Xicom TWTA Manual

Unpacking and Installation, TWTA Octagon CPU
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Unpacking and Installation, TWTA Octagon CPU
Record of Changes
Revision ECO Description Date Initiated By
A 9295 Original Release 11/29/2001 A.L. Crozier, Jr.
B 9933 Add information for Tri-band Power
Connector 06/21/2002 A.L. Crozier, Jr.
C 10096 Replace Fig. 7 07/14/2002 A.L. Crozier, Jr.
D 10197 Update RF Inhibit Information 08/26/2002 A.L. Crozier, Jr.
E 10490 Update to reflect waveguide flange
protection 12/10/2002 A.L. Crozier, Jr.
F 10980 Update Figure 5 to show proper pinouts 04/22/2003 A.L. Crozier, Jr.
G 11340 Add Waveguide Torque Table 08/13/2003 A.L. Crozier, Jr.
H 11883 Correct pinouts on MS Power Plug. Add
Waveguide Switch connector pinouts. 03/08/2004 A.L. Crozier, Jr.
J 12470 Add Hardware Address Select and
Discrete HV ON Indicator 09/01/2004 A.L. Crozier, Jr.
K 12715 Change to reflect absorptive vice
reflective filtering for W/G 04/21/2005 J. Thompson
L 12775 Change title, add Octagon TWT note
and various other edits 04/26/2005 T. Stewart
M 12927 Add German Language translation to
comply with CE requirement 07/07/2005 A. L. Crozier, Jr.
N 13332 Auxiliary Connector Figure 08/22/2005 A. Auld

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Unpacking and Installation, TWTA Octagon CPU
Table of Contents
Paragraph Title Page Number
Unpacking and Installation, TWTA Octagon CPU . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Mechanical Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Waveguide Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Air Ducting Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Power and Interface Interconnections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Prime Power Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
External Interlock (Prime power enable). . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Monitor and Control Connector. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Monitor and Control Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Redundancy Interface (Waveguide Switch) Connector (J6). . . . . . . . . . . . . . 14
RF Inhibit Control (J1-Y) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Serial Interface Ports (J1-A to J1-R). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Summary Fault Indicators (J1-S to J1-X) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Output Voltages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Hardware Address Select (J1-d). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
High Voltage ON Indicator (J1- e). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Local Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

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Unpacking and Installation, TWTA Octagon CPU
List of Figures
Paragraph Title Page Number
Figure 1 , Typical 4 Screw Mounting Flange Tightening Sequence. . . . . . . . . . . . . . . . 8
Figure 2 , Typical 8 Screw Mounting Flange Tightening Sequence. . . . . . . . . . . . . . . . 8
Figure 3 , Connector J2 Pinout for Standard Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Figure 4 , Connector J2 Pinout for EIK Unit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 5 , MS Connector J2 Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 6 , Prime Power Enable Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Figure 7 , M&C Connector Pin Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figure 8 , Waveguide Switch Connector Pinouts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Figure 9 , RF Inhibit with Internal Source. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 10 , RF Inhibit with External Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Figure 11 , RF Inhibit with Switch A Open. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Figure 12 , Typical RS-485 2-Wire Duplex Implementation. . . . . . . . . . . . . . . . . . . . . 18
Figure 13 , Typical RS-485 4-Wire Full Duplex Implementation . . . . . . . . . . . . . . . . . 18

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Unpacking and Installation, TWTA Octagon CPU
List of Tables
Paragraph Title Page Number
Table 1 , Recommended Waveguide Flange Torque . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Table 2 , Monitor and Control Connector Pinouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Table 3 , Redundancy Interface (Waveguide Switch) Connector Pinouts. . . . . . . . . . 14

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Unpacking and Installation, TWTA Octagon CPU
Note
This document is intended for outdoor TWTAs and
other related products with Octagon microprocessors.
Unpacking and Inspection
Inspect the inside and outside of the shipping container for signs
of damage. If any shipping damage is detected, call the shipping
carrier and submit a damage report.
Unpacking
Compare the packing list to the contents of the container to be
certain that all enclosed material has been received. Save all
data sheets. They will be useful during any maintenance
actions. Save the shipping container and packing material and
use it if you need to reship the unit.
Inspection
Inspect all items for any damage received during shipment. If
shipping damage is detected, submit a damage report to the
shipping carrier. Failure to submit a report may invalidate any
future claims.
Mechanical Installation
Some units have mounting brackets supplied to mount the
amplifier. Refer to the appendix titled Mechanical Drawings.
When performing the procedures in this section refer to the
Outline Drawings and Interconnect Drawings for your specific
amplifier. These drawings are located in appendices titled
Mechanical Drawings and Interconnect Drawings.

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Waveguide Connection
Caution
Do not overtighten the waveguide mounting screws.
Overtightening may strip the threads in the waveguide
flange. Failure to comply could result in equipment
damage.
Vorsicht
Überdrehen Sie nicht die Hohlleiter-
Befestigungsschrauben. Dadurch kann das Gewinde
im Hohlleiter-Flansch ausreißen. Nichtbefolgen könnte
Beschädigung des Gerätes zur Folge haben.
The RF input waveguide (Ka Band and Q Band) is located on
the front panel of the amplifier and RF output waveguide port is
located on the rear panel of the amplifier. Ensure that the proper
matching waveguide flange is used to connect the amplifier
input and output to the RF load.
Refer to Figure 1 , Typical 4 Screw Mounting Flange Tightening
Sequence and Figure 2 , Typical 8 Screw Mounting Flange
Tightening Sequence, for the proper tightening sequence on the
flange types installed on your amplifier.
Use the following procedure to install the waveguides on your
amplifier.
Caution
When not connected to the external waveguide system
or a terminated load, waveguide flanges should be
covered with a protective cap or tape that does not
leaveglue residuewhenremoved. Xicomrecommends
the use of Kapton® tape, 3M Brand, #92, Xicom P/N
602-0001-001. Remove tape or cap prior to final
installation. Failure to comply could result in
contamination to the internal waveguide system or
TWT and equipment damage.

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Vorsicht
Wenn Hohlleiter-Flanschen nicht mit dem externen
Hohlleiter-System oder einer terminierten Belastung
verbunden sind, sollten sie mit einer Schutzkappe oder
Band abgedeckt werden, das beim Entfernen keine
Kleberrückstände hinterlässt. Xicom empfiehlt die
Verwendung von Kapton® Band, 3M Brand, #92,
Xicom P/N 602-0001-001. Band oder Kappe vor der
endgültigen Aufstellung entfernen. Nichtbefolgen
könnte Verunreinigung des internen Hohlleitersystems
oder Beschädigung von TWT und Gerät zur Folge
haben.
1 Position the interconnecting waveguide flange with the amplifier
waveguideflange. Makesure thattheflanges canbemated without
strain or torsion.
2. If the two flanges cannot be properly aligned or if the installation is
subject to vibration, a flexible waveguide section should be utilized
to eliminate potential strain on the waveguide connection.
3. Insert any necessary gaskets and windows between the two
flanges.
Note
The waveguide that is connected to the HPAs
should have a good match of 1.5:1 or better for
optimal performance. Waveguide connected to
tri-band HPAs (C, X, Ku) and dual-band HPAs (C,
Ku) in particular need to have this match. These
HPAs do not contain isolators due to their
bandwidths. Also, the in-band harmonics of
excessive power reflected into the HPA can cause
damage to the TWT. It is recommended that a
transition is made to rectangular waveguide and an
isolator used to assure a good match to the HPA
and to absorb reflected powers at the harmonic
frequencies. The typical output VSWR of isolators
when included in the HPA is 1.3:1.
Note
If the connecting waveguide is to be pressurized at
greater than 5 PSI, a waveguide window must be
installed at the output flange of the amplifier. Use an
absorptive type gasket to preclude radiation leakage.
4. Start by hand tightening all waveguide mounting screws.

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5. Tighten all mounting screws with the appropriate size Allen wrench.
6. Useasequentialtightening procedure.Refer toTable1.Proceed as
follows:
•Partially tighten one of the screws (#1).
•Move the tool to the screw that is diagonally opposite to the screw
tightened in step 1 (#2) and partially tighten that screw.
•Move clockwise to the next screw to be tightened (#3) and partially
tighten that screw.
•Move to the screw diagonally opposite screw #3 and partially
tighten that screw (#4).
•If required, repeat this process for the remaining screws (#5-#6, #7-
#8).
•When you reach the first screw tightened in this step (#1) increase
the torque on the screw and repeat the process until the screws
have all been tightened to the correct torque.
Figure 1, Typical 4 Screw Mounting Flange Tightening Sequence
Figure 2, Typical 8 Screw Mounting Flange Tightening Sequence

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Air Ducting Installation
The power amplifier is cooled with a built-in fan. Heated exhaust
air should not be recirculated into the power amplifier. A
clearance of 6-8 inches is recommended to allow the heated
exhaust air to clear the power amplifier air inlet.
If the unit is installed in a closed cabinet or in a configuration
that would tend to recirculate the exhaust air, provisions should
be made to isolate the exhaust air from the intake air supply.
Table 1, Recommended Waveguide Flange Torque
Screw Size Threads per
Inch RecommendedTorque (inch-lb)
No. 4 40 4.5
80 5.5
No. 6 32 8.5
40 10
No. 8 32 18
36 20
No. 10 24 23
32 32

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Power and Interface Interconnections
When performing the procedures in this section refer to the
Wiring and Interconnect Drawings for your specific amplifier.
These drawings are located in the appendix titled Interconnect
Drawings.
Prime Power Connections
The AC Prime Power receptacle is located on the amplifier front
panel. Nominal line voltage is 100 to 260 VAC (180 to 260 VAC
on some high power units), 47-63 Hz, single phase. The
amplifier will operate when the AC line voltage is anywhere in
the specified range. Figure 3 , Connector J2 Pinout for Standard
Unit shows the pinouts for standard ODU. If you have an EIK
(Extended Interactive Klystron) refer to Figure 4 , Connector J2
Pinout for EIK Unit.
Figure 3, Connector J2 Pinout for Standard Unit

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Figure 4, Connector J2 Pinout for EIK Unit
Some amplifiers may have an MS connector. Refer to Figure 5 ,
MS Connector J2 Pinout.
Figure 5, MS Connector J2 Pinout
Refer to the Outline Drawing in the appendix titled Mechanical
Drawings.
External Interlock (Prime power enable)
To enable heater voltage, high voltage and monitor and control
functions pin h (M&C connector) must be connected to ground
(Pins Z or a).
Refer to Figure 6 “, Prime Power Enable Circuit” on page 11 for
pinouts of the Prime Power Enable circuit.
Figure 6, Prime Power Enable Circuit

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Monitor and Control Connector
To externally control the amplifier a M&C interface is provided.
The connector is a 32-pin MIL style waterproof connector.
The Monitor and Control connector provides these interfaces for
the use of the customer:
•COM1 — RS-232 Serial Port.
•COM2 — RS-422/ RS-485 Serial Port.
•Two sets of Form “C” Relay contacts for Summary Fault indication.
•External Interlock
•RF Inhibit Control
•24 VDC @ 100 mA maximum
•15 VDC for monitoring purposes only.
•Hardware Address Select.
•Discrete High Voltage ON Indicator.
Monitor and Control Pinouts
Figure 7 , M&C Connector Pin Layout shows the pin layout and
Table 2 on page 13, lists the pinouts for the typical Monitor and
Control Connector on the Antenna-Mount Power Amplifier.
Figure 7, M&C Connector Pin Layout

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See the appendix titled Specifications for the pinouts on your
amplifier.
Note
Pins V, W, and X are not available when the amplifier is
configured for redundant operation.
Table 2, Monitor and Control Connector Pinouts
Pin Signal Name
ARS-232 DCD
BRS-232 RX
CRS-232 TX
DRS-232 DTR
ERS-232 GND
F RS-232 DSR
GRS-232 RTS
HRS-232 CTS
JRS-232 RI
KSystemGND
L RS-422/485 Transmit +
M RS-422/485 Transmit -
N RS-422/485 Receive +
P RS-422/485 Receive -
R RS-422/485 GND
S Summary Fault A Normally Open Contact
T Summary Fault A Normally Closed Contact
U Summary Fault A Common
V Summary Fault B Normally Open Contact
W Summary Fault B Normally Closed Contact
X Summary Fault B Common
Y RF Inhibit Connect Pin Y to either Pin Z or Pin a
to inhibit RF
ZSystemGND
aSystemGND
b +24 VDC Available for external use
c +24 VDC Current limit of 100 mA
dAddress A/B
eHV ON Indicator
f +15 VDC Monitor only
g +5 to +15 VDC (Input) RF Inhibit optical isolator power input
h Power Supply Enable
(External Interlock) Power Supply is enabled when Pin h is connected to Pin a
j Gain (Analog) Optional

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Redundancy Interface (Waveguide Switch) Connector (J6)
Provides control and status indication for Waveguide Switch
position. Refer to Table 3 and Figure 8.
Passes RF Inhibit command during the switching operation or
Waveguide Switch failure.
Sends and receives Summary fault from primary amplifier in
redundant system (Automatic Mode Only).
Table 3, Redundancy Interface (Waveguide Switch) Connector Pinouts
Pin Signal Function
A Sum Fault Ind. IN When in backup mode, opens when other amp in
redundant system faults. (Contact closure only) Unit
switches online
B Sum Fault Ind. OUT When online, opens during fault. Backup amp in
redundant system switches online. (Contact closure
only)
C W/G Switch Inhibit Open during transition from one position to another,
W/G switch fails, or is not installed.
D W/G Pos A Indicator Grounded when Waveguide Switch is set to Position
A.
E W/G Pos B Indicator Grounded when Waveguide Switch is set to Position
B.
F GND Ground
G Switch to A Control signal to set Waveguide Switch to Position
A.
H Switch to B Control signal to set Waveguide Switch to Position
B.
J GND Ground

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Figure 8, Waveguide Switch Connector Pinouts
RF Inhibit Control (J1-Y)
The TWTA has the capability to Inhibit RF. If the unit has a SSA
preamplifier, inhibit is accomplished by turning off the SSA. If
the unit does not have a SSA preamplifier, the RF Inhibit
command is factory set to disable high voltage to the tube.
Figure 9 , RF Inhibit with Internal Source shows the RF Inhibit
circuit using the TWTA internal 15 VDC and ground. RF will be
inhibited when switch A is closed. When used with a system
controller, pin g can be driven from an external voltage source of
+5 to +15 VDC. In this case pin Y should be connected to the
ground reference of the external supply to prevent damage to
the TWTA or the external supply as shown in Figure 10 , RF
Inhibit with External Source.

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Figure 9, RF Inhibit with Internal Source
Figure 10, RF Inhibit with External Source
Mixing internal and external references can result in damage to
the equipment if there is a difference in ground potential
between the controller and the TWTA. If you need to invert the
RF Inhibit logic, RF inhibited when switch A is open, the TWTA
can be ordered with Jumper JP9 in the alternate position, or an
external resistor can be used as shown in Figure 11 , RF Inhibit
with Switch A Open.

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Figure 11, RF Inhibit with Switch A Open
Serial Interface Ports (J1-A to J1-R)
Dual serial interface connectors (COM1 and COM2) are
available for remote control operation. Both serial interface ports
are always enabled. The amplifier will respond to commands
from either interface. The last command received has
precedence.
COM1 is an RS-232 only serial interface. No switch settings are
required for COM1. Table 2“, Monitor and Control Connector
Pinouts,” on page 13 lists the pinouts for COM1.
COM2 can be configured as an RS-485 2-wire serial interface or
as an RS-485 4-wire serial interface. The pinouts for the COM2
interface are listed in Table 2 on page 13, and typical
implementations are shown in Figure 12 and Figure 13 on
page 18.

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Figure 12, Typical RS-485 2-Wire Duplex Implementation
Figure 13, Typical RS-485 4-Wire Full Duplex Implementation

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Note
Refer to Table 2“, Monitor and Control Connector
Pinouts,” on page 13 for the definition of the pins listed
in the following paragraphs.
Summary Fault Indicators (J1-S to J1-X)
Two sets of Form C relay contacts (Summary Fault A and
Summary Fault B) are used to indicate that a fault has occurred.
The Summary Fault indicator signals change state any time an
amplifier fault occurs. The user has the choice of a normally
open or normally closed circuit.
Output Voltages
(J1-b and c) A + 24 VDC voltage is supplied that can deliver up
to 100 mA. This supply voltage is available on both Pins b and
c. The return for this voltage is either Pin a or Pin Z.
(J1-f) A +15 VDC voltage is supplied that can deliver up to 10
mA. This supply voltage is available on Pin f for monitor
purposes. The return for this voltage is either Pin a or Pin Z.
Hardware Address Select (J1-d)
When this pin is left open the RS-485 address will be set to “A”
41h. When this pin is returned to ground, pins a or Z, the RS-
485 address will be set to “B” 42h.
High Voltage ON Indicator (J1- e)
This pin is connected to an open collector transistor. When the
amplifier High Voltage is turned ON the transistor will be turned
OFF. When the amplifier High Voltage is turned OFF the
transistor will be turned on and sink current (up to 250 mA).
Grounding
WARNING
To prevent Electric Shock the amplifier should be
securely connected to the grounding stud. Failure to
comply could result in personnel injury or death.

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WARNUNG
Zur Vermeidung elektrischer Schläge sollte der
Verstärker fest mit dem Erdungsbolzen verbunden
sein.Nichtbefolgen könntedie Verletzung oderden Tod
von Menschen zur Folge haben.
Local Operation
Xicom Technology digital outdoor units have a built-in
microprocessor for Monitor and Control using Xicom Standard
Protocol. Refer to the chapter titled Amplifier Communication
and Protocol for detailed information.
There are three switches on the front panel of the amplifier that
allow you some local control of the unit. These switches are:
•Primary Power—used to turn AC input power ON or OFF.
•High Voltage—used to turn the High Voltage Power Supply ON and
OFF or to Reset the High Voltage Power Supply.
•Local, Remote Override—used to switch the amplifier from Local
Mode (Manual) to Remote Mode (Microprocessor Control).
There is also a LED indicator on the amplifier front panel. This
indicator shows RED for a fault, GREEN when High Voltage is
ON, AMBER when the unit is in standby, and blinking AMBER
when in filament time delay.
Note
The Local/Remote switch must be in Local in order to
locally control the high voltage or to reset any faults.
To operate from a remote position refer to the chapter titled
Operation.
Operating Procedure
Note
The power supply must be enabled and RF enabled for
the amplifier to operate properly.
Use the following procedure to operate the amplifier in LOCAL
Mode.
1 Ensure that all Wave Guides are connected.