF path to SSPA #1 (J9) contains a manually adjustable phase shifter. This phase shifter
is used to equalize the phase difference of each SSPA signal path to achieve maximum
system output power. It is accessible via a small cover panel. This critical component is
factory set and should only be adjusted if needs arise by carefully following an
appropriate alignment procedure. (See sections on alignment and operation). The path to
SSPA #2 (J10) contains a length of coaxial cable that is factory manufactured to provide
equal phase length paths from the RF input to each PCCB output when the adjustable
phase shifter is set to its midpoint. This provides a maximum adjustable phase range.
There are also several isolators inside the PCCB that maintain good system VSWR. The
user should not alter any RF cable inside (or outside) this box that is part of the RF signal
path.
The RF signals from the PCCB are fed to the RF input of the respective SSPA via a set of
phase matched cables. Again, the phase length (and matching) of these cables is essential
to system operation and no substitutes should be used. The routing should not be such to
cause extreme bends.
The output waveguide combining system consists of balanced waveguide lengths, 2
waveguide transfer switches, a “magic-tee” combiner with termination, and couplers for
test and alignment.

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Figure 1-2. Block Diagram

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.88
R
.13
R.25
7.30
12.70
.45
.43
4X KEY HOLE4X KEY HOLE
1.3 DIMENSIONAL ENVELOPE
Note: All dimensions are in English units; metric units are in the parentheses.
Figure 1-3. Dimensional Envelope
SUM
SSPA1 SSPA2
STATUS

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2
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1
Chapter 2. CONNECTOR PINOUTS
2.1 EXTERNAL CONNECTORS
Figure 2-1. External Connectors
Table 2-1. External Connectors
Name Ref Des Mating Connector Type Function
System Com J1 ITT Cannon MS3116J14-19P
CEFD CN/MS3116J14-19P Customer RS 232/485 and discrete
interface
SSPA Com 1 J2 ITT Cannon MS3116J14-19P
CEFD CN/MS3116J14-19P Connects to SSPA 1
SSPA Com 2 J3 ITT Cannon MS3116J14-19P
CEFD CN/MS3116J14-19P Connects to SSPA 2
SSPA Com 3(only for 1:2
systems) J4 ITT Cannon MS3116J14-19P
CEFD CN/MS3116J14-19P Connects to SSPA 3(only for 1:2
systems)
SSPA SW OUT J5 ITT Cannon MS3116J14-19P
CEFD CN/MS3116J14-19P Connects to both waveguide switches
RF INPUT SWITCH J6 ITT Cannon MS3116J10-6S
CEFD CN/MS3116J10-6S Drive input, selects either RF IN 1 or 2
RF IN 1 J7 Type N RF input 1
RF IN 2 J8 Type N RF input 2
SSPA OUT 1 J9 Type N RF output to SSPA 1
SSPA OUT 2 J10 Type N RF output to SSPA 2
RF IN 1
J7
SSPA
SW OUT
J5
SSPA
COM 1
J2
SYSTEM
COM
J1
RF IN 2
J8
SSPA
COM2
J3
RF INPUT
SWITCH
J6
SSPA
OUT 2
J10
SSPA
OUT 1
J9

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IMPORTANT
To maintain compliance with the European EMC Directive (EN55022,
EN50082-1) properly shielded cables are required for data I/O.
2.1.1 SYSTEM COMM CONNECTOR, J1
Table 2-2. System Comm Connector Pin Assignments, J1
Pin
#Signal Function Signal Name
ARS485_+RX Customer communications interface
BRS485_-RX Customer communications interface
CRS485_+TX Customer communications interface
DRS485_-TX Customer communications interface
ERS232_RD Customer communications interface
FSpare Reserved for future use
GRS232_TD Customer communications interface
HSystem Fault NO When there is a summary fault in the PCB-4000, this pin (NO) will be tied
to the Fault Common pin.
JSystem Fault NC When there is not a summary fault in the PCB-4000, this pin (NC) will be
tied to the Fault Common pin.
KFault Common
LSSPA 1 Fault
NO When there is a fault with SSPA 1, this pin (NO) will be tied to the Fault Common pin.
MSSPA 1 Fault
NC When there is not a fault with SSPA 1, this pin (NC) will be tied to the Fault Common pin.
NGround
PSSPA2Fault
NO When there is a fault with SSPA 2, this pin (NO) will be tied to the Fault
Common pin.
RSSPA2Fault
NC When there is not a fault with SSPA 2, this pin (NC) will be tied to the
Fault Common pin.
SSystem Mute SSPA will be muted if this pin is grounded
TSSPA3Fault
NO When there is a fault with SSPA 3, this pin (NO) will be tied to the Fault
Common pin. (Only for 1:2 systems)
USSPA3Fault
NC When there is not a fault with SSPA 3, this pin (NC) will be tied to the
Fault Common pin. (Only for 1:2 systems)
VGround GND