MCL MT4000 TWTA User manual

TN4000-2
Technical Note
Installation Guide for MT4000 TWTA
October 24, 2003
Mark Schmeichel 10/24/03
Engineering Date

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TABLE OF CONTENTS
1.0 SAFETY SUMMARY ................................................................................................................3
1.1 General Safety Precautions...............................................................................................3
1.2 Definitions of Warnings, Cautions, and Notes.................................................................4
1.3 List Of Hazards.................................................................................................................5
2.0 INTRODUCTION ......................................................................................................................7
3.0 HPA INSTALLATION INSTRUCTIONS...............................................................................7
3.1 Unpacking the TWTA.......................................................................................................7
3.2 Repacking the TWTA....................................................................................................... 8
3.3 Returning Damaged Equipment........................................................................................8
3.4 Typically Required Tools..................................................................................................8
3.5 Configurations Under the HPA Top Cover ......................................................................9
3.6 Installation to Reduce Radiated Emissions.....................................................................10
3.7 Installation of TWTA Drawer into the Cabinet.............................................................. 10
3.8 Computer & Remote Cable Connection.........................................................................11
3.9 Connection to the “User” Interface.................................................................................12
3.10 Connection to the “Switchover” Interface......................................................................13
3.11 Cooling Duct Installation................................................................................................ 14
3.12 Chassis Ground Connection............................................................................................15
3.13 Installation of Primary Power .........................................................................................15
3.14 Clean-Up.........................................................................................................................16
4.0 DIAGNOSTIC INTERFACE INSTALLATION REQUIREMENTS.................................16

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1.0 SAFETY SUMMARY
1.1 General Safety Precautions
The following are general safety precautions and instructions that personnel must understand
and apply during many phases of operation and maintenance to ensure personnel safety and
health and the protection of property. Portions of this information may be repeated in certain
chapters of this publication for emphasis.
WARNING AND CAUTION STATEMENTS
WARNING AND CAUTION statements have been strategically placed in the text to emphasize
certain steps or procedures for the protection of personnel (WARNING) or equipment
(CAUTION). A WARNING or CAUTION once provided should apply each time the related
step is repeated, regardless of the number of times the WARNING or CAUTION is repeated
throughout the text. Prior to starting any task, the WARNINGS or CAUTIONS included in the
text for that task should be reviewed and understood.
KEEP AWAY FROM LIVE CIRCUITS
Operating personnel must at all times observe safety regulations. Do not replace components or
make adjustments inside the equipment with the voltage supply turned on. Under certain
conditions, dangerous potentials may exist when the power control is in the off position, due to
charges retained by capacitors. To avoid injuries, always remove power from, discharge, and
ground a circuit before touching it. Adhere to all lock out/tag out requirements.
DO NOT SERVICE OR ADJUST ALONE
Do not attempt internal service or adjustment unless another person capable of rendering aid
and resuscitation is present.
RESUSCITATION
Personnel working with or near dangerous voltage shall be trained in modern methods of
resuscitation.
COMPRESSED AIR
Use of compressed air for cleaning can create an environment of propelled foreign particles.
Air pressure shall be reduced to less than 30 psi and used with effective chip guarding and
personnel protective equipment.

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1.2 Definitions of Warnings, Cautions, and Notes
An operating or maintenance procedure, practice, condition, statement,
etc., which if not strictly observed, could result in injury to or death of
personnel.
An operating or maintenance procedure, practice, condition, statement,
etc., which if not strictly observed, could result in damage to or
destruction of equipment, or loss of mission effectiveness.
NOTE
An essential operating or maintenance procedure, condition, or statement
which must be highlighted.
WARNING
CAUTION

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1.3 List Of Hazards
The operation of this amplifier may involve some of the following hazards; any of them could
result in serious harm to personnel if proper safety precautions are not taken.
HIGH VOLTAGE
Lethal Voltages up to 15,000 Volts are present in this amplifier when it
is operating. USE EXTREME CAUTION when inside the unit. Do not
insert objects through air intake screen on rear of drawer. When
testing, always ground the drawer chassis.
RF RADIATION
Exposure to RF radiation may cause serious bodily injury possibly
resulting in blindness and death. Cardiac pacemakers may be affected.
Always terminate both the RF input and RF output, even during tests,
which involve no RF drive, to avoid the RF hazard should the TWTA
oscillate.
BERYLLIUM OXIDE
The dust or fumes from Beryllium Oxide (BeO) ceramics used in
microwave tubes are highly toxic and can cause serious injury or death.
WARNING
WARNING
WARNING

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IMPLOSION HAZARD
Ceramic windows from microwave tubes can shatter on impact or crack
in use resulting in injury from Beryllium Oxide dust or fumes.
X-RAY RADIATION
High voltage tubes can produce dangerous, possibly fatal X-Rays.
HOT SURFACES
Surface temperature of tubes and other air-cooled parts can reach
several hundred degrees centigrade.
RF OVERDRIVE
Drive levels as low as –17 dBm may damage the unit for the Model
MT4000 depending upon the settings of the system attenuator. Please
apply RF with caution. Always terminate RF input and output ports
properly when AC power is supplied to the TWTA.
WARNING
WARNING
WARNING
CAUTION

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2.0 INTRODUCTION
This document contains information to help the system integrator to install the MCL MT4000
TWTA. Be sure to completely read this installation guide. This document assumes a
familiarity and working experience with high power microwave RF amplifiers. Once the
MT4000 has been installed, please read TN4000-3 - Operation of MT4000 TWTA,for initial
turn on instructions.
3.0 HPA INSTALLATION INSTRUCTIONS
The MT4000 system is shipped in a fully assembled condition. Several steps in the installation
guide will require heavy lifting and more than one person will be required. The installation
personnel should have a working knowledge of electronic and SatCom equipment.
It is recommended that a professional HVAC engineer consult on the
design of the air intake and exhaust ducts.
3.1 Unpacking the TWTA
Prior to unpacking, inspect the exterior of the packing containers for damage received during
shipment. If damage is present, contact the carrier that delivered the system and submit a
damage report. Failure to do this could complicate, or invalidate a claim. Carefully unpack and
remove all items from their shipping containers and inspect the items further for signs of
damage.
Be careful not to damage components with pry bars when opening
shipping crates. Do not use pry bars to extract components from crates.
Save all packing materials until inspections are complete. Verify that all items listed on the
packing slip have been received. Be sure to find the documentation package, which is packaged
with the HPA.
CAUTION
CAUTION

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3.2 Repacking the TWTA
Use original packing containers if possible. Place the unit in a clean, open work area. Cover
any open RF waveguide flanges with a plastic cap designed for this purpose (adhesive tape is
not recommended as it quickly deteriorates, leaving a residue on the flanges). Wrap the unit in
heavy paper or plastic. Use a suitable shipping container. Surround the unit in shock absorbing
material to provide a firm cushion and prevent movement inside the container. Do not allow
any packing materials to enter any drawers, enclosures or waveguide. Seal the container and
mark exterior “FRAGILE Electronic Equipment.” Further packaging information is available
from MCL (request MCL packaging specification 34A2249).
3.3 Returning Damaged Equipment
If the system must be returned, call the factory for an RMA number (Returned Materials
Authorization). See TN4000-6 - Technical Note, Troubleshooting & Customer Service Guide,
for more information.
3.4 Typically Required Tools
Allen wrench, 5/32 (C-Band only)
Allen wrench, 7/64 (Ku-Band including DBS)
Screwdriver, #2 Phillips
Screwdriver, Standard 1/8
5/16” torque sensing open-end wrench is recommended
5/16” blade screwdriver standard
Socket wrench set
5/16” wrench
3/8” wrench (C-Band only)

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3.5 Configurations Under the HPA Top Cover
There are two hardware configurations under the HPA cover. First the Remote Panel
terminating resistor jumper is located on J16 (pins 1 & 2) of the BFC. Refer to the optional
Remote Panel installation technical note to determine if you need to install the jumper (it is
normally not installed). Second, through the purchase order process the Computer interface
hardware configuration of the MT4000 was set to either RS232 or RS485. At this time verify
that the MT4000 was ordered according to the system integrators requirements. If it was not
you would have to remove the HPA cover and move the cable (W25) between J8 & J4 of the
front panel logic (BFC CCA).
Make sure the top cover of the MT4000 is attached; the cover is part of the
cooling circuit.
CAUTION

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3.6 Installation to Reduce Radiated Emissions
In order to meet the radiated emissions requirements of CE type applications (ETSI EN 300
673:2000) the system integrator is required to provide double-shielded DC cabling to the HPA.
The Switchover (J7) and User (J6) interfaces require the use of a good quality double shielded
(100% foil shield plus 85% or greater braided shield) cable. An example part number is a
Black Box Corporation #EMN25C-0015-MF (25 pin, male-female, 15 ft long). It is also
recommended that the same type cable is used on the Remote (J4) & Computer (J5) interfaces.
Be sure to install the HPA chassis ground braid as detailed below.
3.7 Installation of TWTA Drawer into the Cabinet
The following steps should be taken to insure that the MT4000 is properly installed. Refer to
43D1418 – MT4000 Interface Drawing that is included with TN4000 –7 Customer Schematics
& Assemblies.
Be sure that the MT4000 drawer is firmly supported during installation.
1. Position the MT4000 in close proximity to final installation rack (MCL supplied or
other). This will eliminate any unnecessary moving of the system.
2. Install slides in rack at a location with the dimensions and required interfaces shown on
43D1418.
3. Install the MT4000 into the rack.
4. Make all RF input and output connections.
Be certain that all RF connections are secure and that there is a load, or
an antenna, connected to the RF output waveguide. Failure to secure
these connections will pose a hazard to operating personnel and could
result in malfunction of the equipment.
5. Install the remaining interconnects as required by the system integrator using the
following paragraphs as a guide.
Do not install the AC input until the last step of the installation process.
CAUTION
CAUTION
WARNING

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3.8 Computer & Remote Cable Connection
Connect the Computer interface cable according to the system integrator requirements for
RS232 or RS485. The Remote interface is always a RS485 interface. If a Remote Panel was
ordered see its technical note for installation instructions.

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3.9 Connection to the “User” Interface
The User Interface (J6) has been supplied to provide the user a way to connect the MT4000 to
other equipment. This interface is a 15 position “D” connector located on the back of the
MT4000. The signals available at this interface are listed below:
CONTACT
NUMBER SIGNAL NAME FUNCTION
1 Interlock Fault Input
9 Fault Return
Normally Closed Contact (15mA or
less), Open During a Fault.
2 Waveguide Press. Fault Input
10 Fault Return
Normally Closed Contact (15mA or
less), Open During a Fault.
3, 4, 11 Spare
5 RF Off Input
12 RF Off Return
Normally Closed Contact (15mA or
less), Open During a RF Off.
13 N.O.
6 Com.
14 N.C.
Summary Fault Output Isolated Form C Contact Set,
De-Energized is a Fault.
7 N.O.
15 Com.
8 N.C.
Summary Alarm Output Isolated Form C Contact Set,
De-Energized is an Alarm.
Relay Outputs are rated for the following:
Max. Switching Current 0.3 A DC, AC
Max. Switching Voltage 100 V DC, 120 V AC
Max. Switching Power 30 W, 37 VA

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3.10 Connection to the “Switchover” Interface
The Switchover Interface (J7) has been supplied to provide the user a way to connect the
MT4000 to a Model D13188 switchover (or some other user supplied switchover). This
interface is a 25 position “D” connector located on the back of the MT4000. The signals
available are listed in the table below.
CONTACT
NUMBER SIGNAL NAME FUNCTION
2 This HPA to the Antenna Input Active High (+15V), Latched During
Antenna.
3 This HPA to the Dummy Load Input Active High (+15V), Latched During
Load.
1 RF Off Input
14 Return
Normally Closed Contact (15mA or
less), Open During a RF Off.
6 Exciter Alarm Input Active High (+15V), Latched During
Alarm.
19, 20 – 24 Spare N/A
15 & 16 +15V DC Output
17 & 18 15V Return
For Model D13188 Switchover Only.
4 This HPA to the Antenna Output Active Low (15V return), Pulsed for
200 ms.
5 This HPA to the Dummy Load Output Active Low (15V return), Pulsed for
200 ms.
7 N.O.
8 Com.
9 N.C.
Switchover Fault Output
Isolated Form C Contact Set,
De-Energized is a Fault.
10 Second HPA Switchover Fault Input Active High (+15V), Latched During
Fault.
13 RF Low Switching Input
25 Return
Normally Open Contact (15mA or
less), Closed During a RF Off.
11 Auto Switching Loop Input Active High (+15V), Latched During
Auto.
12 Auto Switching Loop Output Active Low (15V return), Latched
During Auto.
Relay Outputs are rated for the following:
Max. Switching Current 0.3 A DC, AC
Max. Switching Voltage 100 V DC, 120 V AC
Max. Switching Power 30 W, 37 VA

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3.11 Cooling Duct Installation
See 43D1418 for interface locations.
Make sure the top cover of the MT4000 is attached; the cover is part of the
cooling circuit.
3.11.1 Intake Air Temperature
The air supplied to the unit must be maintained between -10°C and 50°C. The maximum must
be derated at 1.9°C per 1,000 ft of altitude (i.e. maximum temperature @ 3,000 ft is 44.3°C).
Operation outside these limits will permanently damage the TWT. Check with local weather
service to see if heating or cooling of intake air will be required at any time.
3.11.2 Ducting Back Pressure
The ductwork must be designed such that the added restriction of airflow from both the intake
and exhaust ducts does not exceed 0.5 in (12.7 mm) H2O backpressure at 190 cfm (323 m3/hr)
airflow.
3.11.3 Intake Humidity and Temperature Differential
In areas of high humidity, a danger of condensation buildup exists when unconditioned air from
outside the shelter is delivered to the MT4000 while the MT4000 is “cold.” The MT4000
should not be operated when a temperature difference of greater than 10°F (5.5°C) exists
between the input cooling air and the MT4000 ambient temperatures. Under these conditions,
a condensation check should be made before attempting a cold-start operation on the MT4000.
3.11.4 Air Filtration
The MT4000 has no air filters. It is the responsibility of the system integrator to provide
filtering for each amplifier. Air filter arrestance shall be 70% or greater when tested per
ASHRAE 52.2.
NOTE
A filter with a minimum efficiency reporting value of 3 (MERV 3 filter) is
recommended.
CAUTION

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3.11.5 Air Flow Warning
Two alarms have been designed into the MT4000 to indicate that there may be a clogged air
filter or some other obstruction in the cooling path. These alarms are “Tube Temperature” and
“Power Supply Temperature” alarms. See the initial turn on section of TN4000-3 - Technical
Note, Operation of MT4000 TWTA.
3.11.6 Use of Shelter Air
Shelter air may be used to cool the HPA, however, care must be taken to prevent re-circulation
of exhausted air back into the HPA, or exhausted air from another piece of equipment into the
HPA. Also the shelter cooling system must be rated to take the heat load of the HPA exhaust.
Each HPA can dissipate up to 2000 Watts into the air.
3.12 Chassis Ground Connection
A stud on the back panel has been supplied to connect system to a good permanent earth
ground. This stud supplies Safety ground to the whole TWTA internal system. A ½’ thick
braided ground strap is recommended between the MT4000’s #10-32 ground stud and earth
ground. The ground strap must be kept as short as possible to prevent high frequency noise
problems. This ground braid is required to meet various safety requirements.
This ground braid is required to meet various safety requirements.
3.13 Installation of Primary Power
Connect the IEC-320 power cord supplied with the MT4000 to a prime power source of the
proper voltage and frequency. The AC input connector (J1) is located on the MT4000 back
panel, refer to 43D1418. The MT4000 source circuit breaker is recommended to be an
equivalent to a Carlingswitch #AB2-B0-21-630. In cases of multiple amplifier installations,
each amplifier shall be provided with a separate breaker.
NOTE
Prime power requirements are:
3.13.1 Input Voltage Amplitude Range 180-264 VAC, Single Phase, 2 wire
3.13.2 Input Frequency Range 47 - 63 Hz
WARNING

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3.13.3 Input Voltage In-Rush Current Limit
The integrated sum of all transients of in-rush current within any interval of time equivalent to
three (3) consecutive one-half alternating current (AC) cycles shall not exceed 28A.
3.13.4 Input Power Factor (Minimum) 0.95
3.13.5 Input Power (Nominal) 2450 VA
3.14 Clean-Up
Make certain that all connectors are attached and tight. Remove all tools, packing materials and
reference materials. Go to the initial turn on section of TN4000-3 - Technical Note, Operation
of MT4000 TWTA.
4.0 DIAGNOSTIC INTERFACE INSTALLATION REQUIREMENTS
Find the CD that is packaged with the documentation for your HPA. This CD contains the
45A0158 Diagnostic Test program. To install this program follow the directions on the cover
of the CD box. Refer to of TN4000-3 - Technical Note, Operation of MT4000 TWTA, for
operating procedures. The system requirements for the 45A0158 Diagnostic Test program are
as follows:
MicrosoftWindowsXP, 2000, NT, 98, or 95
32 MB RAM
5 MB hard disk space
Pentium or higher processor