Ku-band Modumax Sspa Operation And Maintenance

Transcript

Ku-Band ModuMAX SSPA Operation and Maintenance Manual Ku-Band ModuMAX SSPA Operation and Maintenance Manual This title strip goes in the outside spine of the binder. Trim strip to 1" width, just inside the dashed lines. Ku-Band ModuMAX SSPA Operation and Maintenance Manual Supports Firmware Version 2.1X Drawing Number 14563, Revision H, July 29, 2010 ECR 10215 — SLG This manual applies to various models of General Dynamics Ku-Band ModuMAX™ Solid-State Power Amplifiers. EXPORT CONTROL WARNING – The disclosure of this document or its contents to non-U.S. persons, or the transmission of its contents outside the United States must be in compliance with U.S. Export Laws and Regulations. The bearer of this document is under obligation to know the applicable restrictions for the dissemination of its contents that relate to U.S. Export Laws and Regulations or any other U.S. government approvals. Proprietary Notice Information contained in this manual is provided in order to enable users to install, operate and maintain their equipment. All such information, including but not limited to design concepts, block diagrams, schematics, parts lists, assembly drawings, wire lists, theory of operation, and other explanations is the exclusive property of General Dynamics SATCOM Technologies except for the rights expressly granted by contract. The contents of this manual and any subsequent volumes which may become a part thereof may not be copied, reproduced or duplicated by any means, whether photographically, manually or by optical scanning, without express written permission of General Dynamics SATCOM Technologies. Copyright © 2010 by General Dynamics SATCOM Technologies, Inc. All rights reserved. 60 Decibel Road, Suite 200 • State College, PA 16801 USA Phone: 814-238-2700 • Fax: 814-238-6589 www.gdsatcom.com DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Table of Contents Section 1 General Information...........................................................................1-1 1.1 How to Use This Manual.................................................................................... 1-1 1.2 Safety Information ............................................................................................. 1-1 1.3 General Introduction ......................................................................................... 1-2 1.4 Purpose of Equipment ....................................................................................... 1-2 1.5 Equipment and Accessories Supplied................................................................. 1-2 1.6 Specifications .................................................................................................... 1-2 1.7 Compliances...................................................................................................... 1-3 Section 2 Installation ........................................................................................2-1 2.1 General Introduction ......................................................................................... 2-1 2.2 Inspection ......................................................................................................... 2-1 2.3 Mechanical Installation ..................................................................................... 2-1 2.3.1 Choosing a Location.............................................................................. 2-2 2.3.1.1 Airflow................................................................................... 2-2 2.3.1.2 Rear Panel Access.................................................................. 2-3 2.3.2 Installation Procedure........................................................................... 2-3 2.4 Prime Power Connection .................................................................................... 2-6 2.5 Electrical Interface .......................................................................................... 2-12 2.5.1 SSPA RF Input – J1 ............................................................................ 2-12 2.5.2 SSPA RF Output – J2.......................................................................... 2-13 2.5.3 SSPA +11.5 Vdc Input – J3 ................................................................. 2-14 2.5.3.1 ModuMAX with Single Power Supply.................................... 2-14 2.5.3.2 ModuMAX with Two Power Supplies .................................... 2-14 2.5.3.3 Connecting to the Power Supply .......................................... 2-16 2.5.3.4 Connecting to the SSPA ....................................................... 2-17 2.5.4 SSPA Serial I/O – J4........................................................................... 2-18 2.5.4.1 RS-232................................................................................ 2-19 2.5.4.2 RS-485 (4 wire).................................................................... 2-19 2.5.4.3 RS-485 (2-wire) ................................................................... 2-22 2.5.4.4 RS-422................................................................................ 2-24 2.5.4.5 SIO Relay ............................................................................ 2-25 2.5.4.6 Making the Connection........................................................ 2-26 2.5.5 SSPA Parallel I/O – J5 ........................................................................ 2-26 2.5.6 SSPA Network Interface – J6 ............................................................... 2-28 2.5.7 System – J7 ........................................................................................ 2-28 2.5.8 SSPA Power Supply Interface – J9 ....................................................... 2-28 2.5.9 SSPA RF Input Sample – J10 .............................................................. 2-29 2.5.10 SSPA RF Output Sample – J11............................................................ 2-29 2.5.11 Power Supply Remote – PS J4 ............................................................. 2-29 2.5.12 Power Supply Status – PS J5 .............................................................. 2-29 2.5.13 Power Supply Sync – PS J6 ................................................................. 2-29 2.5.14 Power Supply Remote Sense – PS J7 ................................................... 2-30 2.6 Power-Up Tests ............................................................................................... 2-30 Table of Contents i DMAN-14563 Rev. H 2.7 2.8 Ku-Band ModuMAX SSPA Airflow System Installation .............................................................................. 2-33 Optional Accessory Installation ........................................................................ 2-34 2.8.1 Antenna/Dummy Load Switch Assembly............................................. 2-34 2.8.2 RCP-2000 ........................................................................................... 2-34 Section 3 Operation ..........................................................................................3-1 3.1 General Introduction ......................................................................................... 3-1 3.2 RF Operation..................................................................................................... 3-1 3.2.1 Adjusting Gain...................................................................................... 3-1 3.2.2 Selecting Output Level .......................................................................... 3-2 3.2.3 Intermodulation Distortion.................................................................... 3-2 3.2.4 Configurable Power ............................................................................... 3-3 3.3 Front Panel (Local) Control ................................................................................ 3-4 3.3.1 Menus .................................................................................................. 3-4 3.3.1.1 Action Buttons ...................................................................... 3-5 3.3.1.2 Modify Buttons ...................................................................... 3-6 3.3.1.3 Menu Navigation Buttons ...................................................... 3-6 3.3.1.4 Menu Listing ......................................................................... 3-7 3.3.2 Indicators ........................................................................................... 3-12 3.3.3 Amplifier Module Status Lamps .......................................................... 3-12 3.4 Network Interface (NIC).................................................................................... 3-13 3.5 Serial I/O ........................................................................................................ 3-15 3.5.1 Interface ............................................................................................. 3-16 3.5.2 Protocol .............................................................................................. 3-16 3.5.2.1 STX/ETX............................................................................. 3-17 3.5.2.2 Count.................................................................................. 3-17 3.5.2.3 Address ............................................................................... 3-17 3.5.2.4 ACK Response Flag.............................................................. 3-17 3.5.2.5 Message Data ...................................................................... 3-18 3.5.2.6 Checksum ........................................................................... 3-19 3.5.2.7 Message Handling................................................................ 3-19 3.5.2.8 Timing Issues ...................................................................... 3-20 3.5.3 Messages ............................................................................................ 3-22 3.5.3.1 Message Types..................................................................... 3-23 3.5.3.2 Data Values......................................................................... 3-24 3.5.3.3 Programming Compatibility ................................................. 3-26 3.5.3.4 Instruction Codes ................................................................ 3-27 3.5.4 Message Table .................................................................................... 3-28 3.5.5 Accessing Fault Information Using Serial I/O ...................................... 3-32 3.6 Parallel I/O ..................................................................................................... 3-33 3.6.1 Interface ............................................................................................. 3-33 3.6.2 Digital Inputs ..................................................................................... 3-34 3.6.3 Digital Outputs ................................................................................... 3-34 3.6.4 Analog Output .................................................................................... 3-34 3.7 Function Reference.......................................................................................... 3-35 3.7.1 Amplifier............................................................................................. 3-35 3.7.1.1 RF Path Controls ................................................................. 3-35 3.7.1.2 Measurements..................................................................... 3-41 ii Table of Contents DMAN-14563 Rev. H 3.7.2 3.7.3 3.7.4 3.7.5 Ku-Band ModuMAX SSPA 3.7.1.3 Calibration .......................................................................... 3-49 Faults and Warnings .......................................................................... 3-51 3.7.2.1 Summary Fault Conditions.................................................. 3-54 3.7.2.2 Reading Fault Information ................................................... 3-55 3.7.2.3 Fault Settings and Controls ................................................. 3-65 3.7.2.4 Single Module Failure Compensation (SMFC) ....................... 3-68 3.7.2.5 Audible Alarm ..................................................................... 3-71 Remote Control................................................................................... 3-72 3.7.3.1 Ethernet Network ................................................................ 3-72 3.7.3.2 Serial I/O ............................................................................ 3-73 3.7.3.3 Parallel I/O ......................................................................... 3-75 Hardware and Firmware ..................................................................... 3-80 3.7.4.1 Commands.......................................................................... 3-80 3.7.4.2 Information ......................................................................... 3-81 3.7.4.3 Optional Hardware .............................................................. 3-82 3.7.4.4 Reloading Firmware............................................................. 3-84 Security.............................................................................................. 3-84 3.7.5.1 Controls .............................................................................. 3-85 3.7.5.2 Settings............................................................................... 3-88 Section 4 Theory of Operation ...........................................................................4-1 4.1 General Introduction ......................................................................................... 4-1 4.2 System Level Description ................................................................................... 4-1 4.3 Power Supply Description .................................................................................. 4-2 4.4 SSPA Description .............................................................................................. 4-2 4.4.1 RF Path ................................................................................................ 4-3 4.4.1.1 Overview ............................................................................... 4-3 4.4.1.2 SSPA Modules ....................................................................... 4-3 4.4.1.3 Combining Theory ................................................................. 4-5 4.4.1.4 Detector Module .................................................................... 4-7 4.4.2 Cooling System ..................................................................................... 4-8 4.4.3 Power Distribution System.................................................................... 4-8 4.4.3.1 Bus Bar System..................................................................... 4-8 4.4.3.2 Motherboard.......................................................................... 4-9 4.4.4 Logic System ........................................................................................ 4-9 4.4.4.1 Logic Board ........................................................................... 4-9 4.4.4.2 Front Panel ......................................................................... 4-10 4.4.4.3 Parallel I/O Board ............................................................... 4-10 4.4.4.4 Ethernet Board.................................................................... 4-11 Section 5 Maintenance ......................................................................................5-1 5.1 General Introduction ......................................................................................... 5-1 5.2 Recommended Equipment ................................................................................. 5-1 5.3 Preventive Maintenance Procedures ................................................................... 5-1 5.3.1 Power Supply Module Cleaning ............................................................. 5-2 5.3.2 SSPA Module Cleaning.......................................................................... 5-2 5.3.3 Air Cooling System Maintenance ........................................................... 5-3 Table of Contents iii DMAN-14563 Rev. H 5.4 5.5 5.6 5.7 Ku-Band ModuMAX SSPA 5.3.4 DC Power Cable Maintenance ............................................................... 5-4 5.3.5 Adjustments ......................................................................................... 5-4 Adjustment Procedures...................................................................................... 5-4 5.4.1 Power Supply Voltage Adjustments ....................................................... 5-4 5.4.2 RF Phase Adjustments .......................................................................... 5-5 5.4.3 Power Measurement Adjustments ......................................................... 5-6 5.4.4 Analog Output Adjustment.................................................................... 5-8 Performance Verification.................................................................................... 5-8 5.5.1 Power Supply Tests............................................................................... 5-9 5.5.2 RF Tests ............................................................................................... 5-9 5.5.3 Control Panel/Display Test ................................................................. 5-10 5.5.4 Microprocessor Test ............................................................................ 5-11 5.5.5 LED Test ............................................................................................ 5-12 5.5.6 Mute/Operate Test ............................................................................. 5-12 5.5.7 Parallel I/O Tests................................................................................ 5-12 5.5.7.1 Input Function Tests ........................................................... 5-13 5.5.7.2 Output Function Tests......................................................... 5-13 5.5.7.3 Analog Output Test.............................................................. 5-14 Troubleshooting............................................................................................... 5-15 Assembly Replacement .................................................................................... 5-22 5.7.1 Power Supply Module Replacement ..................................................... 5-22 5.7.2 SSPA Module Replacement.................................................................. 5-23 5.7.3 Flexible RF Input Cable Assembly Replacement................................... 5-25 5.7.4 Intake Fan Assembly Replacement (Fan 1–4) ....................................... 5-26 5.7.5 Exhaust Fan Assembly Replacement (Fan 5-8) .................................... 5-27 5.7.6 Logic Board Replacement .................................................................... 5-29 5.7.7 Parallel I/O Board Replacement .......................................................... 5-31 5.7.8 Ethernet Board Replacement .............................................................. 5-32 5.7.9 Front Panel Assembly Replacement ..................................................... 5-33 5.7.10 Detector Module Replacement ............................................................. 5-34 Section 6 Drawings............................................................................................6-1 6.1 General Introduction ......................................................................................... 6-1 6.2 Drawing Index ................................................................................................... 6-1 Section 7 Warranty............................................................................................7-1 7.1 General Introduction ......................................................................................... 7-1 7.2 Technical Support ............................................................................................. 7-1 7.3 Warranty ........................................................................................................... 7-1 7.4 Return Procedures............................................................................................. 7-2 Section 8 System Configuration ........................................................................8-1 8.1 General Introduction ......................................................................................... 8-1 iv Table of Contents DMAN-14563 Rev. H Ku-Band ModuMAX SSPA List of Illustrations Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure Figure 2-2. AC Junction Box Covers.......................................................................... 2-10 2-3. AC Configurations................................................................................... 2-10 2-4. AC Line Filter Connections (3-phase delta connection shown) .................. 2-11 2-5. Typical Bus Bar/Cable Mounting Bracket Assembly Detail ...................... 2-15 2-6. Recommended Power Cable Orientation at SSPA Bus Bar Terminals........ 2-17 2-7. SSPA Bus Bar Cover Assembly ................................................................ 2-18 2-8. A Typical RS-485 4-wire Bus................................................................... 2-21 2-9. A Typical RS-485 2-wire Bus................................................................... 2-23 2-10. A Typical RS-422 Bus............................................................................ 2-24 2-11.Power Supply Module Mating Connector.................................................. 2-30 2-12. Bus Bar Voltage Measurements............................................................. 2-32 3-1. IMD vs. Backoff ........................................................................................ 3-2 3-2. Front Panel Controls and Indicators .......................................................... 3-4 3-3.Serial I/O Framing Protocol ...................................................................... 3-17 3-4.Message Data Framing Protocol ................................................................ 3-22 4-1. Combining Loss vs. Amplitude and Phase Imbalance (0-40 dB).................. 4-6 4-2. Combining Loss vs. Amplitude and Phase Imbalance (0-4 dB).................... 4-6 5-1. SSPA Module Identification (Front View of Chassis) ................................. 5-23 5-2. Rear Panel Intake Fan Identification........................................................ 5-26 5-3. Exhaust Fan Identification (Front View of Chassis) .................................. 5-28 5-4. Locations of Detector Modules................................................................. 5-35 List of Tables Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table 1-1 1-2 2-1 2-2 2-3 2-4 2-5 2-6 2-7 3-1 3-2 3-3 3-4 3-5 3-6 3-7 3-8 4-1 4-2 5-1 5-2 6-1 6-2 List of Equipment and Accessories Normally Supplied.............................. 1-3 List of Optional or Auxiliary Equipment and Accessories .......................... 1-3 3-phase 180-264 Vac Phase-to-Phase (Delta) Load Connection................. 2-8 3-phase 180-264 Vac Phase-to-Neutral (Wye) Load Connection ................ 2-8 Single Phase Load Connection ................................................................. 2-9 Electrical Interfaces............................................................................... 2-13 Serial I/O Interface, J4.......................................................................... 2-20 Parallel I/O Interface, J5 ....................................................................... 2-27 Ethernet Interface, J6 ........................................................................... 2-28 Configurable Power ................................................................................. 3-3 Menu Listing ........................................................................................... 3-7 Instruction Codes.................................................................................. 3-28 Message Table ....................................................................................... 3-29 Fault and Warning Codes ...................................................................... 3-59 SMFC/Gain Control Logic ..................................................................... 3-70 Input Functions .................................................................................... 3-76 Output Functions.................................................................................. 3-78 Module Power.......................................................................................... 4-3 Power Loss .............................................................................................. 4-7 Bus Voltages ........................................................................................... 5-4 Troubleshooting Guide .......................................................................... 5-16 Drawing Types ........................................................................................ 6-1 Drawing Index......................................................................................... 6-2 Table of Contents v DMAN-14563 Rev. H vi Table of Contents Ku-Band ModuMAX SSPA DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Section 1 1.1 General Information How to Use This Manual This manual contains information on how to install, operate, and maintain the VertexRSI Ku-Band ModuMAX Solid-State Power Amplifier. Information is organized according to section, with index tabs for convenience. Within each section, the pages, figures, and tables are numbered by section and by order of appearance within the section. To locate information quickly, refer to the table of contents. To locate a figure or table, refer to the lists of illustrations and tables, which immediately follow the table of contents. To find a definition of an unfamiliar word or acronym, refer to the glossary of acronyms and terms at the end of the manual. Section 7 contains warranty information and return procedures to be followed in the event that factory repair is required. Please refer to this section for information on how to contact the factory for service. 1.2 Safety Information This equipment has been designed to minimize exposure of personnel to hazards, and is a safety class I device. This equipment should not be used in a residential environment. An uninterruptable safety earth ground must be provided from the main power source to the input wiring terminals through the power cord. WARNING Failure to ground the equipment as described will cause a potential shock hazard that could result in personal injury. The equipment is supplied with a junction box on the rear of the Power Supply. The terminals inside this junction box must be connected to a properly grounded power source. Servicing instructions are for use by service-trained personnel only. To avoid dangerous electric shock, do not perform any servicing unless qualified to do so. WARNING Some adjustments described in this manual are performed with power applied while protective covers are removed. Always be careful not to come into contact with dangerous voltages while performing these procedures, and never work alone. General Information 1-1 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Do not operate this equipment in the presence of flammable gasses or fumes. Operation of any electrical equipment in such an environment is dangerous, and can cause explosions and/or fires. 1.3 General Introduction This technical manual provides operation and service instructions for the VertexRSI Ku-Band ModuMAX SSPA. The SSPA system includes one or two Power Supply shelves, an SSPA, and interconnecting cables. Each Power Supply shelf consists of a chassis with three plug-in power supply modules and built-in forced-air cooling. The SSPA consists of a chassis with eight plug-in SSPA modules, a forced-air cooling system, and microprocessor-based monitor and control circuitry. Both the Power Supply and the SSPA are installable in a standard 19-inch equipment rack. 1.4 Purpose of Equipment This solid-state power amplifier is designed for uplink applications in satellite communications systems. The VertexRSI Ku-Band ModuMAX™ SSPA produces up to 57.0 dBm (500 W) of saturated output power, and contains integral metering and fault detection circuitry, as well as built-in redundancy of all major active components. 1.5 Equipment and Accessories Supplied The standard VertexRSI Ku-Band ModuMAX SSPA system includes the items listed in Table 1-1. The plug-in Power Supply modules and SSPA modules are removed from their chassis for shipment to avoid vibration damage to the chassis during shipping. If you ordered a system with a rack cabinet, the cabinet will be in a separate crate; in this case, some of the cables will be installed in the cabinet. Depending on options and accessories you may have ordered, some of the following items may also be present in the shipment. The rack cabinet, if ordered, is usually considered part of the ModuMAX SSPA; the other parts are usually sold as separate line items. 1.6 Specifications Refer to the specification sheet included in Section 8 for performance specifications of the VertexRSI Ku-Band ModuMAX SSPA. 1-2 General Information DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Table 1-1 List of Equipment and Accessories Normally Supplied Quantity Description 1 SSPA Chassis 8 SSPA Plug-In Modules 1 or 2 * Power Supply Chassis * 3 or 6 * Power Supply Plug-In Modules * 1 set Power Supply-to-SSPA Interface Cables 1 set High-Current DC Power Cables 1 Operation and Maintenance Manual 1 1/2" Hex Nut Driver (mounted inside chassis) 1 5/16" Wrench (mounted inside chassis) 1 9-pin D Male Solder Cup Connector and Backshell (mate for J4) 1 37-pin D Female Solder Cup Connector and Backshell (mate for J5) 1 set WR-75 Waveguide Hardware Kit (gaskets and fasteners) * The 800 W ModuMAX includes two Power Supply Chassis and six Power Supply Plug-In Modules as standard equipment. Other ModuMAX models may optionally include a second Power Supply Chassis with a second set of three Power Supply Plug-In Modules as optional equipment. Table 1-2 List of Optional or Auxiliary Equipment and Accessories Quantity 1 1 or more 1.7 Description Rack Cabinet, with integrated waveguide assemblies, RF and interface cables, and power wiring Spares Kits 1 Exhaust Duct Adapter Kit 1 Intake Duct Adapter Kit 1 Maintenance (Antenna/Dummy Load) Switch Assembly 1 RCP-2000 Remote Control Panel 1 Interface Cable, SSPA to RCP-2000 Compliances The ModuMAX SSPA complies with the requirements of the following Directives and carries the CE marking accordingly: • The EMC Directive 89/336/EEC, and • The Low Voltage Directive 72/23/EEC. General Information 1-3 DMAN-14563 Rev. H 1-4 General Information Ku-Band ModuMAX SSPA DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Section 2 2.1 Installation General Introduction To install the VertexRSI Ku-Band ModuMAX SSPA, use the information contained in this section. 2.2 • Inspect the equipment before installation. See Inspection, Section 2.2. • To install the equipment, see Mechanical Installation, Section 2.3. • Before applying power, see Prime Power Connection, Section 2.4. • To connect to the equipment, see Electrical Interface, Section 2.5. • To perform initial checks, see Power-Up Tests, Section 2.6. • If a facility airflow system will be installed, see Airflow System Installation, Section 2.7. • To install optional accessories purchased with the ModuMAX SSPA, see Optional Accessory Installation, Section 2.8. Inspection Inspect the shipping containers for damage. If the containers or cushioning material are damaged, keep them until the contents of the shipment have been checked for completeness and the unit has been checked electrically and mechanically. Check that all items listed in Table 1-1 were received with the shipment. Also check the packing list in the shipping container for a list of additional items that may have been ordered. If the SSPA has been damaged in shipment, file a claim with the carrier. Keep all packaging materials for the carrier’s inspection. If the contents are incomplete or there is evidence of improper packaging, notify General Dynamics SATCOM Technologies immediately. 2.3 Note Mechanical Installation For installation of a combined system, see Section 8, System Configuration. The Ku-Band ModuMAX SSPA system is mountable in a standard 19-inch EIA equipment cabinet. Refer to the outline drawing in Section 6 for mounting details. Installation 2-1 DMAN-14563 Rev. H Note 2.3.1 Ku-Band ModuMAX SSPA When installing a system with multiple ModuMAX SSPAs, it is recommended that you install each chassis in the same position in the cabinet that it occupied during factory testing. Doing so will ensure that system performance will closely match factory data. The individual ModuMAX SSPAs have unique serial numbers that are recorded on the system test data sheet. Choosing a Location You must pay attention to several factors when choosing a location for the system and planning facility interfaces. In addition to the RF and electrical power connections, you must provide for adequate cooling airflow and both front and rear panel accessibility for replacing hot-swappable components. 2.3.1.1 Airflow The Ku-Band ModuMAX SSPA system relies on forced-air cooling to maintain components at safe operating temperatures. The Power Supply intakes air at its front panel and exhausts it at the rear. The SSPA both intakes and exhausts air at the rear. Total airflow for the SSPA is approximately 400 to 450 CFM (~0.19 m3/s). CAUTION Heat is the enemy of any power amplifier. The SSPA system has a forced air cooling system designed to minimize heat buildup inside the enclosure. This system relies on an ample supply of cooling air. Locate the unit so that the intake grills and the exhaust duct on the rear panel are unobstructed. Keep the grills clean at all times. If the system will intake and exhaust air into the room, place the rear of the cabinet at least 12" (305 mm) away from any wall. If you plan to use the optional duct adapters to intake or exhaust air outside, plan your location to accommodate the ducts. Refer to the outline drawing included in Section 6, Drawings, for duct adapter dimensions. If you use intake air from outside, you must filter and condition the air. The additional adapters and ducts will add pressure drop to the airflow system, reducing its effectiveness. The following guidelines describe the maximum intake or exhaust ducting you can add while still allowing the SSPA to cool effectively. If you need more ducting, you may need to add a booster blower to overcome the added pressure drop. Maximum intake duct system: • 2-2 Installation (1) 90° 10" (254 mm) diameter swept bend (no sharp corners); DMAN-14563 Rev. H Ku-Band ModuMAX SSPA • 10 ft (3050 mm) of 10" (254 mm) diameter rigid duct; OR 5 ft (1525 mm) of 10" (254 mm) diameter flexible duct; • The SSPA fans will not overcome the additional airflow resistance added by any dust filter. If you use filtered intake air, add an assist blower to overcome its pressure drop. Maximum exhaust duct system: 2.3.1.2 • (2) 90° 8" (203 mm) diameter swept bends (no sharp corners); • 10 ft (3050 mm) of 8" diameter rigid duct; OR 5 ft (1525 mm) of 8" (203 mm) diameter flexible duct; • Exhaust louver or screen with minimum free area of 50 in2 (323 cm2). • If an intake duct is used in conjunction with the exhaust duct, use a maximum of (1) 90° 8" (203 mm) diameter swept bend in the exhaust duct. Rear Panel Access The fans and plug-in boards on the rear panel are hot-swappable. Plan your system, especially the facility waveguide run, to allow sufficient clearance to remove any of these components without having to disconnect the waveguide. The fans require at least 5" (127 mm) of clearance for removal. The plug-in boards require at least 6.5" (165 mm). 2.3.2 Installation Procedure Follow the steps below to install the system. 1. Choose a cabinet location that will meet the conditions described above. 2. Both the Power Supply and the SSPA include rack slides for installation in a standard 19" EIA cabinet. a. If you have purchased a cabinet from VertexRSI, the removable sections of the slides will already be installed in the cabinet. In this case, check that all slide mounting hardware is securely tightened. b. If you are installing the system into your own rack cabinet, set the rear surface of the rear mounting rails 23¼" ± ¼" (about 590 mm) from the front surface of the front rails. Then install the slides into the cabinet so that the SSPA chassis is located just above the Power Supply chassis. Remove the removable sections of the rack slides from the SSPA and the Power Supply. Mount these sections to the front and rear panel mounting rails in the cabinet. Installation 2-3 DMAN-14563 Rev. H Note Ku-Band ModuMAX SSPA The SSPA rack slides are not interchangeable between left and right sides. To be sure the slides are oriented properly, find the small horizontal tab at the front of the removable section. This tab should be near the bottom edge of the rack slide, not the top edge. On the slide section mounted to the SSPA, the notch in the springloaded catch should face down. c. WARNING Set the slides so that the outside surfaces of the two slides in each pair are 17.625" (448 mm) apart at front and rear. Tighten the hardware securely. Ball-bearing slides can fail if the tracks do not engage the races properly. When installing the equipment, check for proper alignment as the slides are engaged. Support both the front and rear of the equipment as it is slid into the cabinet. Check for proper slide track alignment from the rear before allowing the slides to take the entire weight of the equipment. Personal injury can occur if the slides fail while supporting the equipment’s weight. 3. Make sure none of the Power Supply plug-in sections are installed in the Power Supply shelf. Install the shelf in the cabinet and secure its front panel. 4. Review Section 2.4 – Prime Power Connection below to determine how to configure the power supply wiring and jumpers to match the type of ac power in your facility. Follow the steps in Section 2.4 to connect the Power Supply shelf to the facility ac power bus. You will find this easier to do before installing the SSPA enclosure above the power supply shelf. WARNING The SSPA enclosure weighs approximately 140 lb (63 kg) without modules. Take adequate precautions to avoid injury while installing it. 5. Make sure none of the RF modules are installed in the SSPA enclosure. Lift the SSPA enclosure into position and align its sections of rack slides with the cabinet sections. Be sure the slide sections engage properly. Slide the SSPA into the rack as far as it will go. If the slides stop short of full insertion, you may need to activate the slide release levers to make the races engage properly. 6. Attach the front panel to the rack using hardware suitable for the cabinet you are using. CAUTION 2-4 Installation Do not try to support either unit by its front panel. Always use rack slides or support rails. The front panels are not designed to support the weight of the units. DMAN-14563 Rev. H Ku-Band ModuMAX SSPA 7. Remove the SSPA front cover by loosening its captive fasteners. 8. Unpack the SSPA modules and install them in the SSPA chassis following the procedure below. If the factory test data sheet is available, you should install the modules in the same positions they occupied when the factory test data was measured. This will ensure that the system will be set to maximum combining efficiency. The module serial numbers that were installed in each position are tabulated on the SSPA system’s test data sheet. Each module’s serial number appears on its label. a. Inspect the waveguide output flange on one of the modules. A flat conductive waveguide gasket should be attached to the flange, held in place by the two guide pins. If this gasket is not present, look for it among the packing material. CAUTION Do not apply excessive force when inserting a module into its slot. Doing so could damage the D-connector mounting plate inside the chassis. b. Grasp the module by its handle and support it with your other hand so that the waveguide points away from you toward the chassis, and the nylon guides on the bottom of the module face downward. Slide the module into one of the slots in the SSPA, being careful not to pinch the flexible RF input cable in the chassis. When the module is about halfway in, it will push open the swinging door about halfway down the chassis depth. Continue pushing until the module stops. c. Remove the supplied 1/2" nut driver from its holder in the exhaust fan tray at the bottom of the SSPA chassis. Use it to tighten the two hold-down bolts on the face of the module until they just start to get snug. Then alternately tighten first one, then the other, in small steps until they are tightened to 8 in-lb (90 N-cm). This is approximately finger-tight. Do not overtighten. d. Connect the flexible RF input cable to the module’s RF input connector. e. Repeat with the other SSPA modules. 9. Install the Power Supply modules one at a time by sliding them into the shelf with the cam-lock handle open. When the module has slid in as far as it will go, engage the locking device on the handle and close the handle to secure the module. Tighten the two hold-down screws along the module’s lower edge. Repeat with the other Power Supply modules. 10. Connect the SSPA to the facility earth ground by attaching a suitable conductor between the ground stud on the SSPA’s rear Installation 2-5 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA panel and a bus bar or other conductor connected to earth ground. Note If your system includes a VertexRSI supplied rack cabinet, it contains a bus bar mounted along the left-hand side of the cabinet (as viewed from the rear) for this purpose. Grounding cables for the SSPA and power supply are already attached to this bus bar. Connect the free end of the upper one to the SSPA ground stud. 11. Similarly, connect the Power Supply to the facility earth ground. 2.4 Prime Power Connection The ModuMAX SSPA can operate from a power source of 180 to 264 Vac, 47 to 63 Hz, three-phase or single- phase. Connector styles for prime power vary between facilities, and many installers prefer to wire equipment directly into a circuit breaker. Therefore, no line cord is supplied with this equipment. If the ModuMAX SSPA has been ordered with a rack cabinet, a length of 5conductor #10 AWG cable is included in the cabinet to facilitate connection of the ModuMAX SSPA to facility power. The installer has the responsibility to connect the equipment properly to the facility power. CAUTION Set jumpers for proper ac configuration before applying power. See instructions later in this section. The ModuMAX power supply includes three separate plug-in modules, each of which has its own pair of power wires and a ground wire. In a 3-phase application, the power supplies can be connected in either the delta configuration, with each power supply module connected from one phase to another, or in the wye configuration, with each module connected between one phase and the neutral. NOTE References to “delta” and “wye” configurations in the following discussions refer to the power supply connections, not the configuration of the ac mains source. For example, when wiring to a typical US 3-phase wye source with 208 Vac phase-to-phase, and 120 Vac phase-to-neutral, you would connect the power supplies in the delta configuration, even though your ac source is wye-connected. In this case, you would not use the neutral wire. The 800 W ModuMAX requires two power supply shelves to operate within acceptable load parameters. Lower-power ModuMAX SSPAs may also be operated using two power supply shelves to afford redundancy by operating from two separate 3-phase feeds. ModuMAX SSPAs that are equipped with two power supply shelves 2-6 Installation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA include either a pair of bus bars to facilitate connection of the two shelves to the SSPA, or a pair of high-current cables to connect between the two power supply shelves to ensure current-sharing between the main dc cables when some of the power supply modules are not operating. Select supply lines and circuit breakers to ensure adequate current handling capability. Tables 2-1 through 2-3 provide details of the AC power requirements for each type of SSPA for 3-phase delta (typical US), 3-phase wye (typical European), and single-phase load connections. The tables give the current drawn for both the case where all available power supply modules are on (3 for 500 W and below ModuMAX SSPAs, 6 for the 800 W ModuMAX), and the case where only the minimum number of modules required to operate the system is on (2 for 500 W and below ModuMAX SSPAs, 4 for the 800 W ModuMAX). Note Inrush current of the SSPA is approximately twice normal operating current. Inrush current may last up to two line cycles (33 ms at 60 Hz; 40 ms at 50 Hz). Facility circuit breakers or fuses in the line input path should have sufficient time delay to operate with this inrush current for a duration of up to two line cycles. Wire sizes are based on maximum possible current with the minimum number of power supply modules on, and are taken from requirements of the National Electric Code (NEC®) for installation in environments with ambient temperatures of 30 °C maximum. Breaker sizes should be selected as required by applicable electrical codes. Factors influencing breaker size selection include safety factor and ability to protect the wiring. If you want the breakers to operate at low percentage loading in worst-case current conditions, you may need to use a larger wire size to match the breaker you choose. For example, in a 3-phase 230 Vac wye connection (Table 2-2) for a 500 W ModuMAX SSPA, the maximum worst-case current is 26.9 A. #12 AWG wire has a maximum capacity of 30 A, so it could be used in this application, although #10 AWG would be a more conservative choice. If, however, you want the breaker to operate at 75% maximum, the breaker size must be 36 A minimum, so you would use a 40 A breaker. Since the NEC® specifies that overcurrent protection should not exceed 30 A with #10 AWG wire, you would need to use #8 AWG wire (which allows a 40 A breaker) in this application. Installation 2-7 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Table 2-1 3-phase 180-264 Vac Phase-to-Phase (Delta) Load Connection L1 PS 1 180 - 264 VAC 3-Phase Delta Wiring: L2 PS 2 PS 3 L3 SSPA Rated Power (Watts) Max. Rated Power (Watts) Power (VA) Current (Amps) @ 208 Vac 3 PS / 2 PS Current (Amps) @ 180 Vac 3 PS / 2 PS Minimum wire size 350 5700 5820 16.2 / 24.2 18.7 / 28.1 #10 AWG 500 7000 7145 19.9 / 29.7 22.9 / 34.4 #10 AWG SSPA Rated Power (Watts) Max. Rated Power (Watts) Power (VA) Current (Amps) @ 208 Vac 6 PS / 4 PS Current (Amps) @ 180 Vac 6 PS / 4 PS Minimum wire size 800 * 10400 10610 14.7 / 22.1 17.0 / 25.5 #10 AWG * Current and wire size for the 800 W ModuMAX are given for each of the two power supplies. Table 2-2 3-phase 180-264 Vac Phase-to-Neutral (Wye) Load Connection L1 PS 1 180 - 264 VAC 3-Phase Wye Wiring: N PS 2 PS 3 L2 L3 SSPA Rated Power (Watts) Max. Rated Power (Watts) Power (VA) Current (Amps) @ 230 Vac 3 PS / 2 PS Current (Amps) @ 180 Vac 3 PS / 2 PS Minimum wire size 350 5700 5820 14.6 / 21.9 18.7 / 28.1 #10 AWG 500 7000 7145 17.9 / 26.9 22.9 / 34.4 #10 AWG SSPA Rated Power (Watts) Max. Rated Power (Watts) Power (VA) Current (Amps) @ 230 Vac 6 PS / 4 PS Current (Amps) @ 180 Vac 6 PS / 4 PS Minimum wire size 800 * 10400 10610 13.3 / 20.0 17.0 / 25.5 #10 AWG * Current and wire size for the 800 W ModuMAX are given for each of the two power supplies. 2-8 Installation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Table 2-3 Single Phase Load Connection L1 Single-Phase Wiring: 180 - 264 VAC PS 1 PS 2 PS 3 L2 SSPA Rated Power (Watts) Max. Rated Power (Watts) Power (VA) Current (Amps) @ 230 Vac 3 PS / 2 PS Current (Amps) @ 208 Vac 3 PS / 2 PS Current (Amps) @ 180 Vac 3 PS / 2 PS Minimum wire size 350 5700 5820 25.3 28.0 32.3 #10 AWG 500 7000 7145 31.1 34.3 39.7 #8 AWG SSPA Rated Power (Watts) Max. Rated Power (Watts) Power (VA) Current (Amps) @ 230 Vac 6 PS / 4 PS Current (Amps) @ 208 Vac 6 PS / 4 PS Current (Amps) @ 180 Vac 6 PS / 4 PS Minimum wire size 800 * 10400 10610 23.0 / 34.6 25.5 / 38.3 29.5 / 44.2 #8 AWG * Current and wire size for the 800 W ModuMAX are given for each of the two power supplies. It is the installer’s responsibility to ensure that all wiring and breakers comply with all applicable electrical codes. Follow the steps below to connect the equipment to prime power. 1. Make sure that the circuit to which you are connecting the SSPA system is de-energized and will remain so until you complete the installation. NOTE To easily access all electrical connections and hardware on the rear panel of the power supply, complete the following steps before installing the SSPA in the cabinet above the Power Supply. 2. Remove the two covers over the ac junction box on the rear of the Power Supply. See Figure 2-2. 3. Remove the four #10-32 screws that secure the AC line filter and carefully move it aside, leaving the wires between the LOAD side of the line filter and the Power Supply interior connected. CAUTION Set jumpers for proper ac configuration before applying power. 4. Examine the jumpers between the terminals on the jumper board as shown in Figure 2-3. Adjust them as required depending on your ac configuration. Installation 2-9 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA View with covers in place Exploded view showing fasteners Figure 2-2. AC Junction Box Covers 3-PHASE DELTA - TYPICAL U.S. LINE FILTER 5 L2 - #10 BLK 4 L3 - #10 BLK 3 NC - #10 BLK L1 L1 L2 L2 L3 LINE L1 - #10 BLK LOAD 6 L3 N N L1 - #10 BLK (1) L2 - #10 BLK (2) L3 - #10 BLK (3) NC - #10 BLK (4) 2 1 TB1 GND - #10 GRN/YEL GND - #10 GRN/YEL GND STUD 3-PHASE WYE - TYPICAL EUROPE LINE FILTER 5 L2 - #10 BLK 4 L3 - #10 BLK 3 N - #10 BLK L1 L1 L2 L2 L3 LINE L1 - #10 BLK LOAD 6 N L3 N L1 - #10 BLK (1) L2 - #10 BLK (2) L3 - #10 BLK (3) N - #10 BLK (4) 2 GND - #10 GRN/YEL GND - #10 GRN/YEL TB1 GND STUD 6 L1 - #10 BLK 5 L1 - #10 BLK 4 L2 - #10 BLK 3 L2 - #10 BLK JUMPER - #12 BLK 2 1 TB1 LINE FILTER L1 L1 L2 L2 L3 N LOAD SINGLE-PHASE LINE 1 L3 N L1 - #10 BLK (2) L2 - #10 BLK (3) L2 - #10 BLK (4) JUMPER - #12 BLK GND - #10 GRN/YEL GND STUD Figure 2-3. AC Configurations 2-10 Installation L1 - #10 BLK (1) GND - #10 GRN/YEL DMAN-14563 Rev. H NOTE Ku-Band ModuMAX SSPA If you are configuring the ModuMAX SSPA to operate from singlephase ac, move the wires connected to the line filter’s LOAD side from L2 to L1 and from L3 to N, doubling up these conductors, as shown in Figure 2-3. Also, install #12 AWG jumpers between TB15 and –6, and between TB1-3 and –4, also as shown in Figure 2-3. 5. Return the AC line filter to its original position and secure with the four #10-32 screws removed in Step 4. 6. Route the prime power cable or conduit through the hole in the filter mounting bracket of the Power Supply chassis according to Figure 2-4. A cable clamp is supplied in this hole. Depending on your cable or conduit type, you may need to replace this clamp with a different style. L1 L2 L3 N GND STUD Figure 2-4. AC Line Filter Connections (3-phase delta connection shown) Note If you purchased the system with a rack cabinet supplied by the VertexRSI State College Facility, a piece of 5-conductor #10 AWG cable is included in the cabinet. 7. Connect the prime power cable’s wires to the terminals on the AC line filter according to Figures 2-2 and 2-3. Wire colors in Figure 2-3 are for illustration only, and may not match the actual wire colors in the cable. Connect the ground wire to the ground terminal on the AC line filter. 8. Secure the prime power cable or conduit with the clamp in the hole. 9. Re-install the two covers over the ac junction box on the rear of the Power Supply that were removed in Step 2. Installation 2-11 DMAN-14563 Rev. H Note Ku-Band ModuMAX SSPA If you purchased a rack cabinet with your ModuMAX SSPA, continue with the following steps to complete the prime power wiring. Otherwise, return to the installation procedure if not yet complete; or continue to Section 2.5. 10. If your ModuMAX SSPA system includes two Power Supplies, repeat steps 1-9 above for the second Power Supply. 11. Gain access to the ac junction box interior by removing the blank front panel at the top of the cabinet, then removing the front cover of the ac junction box in the top left front corner of the cabinet. 12. The top panel of the rack cabinet assembly has two to four 3/8" diameter pilot holes. Use a punch of appropriate size to enlarge the holes as needed to the size needed for the facility cable or conduit you are bringing into the cabinet. 13. Install suitable cables or conduit clamps in the holes you just made and route the facility wiring into the ac junction box in the cabinet. 14. Connect the individual facility ac mains wires to the corresponding ModuMAX ac power wires inside the ac junction box. 15. Reinstall the ac junction box cover and blank cabinet front panel. 16. To ground the cabinet to a facility grounding system, attach a suitable wire to the unplated copper bus bar in the rack cabinet. A hole in the cabinet’s top panel allows access to the bus bar. 2.5 Electrical Interface Interfaces to the Ku-Band ModuMAX SSPA system consist of connectors described in Table 2-4. Refer to the outline drawing in Section 6, Drawings, for locations of these connectors. 2.5.1 SSPA RF Input – J1 The RF input is a Type N Female connector, 50-ohm impedance. Input level is -10 dBm nominal. CAUTION 2-12 Installation Never exceed the maximum safe RF input level, or permanent damage to the SSPA may result. The maximum safe level is printed on the unit below the RF Input connector. DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Table 2-4 Electrical Interfaces Ref. Des. Description Connector Type Notes SSPA J1 RF Input Type N female SSPA J2 RF Output WR75G Flange SSPA J3 11.5 Vdc Input Bus bars Interconnecting high-current dc cable set supplied SSPA J4 Serial I/O 9-pin D female Mate supplied SSPA J5 Parallel I/O 37-pin D male Mate supplied SSPA J6 Network Interface RJ-45 Option. See O&M Manual Supplement. SSPA J7 System 15-pin D male Connects to optional Maintenance Switch SSPA J9 Power Supply Interface 9-pin D male Connects to PS J5; cable supplied SSPA J10 RF Input Sample Type N female -10 dBc nominal SSPA J11 RF Output Sample Type N female -50 dBc nominal PS J5 Power Supply Status 9-pin D male Connects to SSPA J9; cable supplied PS J6 Power Supply Sync 9-pin D female In systems with two Power Supplies, connects to J6 of the other PS; cable supplied. PS J7 Power Supply Remote Sense 9-pin D female Connects to SSPA bus bars; cable supplied For systems with a rack cabinet, connect the ModuMAX SSPA J1 to the semi-rigid cable in the rack cabinet, W1. Then connect the facility RF input cable to the cabinet’s RF IN connector. Otherwise, connect the facility RF input cable directly to SSPA J1. Tighten the connection. 2.5.2 SSPA RF Output – J2 The RF output is a WR75G waveguide flange. The SSPA has a window built into the waveguide extension on the rear panel so that the waveguide can be pressurized if desired. Output level is as follows at P1 dB: WARNING 350 Watt: +54.8 dBm 500 Watt: +56.2 dBm 800 Watt: +58.0 dBm A radiation hazard exists if the amplifier is operated unterminated. Do not operate the SSPA without a suitable load or termination at the waveguide output. Installation 2-13 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA For systems with a rack cabinet, connect the ModuMAX SSPA J2 to the cabinet waveguide, W2. Use a conductive flat gasket at the interface. Then connect the facility waveguide to the cabinet’s RF OUT flange. Otherwise, connect the facility waveguide directly to J2 on the SSPA. To avoid RF leakage, use a conductive gasket at the joint. Install a full conductive gasket if mating to a grooved flange, or a half gasket if mating with a flat flange. Fasten the flanges with #6 hardware. Tighten securely. 2.5.3 SSPA +11.5 Vdc Input – J3 DC current is applied to the SSPA via a set of high-current dc power cables. A set of interconnecting cables is supplied with each SSPA system for connecting the power supply to the SSPA. Nominal currents carried by these conductors for each SSPA power level are as follows: 2.5.3.1 350 Watt: 365 Amps 500 Watt: 450 Amps 800 Watt: 540 Amps ModuMAX with Single Power Supply Most ModuMAX SSPAs use one power supply per ModuMAX SSPA. These systems are connected via two pairs of high-current dc power cables. If you ordered a rack cabinet with your ModuMAX SSPA system, the cables will already be installed in the cabinet. If you are installing the cables in your rack, locate the dc power cables, vinyl sleeves, and cable mounting brackets supplied with the system. Two brackets are included that attach to the rear panel mounting rail on most rack cabinets. Cable clamps on these brackets support the vertical cable sections. Refer to the system assembly drawing for details (see Section 8, System Configuration). Attach the mounting brackets to the rack assembly and attach the cables to the brackets. Continue the installation at Section 2.5.3.3, below. 2.5.3.2 ModuMAX with Two Power Supplies The 800 W ModuMAX requires two power supply shelves for operation. Lower-power ModuMAX SSPAs can also be connected to two power supply shelves to improve reliability. Some ModuMAX SSPAs that have two power supply shelves include a pair of bus bars to facilitate the multiple connections. In these systems, the high-current dc power cables connect the power supplies and SSPA to the bus bars. 2-14 Installation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Other ModuMAX SSPAs that have two power supply shelves use high-current cables to directly connect each power supply shelf to the SSPA. In these systems, a pair of high-current cables is also needed to connect the power supply outputs together. If you ordered a rack cabinet with your ModuMAX SSPA system, the cables (and bus bars, if included) will already be installed in the cabinet. If you are installing the system in your cabinet, locate the dc power cables, vinyl sleeves, and dc bus bars (if any) supplied with the system. Mounting brackets are included that attach to the rear panel mounting rail on most rack cabinets. Figure 2-5 below indicates the basic assembly of the bus bars or cables, brackets, and panel mounting rails. Bus bar/cable brackets differ between various versions of ModuMAX SSPAs, so your brackets may look slightly different than the ones shown in Figure 2-5. BUS BAR INSTALLATIONS CABLE INSTALLATIONS PANEL MOUNTING RAIL #10-32 SOCKET-HEAD SCREW, FLAT WASHER, LOCK WASHER (4 PLACES PER BRACKET) BRACKET PANEL MOUNTING RAIL BRACKET #10-32 SOCKET-HEAD SCREW, FLAT WASHER, LOCK WASHER (4 PLACES PER BRACKET) NEGATIVE BUS BAR #10-32 PAN-HEAD SCREW, LOCK WASHER, FLAT WASHER (2 PLACES PER BRACKET) INSULATING SHOULDER WASHER (4 PLACES PER BRACKET) INSULATOR CABLE (4 PLACES) POSITIVE BUS BAR Figure 2-5. Typical Bus Bar/Cable Mounting Bracket Assembly Detail For systems with bus bars, slide one vinyl sleeve over each bus bar for each power cable attachment point (six such points on each bus bar, four for the power supply connections [at 2 per shelf] and two for the SSPA connections). Install the brackets and bus bars into the cabinet. Attach a pair of power supply cables to Installation 2-15 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA each bus bar for each power supply shelf, and a pair for the SSPA, using 3/8"–16 hardware. See the system assembly drawing (in Section 8, System Configuration) for details. Tighten connection hardware on all cables securely. The recommended torque for the 3/8"–16 hardware is 220-240 in-lb (25-27 N-m). To ensure proper hardware installation, use a torque wrench set to break over within the recommended torque range. CAUTION Make certain the dc power cable connections are tightened to the proper torque. The high current can create a hot spot at any loose cable attachment point. After tightening the hardware, cover each cable attachment with a vinyl sleeve, secured in place with a nylon cable tie. 2.5.3.3 Connecting to the Power Supply At the “power supply” end of the cables, slide a vinyl sleeve over each pair of cables before connecting them to the power supply output bus bar terminals. Tighten connection hardware on all cables securely. The recommended torque for the 3/8"–16 hardware is 220-240 in-lb (25-27 N-m). To ensure proper hardware installation, use a torque wrench set to break over within the recommended torque range. CAUTION In systems with two power supplies that use high-current cables only (no bus bars), a pair of short high-current cables is provided for connecting the positive outputs of the two power supplies together, and the negative outputs together. These cables ensure that current is shared between the cables connected to the SSPA in cases where some of the power supply modules are not functioning. Without these cables, operating with one or more non-operational power supply modules would result in cables from one power supply carrying most of the current, and could exceed the cables’ capacity. Make sure that you install this pair of cables between the two power supplies. CAUTION Make certain the dc power cable connections are tightened to the proper torque. The high current can create a hot spot at any loose cable attachment point. After properly tightening the hardware, slide the vinyl sleeve over each connection to completely cover it. Use a nylon wire tie to secure each vinyl sleeve over the connection. 2-16 Installation DMAN-14563 Rev. H WARNING 2.5.3.4 Ku-Band ModuMAX SSPA Any time the vinyl sleeving is pulled back to provide access to the bus bars for voltage measurement, avoid allowing any conductive object to contact both bus bars simultaneously. The short-circuit current can cause severe burns. Connecting to the SSPA At the “SSPA” end of the cables, orient the cable ends on each SSPA input bus bar terminal as shown in Figure 2-6. This will facilitate installation of the bus bar cover assembly. (This illustration is duplicated on a label attached to the bus bar cover assembly.) Tighten connection hardware on all cables securely. The recommended torque for the 3/8"–16 hardware is 220-240 in-lb (25-27 N-m). CAUTION Make certain the dc power cable connections are tightened to the proper torque. The high current can create a hot spot at any loose cable attachment point. (-) BUS BAR BLACK (-) CABLE ORIENT TERMINAL ENDS ON BOTH CABLES SO THAT THEY BEND TOWARD THE MIDDLE. (+) BUS BAR RED (+) CABLE Figure 2-6. Recommended Power Cable Orientation at SSPA Bus Bar Terminals (as Viewed From Above) Before attaching the protective bus bar cover assembly, install the supplied Remote Sense cable. Connect the ring terminal on the red wire of the cable to the #8-32 pressed-in nut on the SSPA’s positive input bus bar. Similarly, connect the ring terminal on the black wire to the #8-32 pressed-in nut on the SSPA’s negative bus bar. Assemble the bus bar cover as shown in Figure 2-7 to completely cover the SSPA power input terminals. Attach the top cover subassembly to the mounting bracket on the SSPA’s rear panel and to the bottom cover subassembly, using the captive fasteners. Installation 2-17 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA TOP COVER SUBASSEMBLY CAPTIVE FASTENERS MOUNTING BRACKET (ATTACHED TO SSPA) BOTTOM COVER SUBASSEMBLY Figure 2-7. SSPA Bus Bar Cover Assembly Route the power supply Remote Sense cable through the holes in the end covers. Connect the 9-pin D connector on the cable to J7 on the Power Supply. PS J7 includes a keying pin in position 1 to prevent plugging in a cable intended for J6, the SYNC connector. 2.5.4 SSPA Serial I/O – J4 The SSPA is equipped with a serial port that allows remote monitoring of amplifier functions. Connections exist for RS-232, RS-485 (4-wire or 2-wire), and RS-422 circuits. To connect to the serial port, you need to know which interface type your system will use. Selection of an interface is done using both the connector wiring and the choices made in the Serial I/O Setup menus. The various interface selections share some lines, so it is important to make sure the appropriate interface is selected on the equipment. Only one of these interfaces may be used at a time, and any pins not used in the desired interface should be left unconnected. No hardware handshaking signals are needed for serial I/O. Units only transmit if they are first polled with an appropriate message. All data is transmitted and received with 8 data bits, 1 stop bit, 1 start bit, no parity, and no software handshaking. The baud rate can be set for 300, 1200, 2400, 4800, 9600, 14400, 19200, or 28800 baud. Since the units do not transmit until polled, you must interrogate the units to determine if there are any faults. Or, you may use the provided summary alarm contacts to alert your system, then poll for status. The summary alarm will activate when a fault occurs. 2-18 Installation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA For RS-422 and –485 interfaces, an AC termination is used in the SSPA that reduces the amount of current drawn when nothing is being transmitted or received. Table 2-5 describes the available signals on the Serial I/O interface. J4 is a 9-pin D female connector, and requires a 9-pin D male mating connector. A solder-cup style connector and metal backshell are supplied with the SSPA system for use in connecting to the Serial I/O port, if desired. NOTE If you are using an RCP-2000 Remote Control Panel to control and monitor your ModuMAX SSPA, it will connect to the ModuMAX’s Serial I/O port. In this case, you can use the RCP-2000’s Serial I/O port to operate the SSPA using the serial I/O commands described in this manual. Use of the serial port is described in more detail in Section 3.5 of this manual. 2.5.4.1 RS-232 RS-232 is a specification that defines both the pin-out and electrical specifications for communicating serial data. ModuMAX equipment does conform to all RS-232 electrical specifications. The pin-out conforms to the DCE end of that specified in EIA/TIA574, which is used on IBM PC-style computer 9-pin COM ports. Since the SSPA appears as the DCE end, it may be connected to an IBM PC-style computer via either a straight through 9-pin cable, or to a 25-pin COM port using a 9-pin-to-25-pin adapter (although only 3 lines are actually needed). The RS-232 electrical specification allows for full-duplex communication over a maximum of 50 feet of cable. One line is used for transmit data, the other for receive. Using lower baud rates or low capacitance cable can extend this distance. Only one driver is allowed on either the transmit data line or the receive data line, so communication is possible between only two devices (i.e., the host computer and the SSPA) on an RS-232 bus. Only three of the RS-232 lines are used: Signal Ground, Transmit Data, and Receive Data. No hardware handshaking lines are used. 2.5.4.2 RS-485 (4 wire) The RS-485 specification allows for full duplex communication over two differential pairs of wires (one pair for transmit data, the other for receive), or for half duplex communication over a single pair of wires. The full duplex mode of operation is called RS-485 (4-wire). In RS-485, the transmit drivers may be switched on and off, allowing more than one driver on a bus. See Figure 2-8. Installation 2-19 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Table 2-5 Serial I/O Interface, J4 9-pin D (F) 5 4 9 Pin Number 3 8 2 7 1 6 Function Notes RS-232 (EIA/TIA-574) (Full duplex, one unit on a bus) 5 3 2 Signal Ground Data In Data Out Connect to DTE signal SG. Connect to DTE signal TD. Connect to DTE signal RD. RS-485 4-wire (Full duplex, multiple units on a bus) 4 3 + Data In – Data In 1 2 + Data Out – Data Out 5 Ground 9 Termination High impedance when not transmitting data, to allow multiple units on a bus. Connect to pin 4 to terminate receiver. Terminate units on ends of bus. RS-485 2-wire (Half duplex, bi-directional bus, multiple units on a bus) 4&1 3&2 + Data I/O – Data I/O 5 Ground 9 Termination Connect indicated pins together for RS-485 interface. Connect to pin 4 to terminate RS-485 bus. Terminate units on ends of bus RS-422 (Full duplex, one unit on a bus) 4 3 + Data In – Data In 1 2 + Data Out – Data Out 5 Ground 9 Termination Transmit driver on continuously. Connect to pin 4 to terminate receiver. Terminate units on ends of bus. SIO Relay (programmable as “Service Request” or “Active Fault”) 6 7 8 2-20 Installation CLOSED on Fault Common OPEN on Fault Form ‘C’ contacts, rated for 100 Vdc, 0.5 A, 3 W max. (resistive load). Relay shown in relaxed (Svc Req/Fault) state. DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Fail-Safe Biasing Host Computer Unit 1 V+ Fail-Safe Biasing V+ 4 V– 3 9 Term. 1 2 V– 5 Unit 2 Last Unit 4 4 3 9 1 3 Termination at Last Unit 9 1 2 5 2 5 Figure 2-8. A Typical RS-485 4-wire Bus There is a common mode voltage specification for RS-485, so it is normally necessary to run a common ground line to all devices on the bus. VertexRSI’s RS-485 pinout complements that on some popular PC plug-in RS-485 interface cards, and can connect to them using a straight through cable. Cable lengths up to 4000 feet are allowed using an RS-485 interface. 2.5.4.2.1 Terminations In Figure 2-8, note the terminations on the receivers for the Host Computer (first unit) and the last unit on the bus. No other unit (in this example Unit 1 or Unit 2) should be terminated. VertexRSI equipment uses an AC style termination, consisting of a 120 Ω resistor and a 0.01 µF capacitor in series. The termination is enabled by connecting the TERMINATION pin (pin 9) to the RX+ input (pin 4). For short cable runs, terminations may not be necessary. 2.5.4.2.2 Fail-safe Biasing Since the RS-485 transmitter is turned off when no data is being sent (to support multiple units on the bus), the bus is left floating (i.e., un-driven, in a high impedance state) between messages. During these times, the line is particularly sensitive to electromagnetic interference and may register as either a “1” or a “0”. In Installation 2-21 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA other words, receiving UARTs on the line may see either random data or errors between legitimate messages. This can cause problems with certain equipment or software, so fail-safe biasing may be necessary. A fail-safe biasing network is basically just a pull-up resistor on the “+” line and a pull-down resistor on the “–” line. This forces the bus into a “1” (or “MARK”) state when nothing else is driving it. Typical fail-safe biasing circuits are shown in Figure 2-3, enclosed in dashed lines. A voltage source (power supply) is needed to provide the pull-up voltage for the “+” line. As a general rule, the supply should be a dc supply of 5 to 12 volts, and the value of each resistor (in ohms) should be approximately R = 2.5 x VS x RZ where R = The resistance of the pull-up and pull-down resistors VS = The voltage of the power supply RZ = The resistance of the terminations (60 ohms for 2-wire, 120 ohms for 4-wire) In an RS-485 (4-wire) system, it is usually not necessary for the transmit driver in the host computer to switch on and off, since it is the only driver on that pair of wires. In this case, no fail-safe biasing is necessary on the transmit output from the host computer. VertexRSI equipment has an internal biasing network on its receiver inputs that guarantees a “MARK” state when the input is not connected. 2.5.4.3 RS-485 (2-wire) With an RS-485 interface, you can connect the transmit and receive pairs together, and communicate in half duplex over only one pair of wires. This mode of operation is called RS-485 (2-wire). To use RS-485 (2-wire) with this connector pinout, connect pins 1 and 4 together to form the positive (+) side of the bus, and pins 2 and 3 together to form the negative (–) side. See Figure 2-9. There is a common mode voltage specification for RS-485, so it is normally necessary to run a common ground line to all devices on the bus. VertexRSI’s RS-485 pinout complements that on some popular PC plug-in RS-485 interface cards, and can connect to them using a straight through cable. Cable lengths up to 4000 feet are allowed using an RS-485 interface. 2-22 Installation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Fail-Safe Biasing Host Computer Unit 1 V+ 4 V– Term. 3 9 1 2 5 Unit 2 Last Unit 4 4 3 3 9 1 Termination at Last Unit 9 1 2 5 2 5 Figure 2-9. A Typical RS-485 2-wire Bus With RS-485 (2-wire), the Host Computer must switch its driver on to talk, and off to listen for a response. The timing for turning the transmitter off depends on the protocol that is being used. The transmitter must be turned off by the earliest time that the unit may generate a response. 2.5.4.3.1 Terminations In Figure 2-9, note the terminations on the receivers for the Host Computer (first unit) and the last unit on the bus. No other unit (in this example, Unit 1 or Unit 2) should be terminated. VertexRSI equipment uses an AC style termination, consisting of a 120 Ω resistor and a 0.01 µF capacitor in series. The termination is enabled by connecting the TERMINATION pin (pin 9) to the RX+ input (pin 4). For short cable runs, terminations may not be necessary. 2.5.4.3.2 Fail-safe Biasing Since nothing is driving the bus between messages, the bus is left floating in an un-driven, high impedance state, and may register as either a “1” or a “0” to any unit on the bus. This ambiguity may cause problems with equipment or software, so fail-safe biasing may be necessary. A fail-safe biasing network is basically just a pull-up resistor on the “+” line and a pull-down resistor on the “–” line. This forces the Installation 2-23 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA bus into a “1” (or “MARK”) state when nothing else is driving it. Typical fail-safe biasing circuits are shown in Figure 2-9, enclosed in dashed lines. A voltage source (power supply) is needed to provide the pull-up voltage for the “+” line. As a general rule, the supply should be a dc supply of 5 to 12 volts, and the value of each resistor (in ohms) should be approximately R = 2.5 x VS x RZ where R = The resistance of the pull-up and pull-down resistors VS = The voltage of the power supply RZ = The resistance of the terminations (60 ohms for 2-wire, 120 ohms for 4-wire) VertexRSI equipment has an internal biasing network on its receiver inputs that guarantees a “MARK” state when the input is not connected. 2.5.4.4 RS-422 The RS-422 specification is similar to RS-485 (4-wire) in that it allows for full duplex communications over two differential pairs of wires: one pair for transmit data, the other for receive. See Figure 2-10. Unlike RS-485, however, RS-422 drivers are on all the time, so only one of them is allowed on either pair of lines. This avoids the problems of fail-safe biasing involved with RS-485, but limits communication to only one device and the host computer. See Figure 2-10. Host Computer Unit 4 3 Termination 9 Term. 1 2 5 Figure 2-10. A Typical RS-422 Bus There is a common mode voltage specification for RS-422, so it is normally necessary to run a common ground line to both devices on the bus. VertexRSI’s RS-422 pinout complements that on some popular PC plug-in RS-422 interface cards, and can connect to them using a 2-24 Installation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA straight through cable. Cables may be up to 4000 feet in length using an RS-422 interface. 2.5.4.4.1 Terminations In Figure 2-10, note the terminations on the receivers for the Host Computer and the Unit. VertexRSI equipment uses an AC style termination, consisting of a 120 Ω resistor and a 0.01 µF capacitor in series. The termination is enabled by connecting the TERMINATION pin (pin 9) to the RX+ input (pin 4). For short cable runs, terminations may not be necessary. 2.5.4.5 SIO Relay The serial I/O interface includes a programmable relay output that can be utilized as a “Service Request” interrupt to alert the host status monitoring system (in single-thread applications), or as an “Active Fault” indicator for use with an external redundancy controller (in redundant systems). The pinout for the SIO Relay is identified in Table 2-5. 2.5.4.5.1 Service Request When programmed as a Service Request, the Serial I/O Relay indicates whether a fault or warning has occurred on the unit. The status monitoring system can poll the unit to determine what the condition is and can reset the Service Request relay contact until another condition occurs. The Service Request is indicated as soon as a fault or warning occurs, and clears when acknowledged by a serial I/O “Clear Service Request” message. 2.5.4.5.2 Active Fault When programmed as an Active Fault, the Serial I/O Relay indicates whether the unit has failed. If this unit is the on-line unit in a redundant system, an external redundancy controller can then switch this unit off-line. The Active Fault is indicated as soon as a fault occurs, and remains set (active) as long as any fault is being reported by the amplifier logic. Installation 2-25 DMAN-14563 Rev. H 2.5.4.6 Ku-Band ModuMAX SSPA Making the Connection Note To maintain CE compliance, use shielded cables on all data lines. For D sub type connectors, attach the cable shield to a metal backshell. Follow the steps below to connect the SSPA Serial I/O connector to your remote controller. NOTE If you are using an RCP-2000 Remote Control Panel, connect your remote controller to the RCP-2000 Serial I/O connector instead of the SSPA Serial I/O connector. You will still set the serial I/O interface controls as described in step 4 below. Also refer to the RCP-2000 Manual Supplement. 1. Determine which pins on the Serial I/O port you will use. Figure out the required connections between the SSPA and remote controller. 2. Use the supplied 9-pin D male connector, or a compatible one, to fabricate an interface cable to connect between the SSPA Serial I/O port and the system controller. For best EMC performance, use shielded cable, and terminate the shield on the metal backshells of the connectors. 3. Connect the SSPA end of the cable to J4. Mechanically secure the connector flange to J4 with appropriate hardware. 4. Select your desired interface using the front panel controls (see Section 3.7.3.2.1). 2.5.5 SSPA Parallel I/O – J5 The parallel I/O interface, described in Table 2-6, provides relay contact closures for status indicators, and opto-isolated control inputs. J5 is a 37-pin D male connector and requires a mating 37pin D female connector. A solder-cup style mating connector and backshell are supplied. Section 3.6 describes the operation of the parallel I/O port in more detail. To connect a remote monitor & control system to the Parallel I/O port, follow the instructions below. 1. Figure out which signals you want to connect between the SSPA Parallel I/O port pins and your remote controller. 2. Use the supplied 37-pin D female connector, or a compatible one, to fabricate an interface cable to connect between the SSPA Parallel I/O port and the remote controller. For best EMC performance, use shielded cable, and terminate the shield on the metal backshells of the connectors. 2-26 Installation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Table 2-6 Parallel I/O Interface, J5 37-pin D (Male) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 Name Pin Number Status Outputs (Form ‘C’ relay contacts, 1 OUTPUT 1 20 2 Comments NC = closed when de-energized) NC COM NO OUTPUT 2 21 3 22 NC COM NO OUTPUT 3 4 23 5 NC COM NO OUTPUT 4 24 6 25 NC COM NO OUTPUT 5 7 26 8 NC COM NO OUTPUT 6 31 13 32 NC COM NO OUTPUT 7 14 33 15 NC COM NO OUTPUT 8 18 37 19 NC COM NO Analog Output (differential, 0.1 V/ 1 dBm of output power) ANALOG OUTPUT 27 (+) Positive 9 (-) Negative Control Inputs (optically isolated, “high” when open) INPUT 1 28 INPUT 2 10 INPUT 3 29 INPUT 4 30 Connect to INPUT GROUND pin to generate a “low”. INPUT 5 12 INPUT 6 34 INPUT 7 16 INPUT 8 17 INPUT GROUND 11 Shield Ground Shield Ground 36 Ground reference for all inputs. Installation 2-27 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA 3. Connect the SSPA end of the cable to J5. Mechanically secure the connector flange to J5 with appropriate hardware. 4. Select the functions you desire for the parallel I/O inputs and outputs (see Sections 3.7.3.3.3 and 3.7.3.3.4). 2.5.6 SSPA Network Interface – J6 On SSPAs that don’t include support for the RCP remote control panel, the Ethernet network interface (RJ-45) allows control of a subset of firmware functions and features. The SNMP interface uses standard protocol serial I/O instruction and sub-instruction codes as an MIB address. Table 2-7 shows the Ethernet interface connector pin-out, which is a standard RJ-45 jack. Table 2-7 2.5.7 Ethernet Interface, J6 Pin Number Function 1 2 3 6 Transmit + Transmit Receive + Receive - System – J7 J7 is used to support optional equipment in some custom configurations. If you purchased a maintenance switch assembly with your ModuMAX SSPA, connect the switch cable to J7. 2.5.8 SSPA Power Supply Interface – J9 The SSPA monitors the health of the Power Supply via a set of Form ‘C’ relay contacts on J5 of the Power Supply. Connect J9 on the SSPA to J5 on the Power Supply rear panel using the supplied cable. This cable has a 9-socket D connector at each end. 2-28 Installation DMAN-14563 Rev. H NOTE 2.5.9 Ku-Band ModuMAX SSPA Since the interface cable has the same type of connector at each end, it is possible to install it backwards. To help prevent this, the cable’s connector backshells are labeled “SSPA J9” and “PS J5” to indicate where each end is to be connected. SSPA RF Input Sample – J10 The RF Input Sample port is a Type N female connector that provides a nominal –10 dBc sample of the input RF power to the SSPA. You can attach a power meter, spectrum analyzer, or other monitoring instrument to this port. This port may be left unterminated when not in use. 2.5.10 SSPA RF Output Sample – J11 The RF Output Sample port is a Type N female connector that provides a nominal –50 dBc sample of the output RF power from the SSPA. You can attach a power meter, spectrum analyzer, or other monitoring instrument to this port. This port may be left unterminated when not in use. 2.5.11 Power Supply Remote – PS J4 PS J4 carries various status signals that are made available to monitor the health of the power supply and its plug-in modules. However, it is not used in the ModuMAX SSPA system. 2.5.12 Power Supply Status – PS J5 The Power Supply Status connector is a 9-pin D connector that carries a set of Form ‘C’ contacts to the SSPA. The SSPA monitors these contacts to determine whether any Power Supply modules are faulted. The connection between J5 on the Power Supply and J9 on the SSPA is described in Section 2.5.8. 2.5.13 Power Supply Sync – PS J6 PS J6 is used when two power supplies are connected in parallel to provide redundancy of the ac mains circuit. It transfers synchronization pulses and the remote sense voltage between the power supplies, to improve current sharing among the installed modules. If you have purchased two power supplies for your ModuMAX SSPA, use the supplied sync cable to connect J6 on one of the power supplies to J6 on the other. PS J6 includes a keying pin in position 9 to prevent plugging in a cable intended for J7, the SENSE connector. Installation 2-29 DMAN-14563 Rev. H 2.5.14 Ku-Band ModuMAX SSPA Power Supply Remote Sense – PS J7 The Power Supply Remote Sense connector is a 9-socket D connector to which a 2-wire cable is attached for remote sensing of the SSPA input voltage at its bus bars. The Remote Sense cable was attached to the SSPA and the power supply in Section 2.5.3.4. 2.6 Power-Up Tests This section describes initial tests to conduct after installing the equipment for the first time. These tests will ensure that the equipment is installed and connected properly. NOTE If your ModuMAX system includes two power supplies, conduct the power-up tests on both power supplies. 1. Check all connections made to the SSPA and Power Supply: a) Make sure all cables are securely attached to their mating connectors. b) Make sure all hardware connecting the dc power cables to the SSPA and PS bus bars is tight. c) Make sure that the SSPA RF Output is properly terminated in a suitable load. 2. Remove all three Power Supply modules from the Power Supply chassis. 3. Energize the prime power wiring to the Power Supply. 4. Refer to Figure 2-11. Use a DVM to verify that the input voltage between pins 37 and 38 on the mating connector inside the power supply chassis is between 180 and 264 Vac for each power supply module. Figure 2-11. 2-30 Installation Power Supply Module Mating Connector DMAN-14563 Rev. H Ku-Band ModuMAX SSPA 5. Re-install the three Power Supply modules in the Power Supply chassis. 6. Turn ON all three circuit breakers on the Power Supply modules, by simultaneously switching on two of the modules, then the third. (At least two power supply modules must be ON to operate the system.) 7. Use a DVM to measure the dc input voltage at the SSPA bus bar terminals. The voltage should be 11.5 +/- 0.05 Vdc. If the voltage is outside this window, adjust the voltage as described in Section 5.4.1 in the Maintenance section of this manual. 8. Refer to Figure 2-12. Measure the voltage drop from the Power Supply positive bus bar terminal to the SSPA positive bus bar terminal. This voltage should be no greater than 0.15 Vdc. Similarly, measure the voltage drop from the Power Supply negative bus bar terminal to the SSPA negative bus bar terminal. This voltage should also be no greater than 0.15 Vdc. NOTE The 0.15 Vdc drop applies to ModuMAX systems where the SSPA is mounted directly above the Power Supply. In multiple-chassis systems where the power supplies are all installed in the bottom of the cabinet, the cables will be longer, and will have a proportionally higher voltage drop. WARNING A voltage drop greater than 0.15 Vdc across a pair of power cables indicates excessive resistance, likely caused by loose or damaged connections between the dc power cables and bus bar attachment points. Power dissipated in loose connections can make the power cables extremely hot. To avoid personnel burns and fire hazard, immediately turn off all three power supply modules, and examine the dc power cable attachment points. Tighten loose connections. 9. Observe the SSPA front panel. The Fault indicator should not be lit. If it is, refer to the troubleshooting guide, Table 5-2 (in Section 5, Maintenance), to determine and remedy the cause. The Warning indicator may be lit to indicate a power up warning. If so, press Fault Reset to clear the warning. 10. Allow the SSPA to operate for approximately 5 minutes. After this time, check the temperature of the dc power cable attachment points at the SSPA and the Power Supply. The bus bar temperature should be no more than 35 °C above the ambient air temperature. If any of the dc power cable attachment points are significantly warmer, turn off all three power supply modules. Disconnect the cable at the hot spot. Re-connect it using new lock washers, and torque them to the recommended torque specified in Section 2.5.3. Installation 2-31 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA 11.5 ± 0.05 Vdc between terminals on SSPA J4-SERIAL I/O J7-SYSTEM J9-PS INTERFACE J5-PARALLEL I/O RS-232/422/485 A13 - LOGIC PCB A14 - PARALLEL I/O PCB A15 - NETWORK Turn fan OFF before removing. Turn fan OFF before removing. Turn fan OFF before removing. Turn fan OFF before removing. 0.15 Vdc drop maximum between positive bus bars (PS to SSPA) 0.15 Vdc drop maximum between negative bus bars (PS to SSPA) J1 - RF IN ! 2120 Old Gatesburg Road State College, PA 16803 Phone: 814-238-2700 Fax: 814-238-6589 www.tripointglobal.com WARNING: Radiation hazard when unterminated. Do not operate SSPA without a termination. J2 - RF OUT 11.8 Vdc maximum between terminals on Power Supply Figure 2-12. Bus Bar Voltage Measurements 2-32 Installation DMAN-14563 Rev. H 2.7 Ku-Band ModuMAX SSPA Airflow System Installation If you plan to intake air from the outside or exhaust air to the outside through a ducting system, you should evaluate the ducting system’s effect on thermal performance. Begin by taking baseline module temperature measurements without the ducting system installed. To do so, allow the SSPA system to operate for at least 20 minutes with RF ON. Then enter the Srvc / Module / Temp menu to display the temperature of Module 1. Make note of Module 1’s temperature, then use the MENU button to step through the other module temperature readings, making note of each one. These module temperature readings are the baseline. If you purchased intake or exhaust duct adapter kits from VertexRSI, shut off the SSPA and connect the kit(s). Refer to assembly drawing 13141 (included with the kits) for details of how to attach them. Note that you must remove the exhaust grill before installing the exhaust duct adapter. Then connect the facility air ducting system, including any booster blowers, to the duct adapter(s). Apply power to the ModuMAX system and allow it to operate for at least 20 minutes with RF ON. Then record the module temperatures again, from the Srvc / Module / Temp menu, and compare the readings to the baseline readings recorded above. If you did not add a booster blower to compensate for the pressure drop added by the ducting, the module temperatures will probably be higher than the baseline values. If the average temperature increase is less than approximately 5 °C, it indicates that the ducting system has not significantly compromised thermal performance. If the module temperatures are on average more than 5 °C above the baseline, the system may still be useable; however, the maximum ambient temperature in which the system can operate without generating a temperature fault or shutting down due to overtemperature will be reduced. Also, semiconductor life expectancy decreases by a factor of approximately 2 for each 10 °C temperature increase, so reliability may be compromised. If your ducting system causes excessive module temperature increases, you may want to consider redesigning it. Possible means of improvement include: • Reduce duct length • Replace flexible duct with rigid duct, which has lower pressure drop per unit length • Replace tight, small radius bends with larger radius swept bends • Add one or more booster blowers Installation 2-33 DMAN-14563 Rev. H 2.8 Ku-Band ModuMAX SSPA Optional Accessory Installation If you ordered any optional accessories with your ModuMAX system, install them now. 2.8.1 Antenna/Dummy Load Switch Assembly The Antenna/Dummy Load Switch Assembly, also called the Maintenance Switch Assembly, permits the operator to route the RF output to either the antenna or a high power dummy load included with the switch assembly. To install it, attach waveguide switch Port 1 to the ModuMAX RF output. Use a conductive gasket at the interface, and secure with #6 hardware. Refer to assembly drawing 14566 for details. Connect the MS connector on the cable assembly to the switch control port. Connect the 15-socket D connector on the cable assembly to SSPA J7. 2.8.2 RCP-2000 The RCP-2000 Remote Control Panel provides real-time, remote interfacing with a properly configured VertexRSI ModuMAX SSPA. The front panel display and controls of the SSPA are mimicked on the RCP-2000 which is especially convenient for situations where the SSPA is located in an inaccessible, inconvenient, or hostile location. The RCP-2000 is designed to mount in a standard 19inch rack. If you have purchased an RCP-2000, refer to the RCP-2000 manual supplement for installation and operation details. NOTE RCP-2000 support is not included in ModuMAX SSPAs that have an Ethernet port installed. If you have an SSPA that has an Ethernet port, and wish to convert to control via RCP-2000, contact the factory for a firmware upgrade. The RCP-2000 connects to the SSPA’s Serial I/O port with an RS422 serial communication link. The interconnection cable can be up to 4000 feet in length. This may be a user-supplied cable or purchased separately from GD SATCOM. See the link cable assembly drawing included with the RCP-2000 supplement for more information. You can use the RCP-2000’s Serial I/O port to operate the SSPA using the serial I/O commands described in this manual. 2-34 Installation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Section 3 3.1 Operation General Introduction To operate the VertexRSI Ku-Band ModuMAX SSPA, use the information contained in this section. 3.2 • To learn about the principles of ModuMAX SSPA RF operation, see RF Operation, Section 3.2. • To learn about the front panel manual controls and indicators, see Front Panel (Local) Control, Section 3.3. • To use the network interface to control and monitor the SSPA, see Network Interface, Section 3.4. • To use Serial I/O to control and monitor the SSPA, see Serial I/O, Section 3.5. • To use Parallel I/O to control and monitor the SSPA, see Parallel I/O, Section 3.6. • For more details on how the amplifier controls, measurements and settings affect the RF performance, see Function Reference, Section 3.7. RF Operation This section explains the relation between the RF operating parameters of gain, input and output level, and intermodulation distortion. 3.2.1 Adjusting Gain The RF input level and SSPA gain together determine the output level. Since input level is often fixed in a particular installation, the ModuMAX SSPA includes a gain adjustment feature that can be used to set a desired output level. The gain adjustment can be controlled from the front panel or remotely as described in Section 3.7.1.1.5. Gain is adjustable 0.1 dB steps, and is relative to the maximum gain value. Gain in dB is computed by adding the (negative) gain reading to the unit’s maximum gain from the test data sheet; for example, a unit with 75.0 dB maximum gain will have 65.0 dB gain when the gain adjust is set to -10.0 dB. At this setting, the unit would produce a +45.0 dBm output level if a -20.0 dBm signal is applied to the input. Operation 3-1 DMAN-14563 Rev. H 3.2.2 Ku-Band ModuMAX SSPA Selecting Output Level The ModuMAX SSPA can safely be operated up to and slightly above its rated output. Gain will start to compress as output level approaches rated power. The SSPA will saturate, or reach maximum output level, at 0.5 to 1.0 dB above its 1 dB compression point. If input level or gain is further increased once the SSPA saturates, the current drawn by one or more of the RF devices may change, generating current alarms. You may safely operate the SSPA in saturation; however, do not drive the input more than 3 dB beyond the level needed to produce 1 dB gain compression for an extended period. CAUTION 3.2.3 Never exceed the maximum safe RF input level, or permanent damage to the SSPA may result. Intermodulation Distortion For linear operation, minimization of intermodulation distortion (IMD) levels is an important consideration. Figure 3-1 shows IMD versus backoff from rated P1 dB using two-tone CW, single-, and dual-QPSK signals. -10 TWO-TONE -15 -20 DISTORTION (dB) -25 -30 DUAL QPSK -35 -40 SINGLE QPSK -45 -50 -10 -9 -8 -7 -6 -5 -4 -3 -2 -1 0 BACKOFF (dB) Figure 3-1. IMD vs. Backoff In Figure 3-1, backoff is the reduction in total output power below the SSPA’s 1 dB gain compression point. The plot is based on measured data from typical SSPAs, and can be used to determine required backoff from P1 dB to achieve a given IMD suppression. 3-2 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA After choosing an appropriate operating point from Figure 3-1, adjust input level and gain to set the output to the required backoff. 3.2.4 Configurable Power The ModuMAX SSPA combines the RF output power from eight amplifier modules to obtain its rated power capacity. These amplifier modules can be individually turned on and off using the Module Disable function described in Section 3.7.1.1.2. Some installations can exploit this Module Disable capability to reduce power consumption during times when required RF output power is relatively low. The ability to adjust the number of enabled modules to match the output power requirements at any given time is called configurable power. Configurable power is implemented by determining the minimum number of modules that must be enabled to provide the RF output power required. If N+1 redundancy is desired, one additional enabled module would be required. Then, any modules not needed to support the traffic are disabled, either locally or via one of the remote interfaces. The customer’s remote M&C system will monitor the ModuMAX SSPA for faults. If it detects a fault in one of the enabled modules, it enables one of the disabled modules to compensate for its loss. The SSPA modules have no minimum warm-up time, so can be put into service immediately upon being enabled. The advantage of configurable power is that power consumption can be significantly reduced by disabling one or more modules. Power consumption is approximately proportional to the number of enabled modules. RF output capacity is proportional to the square of the number of enabled modules (see Section 4.4.1.3 for a discussion of combining theory). Table 3-1 shows rated RF output and typical power consumption for various numbers of enabled modules. Table 3-1 # Enabled Modules 8 7 6 5 4 3 2 1 Configurable Power 350 W Ku-Band Power P1 dB Consumption +54.8 dBm 4.5 kW +53.6 dBm 3.9 kW +52.3 dBm 3.4 kW +50.7 dBm 2.8 kW +48.8 dBm 2.3 kW +46.3 dBm 1.7 kW +42.8 dBm 1.1 kW +36.7 dBm 0.6 kW 500 W Ku-Band Power P1 dB Consumption +56.2 dBm 4.8 kW +55.0 dBm 4.2 kW +53.7 dBm 3.6 kW +52.1 dBm 3.0 kW +50.2 dBm 2.4 kW +47.7 dBm 1.8 kW +44.2 dBm 1.2 kW +38.1 dBm 0.6 kW Operation 3-3 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA For example, if you require +53.7 dBm (230 W) of rated RF output power (P1 dB) from your 500 W ModuMAX SSPA to meet receive signal level and intermodulation distortion, and you need N+1 redundancy, you could enable seven of the eight RF modules and save approximately 600 watts of power. If one of those RF modules failed during operation, the ModuMAX would still operate at or above the minimum power threshold until the M&C system could detect the fault and enable a standby module. 3.3 Front Panel (Local) Control The control panel for the amplifier is located at the top of the front panel. This control panel contains four indicator lights, four MENU navigation buttons, two MODIFY data buttons, a display window, and buttons for five actions. The front panel of each amplifier module is visible through the front cover of the chassis. Each amplifier module has a status indicator lamp that allows you to quickly determine its status. RF On, Mute Indicators and Action Buttons Gain Adjust Buttons Control Menu and Status Message Display Window Modify Data (INC, DEC) Buttons Menu Navigation Buttons MODIFY MENU Warning, Fault Indicators and Fault Reset Button ® RF ON MPKM14500R WARNING PREV GAIN SEL MUTE FAULT FAULT RESET Figure 3-2. Front Panel Controls and Indicators 3.3.1 Menus The display presents measurements, controls and settings of the amplifier in several screens arranged into menus. The buttons are used to navigate through the menus and screens, and to change settings on screens containing controls. When power is first applied, the Default Status Screen will be shown. This screen contains some general information about the amplifier, its fault status, and the control mode. This screen is displayed whenever one of the following occurs: • The system is powered on. • The PREV • No buttons are pressed for five minutes. button is pressed in the main menu. Pressing any MENU button while the Default Status Screen is showing will take you to the Main Menu. 3-4 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA The top line of every menu will show a title or important piece of information related to the content of the screen. The bottom line will generally contain your choices, or data that is editable on that screen. A pair of heavy brackets [ ] appears on the bottom line if there is more than one choice. The brackets can be moved left or right with the or MENU buttons. Pressing the SEL button will select or activate the item chosen. If the item chosen is a number, pressing a MODIFY button ( or ) will change it. Some screens display measurements only, and have no editable data. In this case, no selection brackets will appear, and the MODIFY buttons and will not function. Left or right arrowheads () appear on the bottom line of screens that have more choices or data than will fit on the line. In this case, pressing the or MENU buttons will “scroll” the screen to show the extra data. The following sections describe the use of the menus, screens and buttons in general. In some screens, the behavior of the buttons or selection brackets may vary. Read the specific section describing the screens for more information. 3.3.1.1 Action Buttons Five buttons on the front panel cause immediate actions to occur. This eliminates the need to navigate through menus to perform common tasks. RF ON MUTE GAIN If the amplifier is currently MUTED, pressing this button will turn amplifier RF output on. This button will not turn on any RF modules that are disabled or shutdown due to a fault. This button will not override a Parallel I/O RF Inhibit. Pressing this button when RF output is already on will have no effect. If the front panel is locked or in REMOTE mode (with “Remote Disables Local” on), pressing this button will have no effect. If RF output is currently on, pressing this button will immediately mute the amplifier, turning RF output off. Pressing this button when the amplifier is already muted will have no effect. Pressing this button if the front panel is locked or in REMOTE mode (with “Remote Disables Local” on) will have no effect. Pressing either button once will display the amplifier gain setting. Additional presses will each increase or decrease amplifier gain by 0.1 dB. Pressing and holding the button will cause gain to change rapidly. If the front panel is locked or in REMOTE mode (with “Remote Disables Local” on), pressing these buttons will display the gain, but will not change it. Operation 3-5 DMAN-14563 Rev. H FAULT RESET 3.3.1.2 Ku-Band ModuMAX SSPA Pressing this button issues a Fault Reset command. A Fault Reset command will clear New Fault or Power Up warnings, and certain other fault events, such as a Spurious Reset, or Illegal Op-code. Modify Buttons Two buttons on the front panel are used to modify amplifier settings: MODIFY 3.3.1.3 Increments or decrements the value of numeric data by one resolution step. If pressed while on a multiple-choice item, the selection will change to the next or previous choice. Pressing and holding these buttons will change the data rapidly. Menu Navigation Buttons PREV MENU SEL The front panel contains four Menu buttons for navigating the menus. All buttons have an auto-repeat function that activates if you press and hold the button for more than about 0.6 seconds. The functions of the four Menu buttons are described below. This button moves the selection brackets [ ] left on the menu line. If there is a left arrowhead on the left side of the screen, this button will scroll the display to show further choices or data to the left of the current position. This button moves the selection brackets [ ] right on the menu line. If there is a right arrowhead  on the right side of the screen, this button will scroll the display to show further choices or data to the right of the current position. PREV SEL 3-6 Operation This button takes you up one level in the menu hierarchy. It will take you back to the menu you were in before you entered the current screen. From the main menu, this will take you back to the Default Status Screen. This button selects or activates the current menu item indicated by the selection brackets [ ]. The action taken depends upon the type of current menu item as follows: • ANOTHER MENU: You will be taken to the new screen and presented with a new list of choices or data. • COMMAND: The indicated command will be executed when you press SEL . Some commands are protected by another screen that reads “PRESS SEL TO…”. You then have the choice of pressing SEL if you really wish to execute the command, or pressing PREV to go back to the menu. • DATA ITEM: Unless otherwise noted, pressing SEL will have no effect on numeric data. You must press the MODIFY ( or ) buttons to alter numeric data. DMAN-14563 Rev. H 3.3.1.4 Ku-Band ModuMAX SSPA Menu Listing Table 3-2 shows the entire menu structure available from the front panel. Some choices appear only under certain conditions. These are marked with circled numbers, as follows. c The Unlock screen (Unlk) appears only if a screen password is enabled, or if a Local Lockout serial command is issued. d The Antenna/Dummy Load switch control screen appears only if that switch is installed. e Menus for status of six power supply modules appear only in systems that have dual, redundant Power Supplies, A and B. (A single Power Supply has three modules.) f Parallel I/O related screens appear only if Parallel I/O hardware is installed. Remote parallel I/O menus appear only if an RCP-2000 with Parallel I/O is connected to the SSPA and operating properly. g Ethernet related screens appear only if an Ethernet card is supported. This is the standard ModuMAX configuration. If your particular ModuMAX includes support for an RCP-2000 Remote Control Panel, Ethernet will not be supported. In this manual, selection of a particular menu is described in the form “... Menu / Submenu / … ”. For example, ... select Set / Faults / Limits / Pfwd ... In the manual text, this means select the Set menu, then the Faults menu, then the Limits menu, then the Pfwd menu. See the sections listed by each screen for more details. Table 3-2 Menu Listing Default Status Screen Top Line (one of the following) Currently Active Fault (if a Fault is active) or Warning (Section 3.7.2.2.1); or New Fault, if a Fault has occurred, but is no longer active (Section 3.7.2.2.1); or Output Status, if RF is off (Section 3.7.1.2.1); or Forward Power, in dBm, dBW, or Watts, as selected (Section 3.7.1.2.2) Bottom Line Control Mode, i.e., Local, Remote, or Maint (Section 3.7.5.1.1) NOTE: Pressing any MENU button while the Default Status Screen is showing will take you to the Main Menu, below. Operation 3-7 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Table 3-2 Menu Listing Main Menu c [Unlk] (appears if screen password is enabled, or local lockout command is issued) Enter Password (X X X X X X) (Section 3.7.5.1.3.) [Flt] (Fault status information) Fault Menu [Active] Active Fault List (Section 3.7.2.2.1.) [Inf} Active Fault Info, when available (Section 3.7.2.2.2.) [Log] Event Log (Section 3.7.2.2.3.) [Reset] Fault Reset (Section 3.7.2.3.5.) [Oper] (Operate) Operate Menu [Mute] SSPA: (followed by mute status and source if muted) [Mute] or [Operate] (choose one; see Section 3.7.1.1.1.) [Gain] Pfwd: (forward power) Gain and Gain Range (settable from -20.0 to 0.0 dB in 0.1 dB steps, or -18.8 to 0.0 dB when SMFC is enabled. See Section 3.7.1.1.5.) [Mod] (Module) Mod: 1 2 3 4 5 6 7 8 Status for each of 8 modules ( = enabled, X = disabled; Section 3.7.1.1.2.) [Ctl] (Control) Ctl Mode: (control mode) [Remote] or [Local] or [Maint] (choose one; Section 3.7.5.1.1.) d [AntDL] (Antenna/Dummy Load, appears only if switch is installed) AntDL Switch: (switch position) [Antenna] or [DummyLd] (choose one; Section 3.7.1.1.6.) [Srvc] (Service) Service Menu [Pfwd] (Forward Power) Pfwd= (forward power; Section 3.7.1.2.2) [dBm] or [dBW] or [Watts] (power units, choose one; Section 3.7.1.2.9.) [Prefl] (Reflected Power) Reflected Power/Return Loss/VSWR (measured value; Section 3.7.1.2.3.) [Pwr] or [RetLoss] or [VSWR] (choose one; Section 3.7.1.2.10.) [Module] Mod (module number, 1-8) : Status (Section 3.7.1.2.4.) [Po] (output power) Mod (1-8) Po= (output power; Section 3.7.1.2.5.) [dBm] or [dBW] or [Watts] (power units, choose one; Section 3.7.1.2.9.) 3-8 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Table 3-2 Menu Listing Service Menu, continued: [Temp] (temperature) Mod (1-8) Temperature (module temperature; Section 3.7.1.2.8.) [V] (voltage) Mod (1-8) Vin= (input voltage; Section 3.7.1.2.7.) Vg= (gate voltage) Vr= (regulated voltage*) (* regulated voltage measurement is not available in older modules) [ I ] (current) Mod (1-8) Current (module current; Section 3.7.1.2.6.) [Fan] Fan: 12345678 Status for each of 8 fans ( = OK, X = Failed; Section 3.7.1.2.11.) e [PS] (Power Supply) PS Mod: A123 B123 (if two power supplies) or PS Mod: 123 (if only one) Power supply module status ( = OK, X = Failed; Section 3.7.1.2.12.) [Timer] Operation Time XXd, XX:XX:XX (days, hours, minutes, and seconds; Section 3.7.4.2.3.) f [Inp] (Parallel I/O Inputs, appears only if Parallel I/O is installed) Inp (1-8) : Input Function High or Low (present status; Section 3.6.2 and 3.7.3.3.3) Inp (R1-R8) : Input Function (for Parallel I/O inputs on RCP-2000, if installed) High or Low (present status; Section 3.6.2 and 3.7.3.3.3) [Test] Self-Test Results (Section 3.7.4.1.1.) [Reset] Press SELECT to reset Processor (Section 3.7.4.1.2.) [Ver] (firmware Version information) Version Menu [LogicBrd] (Logic Board) MultiMOD ModuMAX vX.XX (firmware version) (Section 3.7.4.2.1.) [Modules] Module (1-8) Version (module firmware version; Section 3.7.4.2.1.) g [Ethernet] Ethernet (c)2006 (Ethernet firmware version; Section 3.7.4.2.1) [Set] (Setup) Setup Menu [Faults] Operation 3-9 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Table 3-2 Menu Listing Setup Menu, continued: Setup Faults [Limits] Setup Fault Limits [Pfwd] (Forward Power) Pfwd: (measured forward power; Section 3.7.2.3.1.) (low limit) to (high limit) [Prefl] (Reflected Power) Prefl: (measured reflected power) Limit: (reflected power high limit; Section 3.7.2.3.2.) [PwrUp] (Power-Up) PwrUpWarn: (Power-Up fault warning status, Enabled or Disabled) [Enable] or [Disable] (choose one; Section 3.7.2.3.3.) [Loc] (Local) LocWarn: (Local Mode fault warning status, Enabled or Disabled) [Enable] or [Disable] (choose one; Section 3.7.2.3.4.) [SMFC] (Single Module Failure Compensation) SMFC: (status, Enabled or Disabled) [Enable] or [Disable] (choose one; Section 3.7.2.4.) [AudAlm] (Audible Alarm) AudAlarm: (setting, either Off, Fault, or All; Section 3.7.2.5.1.) [Off] [Fault] [All] or [Test] (choose one) [PwrCal] (Power Calibration) Power Cal [Pfwd] (Forward Power) Pfwd: (measured forward power) Offset: (forward power detector offset; Section 3.7.1.3.1.) [Prefl] F (forward power), R (reflected power) R Offset= (reflected power detector offset; Section 3.7.1.3.2.) g [Net] (Network) Setup Network [IP Address] (IP Address; 0-255; Section 3.7.3.1.1) Network IP Address [IP Address (1)] [IP Address (2)] [IP Address (3)] [IP Address (4)] [Netmask] (Network IP Mask; Section 3.7.3.1.2) Network Net-Mask [IP Mask (1)] [IP Mask (2)] [IP Mask (3)] [IP Mask (4)] [Gateway] (Network Gateway; Section 3.7.3.1.3) Network Gateway [Gateway(1)] [Gateway(2)] [Gateway(3)] [Gateway(4)] [Ser] (Serial I/O) Setup Serial IO 3-10 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Table 3-2 Menu Listing Setup Serial I/O Menu, continued: [Intfc] (Interface) SIO Intfc: (setting, RS-232, RS-485 4-wire, RS-485 2-wire, or RS-422) [RS232] [RS485:4] [RS485:2] or [RS422] (choose one; Section 3.7.3.2.1.) [Baud] (Baud Rate) SIO Baud Rate: (baud rate, 300 to 28800; Section 3.7.3.2.2.) [300] [1200] [2400] [4800] [9600] [14400] [28800] (choose one) [Adr] (Address) SIO Address: (serial I/O address, 0-255; Section 3.7.3.2.3.) [Relay] (Relay) SIO Relay: (Serial I/O Alarm setting; Section 3.7.3.2.4) [SvcReq] or [ActiveFlt] (Service Request or Active Fault, choose one.) f [Par] (Parallel I/O; appears only if Parallel I/O is installed) Setup Parallel IO [Inp] (Inputs) Inp (1-8): (input function) (input function selection list; Section 3.7.3.3.3.) Inp (R1-R8): (input function; available only if RCP-2000 is installed) (input function selection list; Section 3.7.3.3.3.) [Outp] (Outputs) Out (1-8): (output function) (output function selection list; Section 3.7.3.3.4.) Out (R1-R8): (output function; available only if RCP-2000 is installed) (output function selection list; Section 3.7.3.3.4) [AnAdj] (Analog Adjust) Adjust for 5 V on (Remote or Local) Output: (analog adjustment value) (Remote is available only if RCP-2000 is installed; Section 3.7.3.3.6.) [R/L] (Remote/Local) Remote Disables Loc: (Yes or No) [No] or [Yes] (choose one; Section 3.7.5.2.3.) [PwrUp] (Power-Up state) Power Up: (amplifier Power-Up state) [Mute] [Oper] [Prev] (choose one; Section 3.7.1.1.4.) [Opts] (Options) Press SEL to Remove (Removable options list; Section 3.7.4.3.2.) [Passw] (Password) Password: (Enabled or Disabled) [Disable] [Enable] [Set] (choose one; Section 3.7.5.2.1.) [Set] (Set a screen password; Section 3.7.5.2.2.) Operation 3-11 DMAN-14563 Rev. H 3.3.2 Ku-Band ModuMAX SSPA Indicators Four indicator lights are used to present critical status information quickly. These indicators are described below. • RF ON (Green): The RF ON indicator is lit if any amplifier module is on. It is dark if all amplifier modules are off for any reason (e.g. Mute, Inhibit, Module Disable) (see Section 3.7.1.2.1). • MUTE (Amber): This indicator is lit if the Mute Control is set to MUTE. It is dark if the Mute Control is set to OPERATE (see Section 3.7.1.1.1). • WARNING (Amber): The WARNING indicator is lit if a warning is detected in the amplifier system. This includes the New Fault warning, which indicates a fault has occurred, even if it is not currently active (see Section 3.7.2.1.3). • FAULT (Red): The FAULT indicator is lit if a problem is currently detected in the amplifier system (see Section 3.7.2.2). It will also light if a complete failure of the Logic Board or Front Panel occurs (see below). The Front Panel contains a circuit to detect catastrophic failure of its circuitry or the Logic Board. This circuit will illuminate the red FAULT indicator if such a failure is detected. If you observe the FAULT indicator lit, and the front panel seems unresponsive, first check the cable to the Front Panel. If it is in place, try replacing the Front Panel. If that does not correct the problem, replace the Logic Board. 3.3.3 Amplifier Module Status Lamps Each amplifier module is equipped with a status indicator lamp, visible from the front of the chassis, which should quickly draw your attention to a module that requires servicing. The indicator lamp can be one of three colors, blinking, or off. Lamp colors have the following meanings: 3-12 Operation Green: The amplifier module is functioning normally. Amber: The amplifier module’s RF output is off (muted, disabled, or inhibited). If you have not commanded the amplifier module to be turned off, something may be wrong with it. Remember that an amplifier module is disabled (RF is off) by default when first plugged into an operating system; you must manually enable the module from the front panel. Red: The amplifier module has failed. You can refer to the menu screen on the front panel for more information, but this is most likely a module that should be serviced. DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Off: The amplifier module has no power. If the amplifier is plugged into an operating rack, and the indicator is OFF, something is probably seriously wrong. The fusible link within the module may have opened due to a short circuit. Note that the indicator lamp may turn off while the module is being loaded with new firmware; this is normal. In addition, the lamp may alter states to indicate more than one condition simultaneously. If the lamp “flickers” (briefly turns off) once every second or so, then the module is operating, but has lost communications with the main Logic Board. This may indicate a problem on the Logic Board or in the module. If the main Logic Board fails or is unplugged, all modules’ lamps will flicker. If the lamp alternates between AMBER and RED, then the module is faulted and its RF output is off. 3.4 Network Interface (NIC) Standard ModuMAX amplifiers are equipped with an Ethernet interface which allows the user to control and monitor the unit. There is no support for DHCP in the NIC. Users must employ a Static (fixed) IP Address. The Ethernet interface uses the industry-standard Simple Network Management Protocol (SNMP) to control and monitor the amplifier. SNMP (Simple Network Management Protocol) implements the controls and measurements of a device as a set of objects, which can be read or written. The set of objects for a particular device are all listed formally in a Management Information Base (MIB). The MIB assigns a numeric value to each object, called the Object Identifier (OID). The information is usually presented in a hierarchal format, so the Object Identifier consists of a series of numbers, separated by periods (.). Each value identifies which branch to take at each level, until you reach the actual object, or “leaf”. Any SNMP-aware software can read the MIB (which is just a text file) and understand the set of objects which can be read or written in the device. The Management Information Base for ModuMAX consists of a set of objects, whose numeric object identifiers are equal to the serial I/O instruction and sub-instruction (if any) that would be used to access the information via the serial port. All ModuMAX objects branch off the following tree: iso.org.dod.internet.private.enterprises.vertexrsi.vertexrsiProducts.ModuMAXSSPA (i.e., 1.3.6.1.4.1.1414.2.5) Operation 3-13 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Objects representing all serial I/O messages are included in the MIB, except for the following: 09 Clear Service Request (there is no service request on the network) 16 52 - Get Module Current (the information is duplicated in message 16 58) 17 1E - Set/Get IP Address (NIC settings should not be changed via the NIC) 17 1F - Set/Get NETMASK (NIC settings should not be changed via the NIC) 17 20 - Set/Get Gateway (NIC settings should not be changed via the NIC) The type of every object in the MIB is an octet string. When a request to read an object is made via SNMP, the corresponding serial I/O message is sent to the Main Logic Board. The message body of the reply is returned, without the subinstruction (if any). If there is no answer to the serial message, an octet string containing a single exclamation point (“!”) will be returned. When a request to set the value of an object is made via SNMP, the serial message is sent to the Main Logic Board, with a message body that includes the data to be set. For serial messages that correspond to commands, an empty string will be returned when the object is read via SNMP. A request to set the value will cause the command to be sent. If the command requires some data, the data being written to the object via SNMP will become the data sent with the command; however, if the object is read afterwards, it will still return an empty string. For any serial messages that require a module number, eight branches are added to the MIB, numbered 1 through 8, corresponding to the eight modules in a ModuMAX amplifier. The module number will automatically be added to the serial message sent to the Main Logic Board; and will automatically be removed from replies received back from the Main Logic Board, before being returned over the network. For example, the serial message to read the module temperature is 16 51 (hex). So the temperatures of the four modules are represented in the MIB as: ...22.81.1 ...22.81.2 ...22.81.3 ...22.81.4 Note that 16 (hex) is 22 (decimal), and 51 (hex) is 81 (decimal). 3-14 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Messages 16 51 16 58 16 60 16 62 16 64 16 65 18 56 requiring a module number are: - Get Module Temperature - Get Module Current - Get Module Internal Measurements - Get Module Firmware Version - Get Module Output Power - Get Module Status - Set/Get Module Enable/Disable Two other serial messages require additional arguments: 16 63 - Get Fault Text (requires a one- or two-byte fault code) 16 66 - Get Fault Log Entry (requires a log entry sequence number) These are handled by adding two or three additional branches to the MIB: .1 - Read/write: the additional argument that should be sent with the serial message. .2 - Read only: the value returned when the serial message is sent with the argument specified in .1 .3 - Read only: the value returned when the serial message is sent with no argument. Note that the .3 branch is used only for the 16 66 (Get Fault Log Entry) message. It returns the sequence number of the most recent log entry, and the total number of entries in the log. The additional argument is NOT removed from the reply as is done with the module number in module-related messages. Because the SNMP MIB objects directly correspond to serial messages, following the rules presented here, you can refer to the serial protocol for more information about how each will function. Also, the MIB contains details on the functions and use of every object, in the DESCRIPTION section for each MIB entry. NOTE 3.5 Any commands or settings received via the Network Interface are treated as “Remote” for purposes of the control mode or Remote Disables Local settings. Thus, they will be ignored if the control mode is set for Local. Serial I/O The amplifier is equipped with a serial port that allows remote monitoring and control of virtually all functions of the amplifier. Use of the serial port requires knowledge of electrical interface standards (RS-232, RS-422, or RS-485) and of how serial communications operates. Operation 3-15 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA All ModuMAX equipment uses a polled binary protocol. You must either write or obtain software that will communicate with this equipment in order to make use of the serial features. The protocol used is described below. A special case of Serial I/O use is with an RCP-2000 Remote Control Panel. When an RCP-2000 is connected, it automatically establishes communications with the ModuMAX SSPA. All Serial I/O settings (baud rate, interface type, etc) will automatically be transferred to the RCP-2000’s Serial I/O Port, and all information contained about serial I/O communications in this manual applies to the Serial I/O Port on the RCP-2000. Note 3.5.1 You cannot monitor or control this equipment with HyperTerminal or any other “terminal emulation” program. Interface The interface supports RS-232, RS-422, or RS-485 (4-wire or 2wire) connections. Only one of these interfaces may be enabled at any time. Pin-outs for all three interfaces are shown in Table 2-5. Further details of these interfaces are given in Section 2.5.4. The various interface selections share some lines, so it is important to make sure the appropriate interface is selected on the equipment. Selection of an interface is done using both the connector wiring and an interface selection set via the front panel of the equipment. The SIO Alarm is a programmable Form ‘C’ relay contact set that indicates whether a fault or any other condition needing attention has occurred on the unit. Depending on the application, it can be set to indicate either a “Service Request” or an “Active Fault” condition; see Section 2.5.4.5. All data is transmitted and received with 8 data bits, 1 stop bit, 1 start bit, no parity, and no software handshaking. The baud rate is selected from the front panel using the Setup Menu. 3.5.2 Protocol The ModuMAX serial I/O framing protocol, illustrated in Figure 3-3, is used for communications between a host (i.e., your M&C system) and a unit (the ModuMAX SSPA). This is a polling protocol, meaning that units answer ONLY when they receive a correctly formatted message from the host. Since the units do not transmit until polled, you must interrogate the units to determine if there are any faults. Or, you may use the provided summary alarm contacts to alert your system, then poll for status. 3-16 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Byte 1 Byte 2 Byte 3 STX 02 COUNT nn ADDRESS aa Byte 4 A 1 0 C K 6 bits ... Byte nn-2 Byte nn-1 Byte nn 3 CHKSUM cc ETX 03 End Body 2A 1444444444244444444314444244443 14444444244444443 FRAMING HEADER FRAMING FOOTER MESSAGE DATA 2 1 2 3 The most significant bit of Byte 4 is reserved, and should always be 0. The message data can be of any length from 1 byte (6 bits of Byte 4) to 250 bytes (249 if End Body byte is used). Bytes having the values 02 and 03 may not appear in the message data. End Body byte (2A) is optional, and is included for compatibility with version 1 of this protocol. Figure 3-3. Serial I/O Framing Protocol The same framing protocol is used for all messages to and from a unit. A message from a unit in response to one from the host is referred to as a reply. 3.5.2.1 STX/ETX All message frames start with the framing byte STX (02) and end with the framing byte ETX (03). No byte in the message data can have a value of 02 or 03, or message framing will be reset! 3.5.2.2 Count The second byte of the message frame is the count of all bytes in the entire message, including the STX and ETX bytes. The protocol’s framing determines that the smallest message possible is 6 bytes. 3.5.2.3 Address The third byte of the message frame is the address. Any unit whose address setting matches this byte will accept the message. An address of 00 is used to send a command or control message to all units on the bus. A reply, if any, will contain the unit’s set address. 3.5.2.4 ACK Response Flag Bit 6 (with bit 0 being the least significant bit, and bit 7 the most significant bit) of the fourth byte in a message frame is used to request an ACK (acknowledge) response. This bit will never be set in a reply. Operation 3-17 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA If a unit returns an ACK response, it will be sent quickly following receipt of the last byte of the host message, if possible. See Section 3.3.2.8.3 for specifications. An ACK response will be returned ONLY if both of the following conditions are true: 1. The address of the host message matches that of the unit. (In other words, a unit will send an ACK response to a message addressed to 0 only if its own address is set to 0.) 2. The message is not REJECTED for any of the reasons described under Section 3.3.2.7.1. An ACK response is a correctly framed message, with the least significant 6 bits of Byte 4 equal to the value 3F. Example, ACK response from unit address 1: 02 06 01 3F 40 03 3.5.2.5 Message Data The actual content of the message starts with the least significant 6 bits of Byte 4, and can be of any length up to 250 bytes (including Byte 4). An optional End Body byte may be placed in the message footer (at the end of the Message Data), in which case the maximum length of the message data itself is 249 bytes. The optional End Body byte is used for compatibility with version 1 of this protocol, in which the End Body byte was required if the message data contained more bytes than Byte 4. Units determine whether or not to send this byte as follows: • A setting in the unit will determine whether replies should contain an End Body byte. Units will be shipped from the factory defaulting to use the End Body byte. • If the unit receives a message with more bytes in the message data than Byte 4, but not containing an End Body byte, the setting will be changed to NOT use the End Body byte in replies. • If the unit receives a message WITH an End Body byte, the setting will be changed to use the End Body byte in replies. Messages will always be accepted by units, with or without the End Body byte. The least significant 6 bits of Byte 4 are not allowed to be equal to 02, 03, or 3F and no value in the message data can be equal to 02 or 03. The least significant 6 bits of Byte 4 are normally an instruction code. 3-18 Operation DMAN-14563 Rev. H 3.5.2.6 Ku-Band ModuMAX SSPA Checksum The checksum is the arithmetic sum of all the bytes starting with the address, and ending with the byte preceding the checksum. The sum is truncated to the least significant byte. The checksum is the second to last byte of a message frame. 3.5.2.7 Message Handling 3.5.2.7.1 Rejected Messages Messages will be rejected if any of the following are true: • The message does not start with an STX (02). • A communications (framing) error occurs on any byte. • The message COUNT (nn) is less than 6. • The last byte of the message, as determined by the COUNT is not an ETX (03). • The message ADDRESS does not match the unit’s address, and is not 00. • The fourth byte of the message contains a 1 in the most significant bit. • The low six bits of the fourth byte are equal to 3F. • A byte equal to 02 or 03 is received anywhere in the MESSAGE DATA. • The message checksum (CHKSUM) is not equal to the low byte of the arithmetic sum of bytes 3 (ADDRESS) through nn-2 (where nn is the COUNT). • The receive buffer has become full, causing the unit to miss bytes of the message. If a message is rejected because of any of these conditions, no ACK response will be returned, if requested in Byte 4 of the message. (As mentioned previously, an ACK response will also not be sent if the global address (00) is used, and the unit address is set to something other than 00.) The unit will immediately begin watching the data stream for the next STX (02) byte AS SOON AS one of the listed problems is detected. A message may also be rejected at a higher level if something is wrong with the MESSAGE DATA itself (e.g., illegal instruction code), but in this case an ACK response will still be sent. Refer to the specific messages in Section 3.5.4 for details of the message format. Operation 3-19 DMAN-14563 Rev. H 3.5.2.7.2 Ku-Band ModuMAX SSPA Framing Synchronization A unit not currently receiving a message watches the message stream for an STX (02) byte. Upon receiving that byte, the unit begins looking for the rest of the message. If a byte value of 02 or 03 is received for the message count, or anywhere in the message data, the unit assumes that it is the start of a new message (if 02 is received), or the end of the message (if 03 is received), and rejects the original message. The STX byte value (02) can legally appear as either an address (Byte 3) or a checksum (next-to-last byte) in a message. This has the potential for causing mis-synchronization if a unit starts up in the middle of a message. But this is not likely, for the following reasons: • Should a unit detect a valid address of 02 as being the STX byte, it will interpret the following byte (Byte 4) as being the message count, and attempt to receive the address, message data, checksum and ETX from the bytes that follow. In this case, the ETX (03) from the actual message will terminate this false message, and the interpreted byte count, unit address, message data or checksum will most likely be invalid and will be rejected. • Should a unit detect a valid checksum of 02 as being the STX byte, it will interpret the immediately following ETX byte (03) as the byte count of the message. Because a byte count of 3 is not valid (all messages must have at least 6 bytes), the unit will abort receiving the message, and start looking for the STX again. If you wish to guarantee that all listening units are synchronized, send a string of 3 ETX (03) bytes. This will terminate all units’ receive sequences, after which they will start looking for the STX (02) byte again. 3.5.2.7.3 Address A means is provided on every unit to set its address. In any interface bus in which messages are received by more than one unit, each unit should be assigned a unique address that is not equal to 00. 3.5.2.8 Timing Issues 3.5.2.8.1 Inter-character spacing There is no maximum specification on inter-character spacing in messages in either direction. Bytes in messages to units may be spaced as far apart as you wish. However, be aware that if you are 3-20 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA using a half-duplex interface and a unit is ready to send an ACK response or reply, it will be watching the receive data stream for an idle period to send its message. Generally, there will be no spacing between characters in replies generated by units, but this is not guaranteed. 3.5.2.8.2 Inter-message spacing There is no requirement to provide any space between messages. However the following points should be considered if message spacing becomes too short. The receive data buffer of the unit may become full if too many messages are received at once. If this happens, subsequent messages will be rejected until the receive buffer has room. The receive buffer size may vary with software version, so there is no definite size specification available. When using a half duplex interface (such as RS-485), ACK responses or replies will be held until the line is idle for a specified time (see next section). Therefore, an idle time should be provided for any message that expects an ACK response or a reply. If an ACK response is requested on every message, the host will know if a message was rejected (for ANY reason) because it will not receive the quick ACK response. 3.5.2.8.3 ACK Responses If requested, an ACK response will be generated as quickly as possible following receipt of the original message. With a full duplex interface, if the unit is already transmitting when it becomes time to send an ACK response, it will send the ACK as soon as it finishes transmitting the existing message. When using a half-duplex interface, a delay of 1 byte time is introduced to allow time for the host to switch from transmitting to receiving. The line must be idle during this time. Another delay of 1 byte time is always introduced when the transmitter is turned on. The timing of the ACK response (after the end of the host message) is as follows: FULL DUPLEX interface: MINIMUM: 1 BYTE TIME MAXIMUM: (1 BYTE TIME + 1 millisecond), or as soon as the transmitter is done sending a message HALF DUPLEX interface: MINIMUM: 2 BYTE TIMES with idle line MAXIMUM: (2 BYTE TIMES + 1 millisecond) with idle line Operation 3-21 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA NOTE: If the half duplex line is not idle, the unit simply waits for the line to be idle for 1 BYTE TIME, then generates the ACK response. 3.5.2.8.4 Replies If a message generates a reply, that reply should start no more than 100 ms after the original host message. With a full duplex interface, if the unit is already transmitting when it becomes time to send a reply, it will send it as soon as the transmitter is finished. If a message generates a reply and an ACK response, the ACK response will always be first (according to ACK Response specifications), followed by the reply, within its specified time frame. The MINIMUM time for a reply (with no ACK response) is the same as the MINIMUM specification for an ACK response above, depending on the interface. 3.5.3 Messages Serial I/O messages are normally sent using the ModuMAX Serial I/O Message Framing Protocol. This protocol imposes the following restrictions on the message content. • The message data must contain at least 1 byte, and at most 249 bytes. • The first byte is limited to a six-bit value ranging from 00 to 3E, excluding the values 02 and 03. • No byte in the message body can be 02 or 03. In this protocol, illustrated in Figure 3-4, the first byte of the message data is referred to as the instruction code, which ranges in value from 00 to 20. Normally if there is a reply, it will contain the same instruction code as the host message. MESSAGE DATA 64444447444444 In struct ion Code (6 bits) ... 1444442444443 FRAMING HEADER S ub-Instruction ( optional) Figure 3-4. 3-22 Operation Message bo dy (o ptional) En d Body 2A ... 1444444442444444443 FRAMING FOOTER Data Value(s) (optional) Message Data Framing Protocol DMAN-14563 Rev. H Ku-Band ModuMAX SSPA If further data is included, it follows the instruction code and is referred to as the message body. Some instruction codes require a sub-instruction. If required, the sub-instruction is sent as the first byte of the message body. If there is a reply, the reply will contain the same sub-instruction. Data values, if required, are sent in the message body following the instruction code or the sub-instruction (if it is present). 3.5.3.1 Message Types The message type is determined by the instruction code. The message type determines: • Whether or not a reply will be sent. • Whether or not the reply (if any) contains data. There are three general types of message: Status, Control/Configuration, and Command. 3.5.3.1.1 Status Messages Status messages request data without affecting any controls or settings. A response message containing the requested data in the message body will be generated by the unit. Normally status messages may be used regardless of the operational mode of the unit. 3.5.3.1.2 Control/Configuration Messages Control messages set the value of an operational control on the unit, whose value can be either set or queried. Controls usually correspond to some important feature, such as the gain of an amplifier. To set the value of a control, a message is sent containing the desired value. To determine if the control was actually set to the desired value, another message should be set to query the value of the control. To query the value of the control, a message is sent without any setting value (although some messages do require other data values, which should be sent). A reply will be generated containing the current value of the control. Configuration messages are identical to control messages in their behavior, but the data in them corresponds to some setting, that is usually only used once when the system is set up. Units in Local Mode will not obey control or configuration messages to set values. There may be other conditions under Operation 3-23 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA which certain messages will not be obeyed. Refer to specific messages in Section 3.5.4 for details. Normally the value of any control or setting may be queried regardless of the operational mode of the unit. 3.5.3.1.3 Command Messages Command messages cause the device to perform some action or function that can’t necessarily be evaluated. Commands may (but do not have to) contain data in the message body. Command messages are also used for controls that may take a significant amount of time to change. There will be another status message that can be used to determine the value of such controls. Units in Local Mode will not obey command messages. There may be other conditions under which certain messages will not be obeyed. Refer to specific messages in Section 3.5.4 for details. 3.5.3.2 Data Values Data values are used in the message body to transfer measurements, settings, and other information. Data values are normally represented as ASCII characters, to conform to the limitations imposed by the framing protocol. Where more than one data value is sent, they are usually separated by some delimiter such as a comma (“,” ASCII code 2C). The following are descriptions of the most commonly used types of data: 3.5.3.2.1 Analog Value An analog value represents a numeric measurement, control, or setting such as currents, voltages, gain, etc. Analog values are formatted as an ASCII string containing the numeric value. Analog data can be a floating-point value (e.g. “3.12”), or an integer value (e.g. “14”). The data can be signed (preceded by a “+” or “-”) or unsigned (no sign character preceding). The ASCII characters recognized are digits “0” - “9”, the decimal point (“.”), and a sign (“+” or “-”). Only one decimal point may appear, and the sign, if any, must appear at the beginning of the string. Exponential notation (“X.XXXE+YY”) is not used. Any other character will terminate the number. Over-range and under-range values are preceded by a “>“ or “<“ symbol, respectively. If the measurement is unavailable for some reason, a question mark (“?”, ASCII code 3F) will be returned. If more than one data 3-24 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA value is included, values will be separated from the analog data value by commas (“,”, ASCII code 2C). The following symbols will be used to represent analog data being sent in the message body: an unsigned floating point value Nlabel a signed floating point value ±Nlabel an unsigned integer value Ilabel a signed integer value ±Ilabel where 3.5.3.2.2 label is text representing the function of the value. Enumerated Value An Enumerated Value can be represented as one of two or more states. For example, an amplifier may be “ON” or “OFF”. Enumerated values are represented by a single byte. Each possible state is represented by a different value. Usually the ASCII code for “0” (30) is used to represent NO, OFF, FALSE, etc. and the ASCII code for “1” (31) is used to represent YES, ON, TRUE, etc. Other codes may represent other conditions, such as “?” (3F) for “unknown”. In cases where more than one enumerated value is sent, each value is represented by a single byte with no delimiter between them. However, enumerated values will be separated from other data values by a comma (“,”, ASCII code 2C). The following symbol is used to represent enumerated values in the message body: Blabel where label a single enumerated value is text representing the function of the value. A brief description of the meanings of the values for each byte will follow. 3.5.3.2.3 Bit Flag Value Groups of flags representing simple YES/NO or TRUE/FALSE data are represented as bits in a single byte. Bit flag values are transferred in the least significant six bits of a byte, with the most significant two bits being 0 and 1 (bit 7 is 0). In cases where more than 6 bit flag values are needed, more bytes are sent, with no delimiters between them. However, bit flag values will be separated from other data values by a comma (“,”, ASCII code 2C). The following symbols are used to represent a byte of bit data in the message body: 01blb50blb3blb2blb1blb0 Operation 3-25 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA where lbx is a label that identifies the function of each bit; 0 represents bits that are not used, and will always be set to 0; 1 represents bits that are not used, and will always be set to 1. The list will be followed by brief descriptions of each bit’s meaning. 3.5.3.2.4 String Value Text data, such as the version and mask number, is represented simply as a string of ASCII characters. In cases where more than one string value is needed, the text values will be delimited. Refer to specific messages in Section 3.5.4 for details on which messages use which delimiters. The following symbol will be used to represent string data in the message body: “label” where label is text identifying the function of the string value. Note that the quotation marks are shown above to identify a string value, and are NOT actually present in the message body. 3.5.3.2.5 Protocol Symbols Certain symbols are used in protocol documents to represent different types of data values. In addition, other notations have other meanings: [ ] Brackets enclose segments of the message body that may or may not be present. The brackets may be nested. ... Ellipses represent that more than one of the same value may be present in the message body. 3.5.3.3 Programming Compatibility The contents of any message are subject to change as features and improvements are made to the product line. Therefore, changes to the protocol may be necessary. Wherever possible, the changes will be made in such a way as to maintain compatibility with existing systems, provided the following rules are followed: Make no assumptions as to the range or step size of any analog value. EXAMPLE: If a gain setting can currently be controlled from 0 to 20 dB in 0.1 dB steps, the range may be extended to 30 dB in the future, or the step size may be changed to 0.05 dB. 3-26 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Allow for extra data values to be returned at the end of any message or at the end of a group of enumerated or bit values delimited from other values. It is not necessary to predict the meanings of such values, but their presence must be tolerated. The original values will be left in the same positions and order in the message body, new ones will be added to the end. EXAMPLE: If a message currently returns 3 Analog Values, a fourth may be added to support a new feature in the future. Allow for extra codes (not currently documented) in enumerated values. Again, it is not necessary to predict the possible meanings of such codes, but code values other than those listed should be tolerated. The meanings of existing codes will be left unchanged. EXAMPLE: An enumerated control currently has settings for “OFF” (30) and “ON” (31). In the future, a third choice may be added, called “STANDBY” (32). “OFF” and “ON” will retain their same values (30) and (31), and “STANDBY” will use a new code value (32). Make no assumptions about the presence of hardware or options in a particular model. There are messages that can be used to determine the number of power supplies, current stages, etc., and the presence or absence of various pieces of hardware. Use these messages, if necessary, to prevent problems with your software should something be added or removed in a future product release. EXAMPLE: The 16 60 message returns three voltage measurements for a module (under the existing firmware release). At some point in the future, other internal voltage measurements may be added that will also be reported in that message. 3.5.3.4 Instruction Codes All ModuMAX equipment uses a common set of instruction codes, listed in Table 3-3 below. Some equipment types do not use all messages. Refer to Section 3.5.4 for a list of messages used in this product. Unless otherwise indicated, the instruction code sent with the message is returned in the reply. Some instruction codes require a sub-instruction that depends on the type of equipment. Refer to Section 3.5.4 for details. Operation 3-27 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Table 3-3 Instruction Codes Instr Code SubInstr 04 NO Command Reset Unit 07 NO Status Unit Type 08 NO Status Get Faults 09 NO Command Clear Service Request 0A NO Command Fault Reset 0B NO Command Self Tests 0E NO Control Local Lockout 16 YES Status Get Measured Data 17 YES Configuration Set/Read Configuration 18 YES Control Set/Read Controls 19 YES Command Unit Commands 1C - Status/Special RC Panel Status/Message 20 NO Status Unit Status 3.5.4 Type Description Message Table Table 3-4 summarizes the messages used to control and monitor the amplifier via Serial I/O. The first column shows the message instruction code, which is described above. The second column shows the sub-instruction, if one is needed. The third column shows the name of the function performed by the message, and which section you should read in the Function Reference for more information. The last column briefly describes the data values sent to or received from the amplifier in that message. Data values in the last column are preceded with a ⇒ for messages being sent to the amplifier, and a ⇐ for messages being returned by the amplifier. Remember that Control or Configuration messages can either receive a value (if the host computer wishes to change the control or setting) or return a value (if the host computer is just checking to see what the current setting is). In the first case, no response will be returned (other than an ACK, if requested). In this table, the two forms of these messages are represented by showing the Data Values as being optional in both directions. 3-28 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Table 3-4 Instr 04 SubInstr 07 08 09 Message Table Name (Section) Microprocessor Reset (3.7.4.1.2) Unit Type (3.7.4.2.2) Get Active Faults (3.7.2.2.1) Clear Service Request (3.7.2.3.6, 3.7.2.3.7) Fault Reset (3.7.2.3.5) Self Test (3.7.4.1.1) Local Lockout (3.7.5.1.2) 0A 0B 0E None ⇒ ⇐ ⇒ ⇐ Data Values ⇒ Sent to Amplifier ⇐ Returned by Amplifier None BTYPE = 35 for ModuMAX SSPA System (N+1, 1:1, single) None [01 bPS_DISCONNECTbPFWD_HIGHbPFWD_LOWbPREFL_HIGHbLOGIC_BOARD_FAIL 0 01 bPSU_MOD_3AbPSU_MOD_2AbPSU_MOD_1AbPSU_MOD_3bPSU_MOD_2bPSU_MOD_1 01 bPSU_MOD_3BbPSU_MOD_2BbPSU_MOD_1BbMOD_PWR_MISMATCHbMODULE8bMODULE7 01 bMODULE6bMODULE5bMODULE4bMODULE3bMODULE2bMODULE1 01 bFAN8_FAILbFAN7_FAILbFAN6_FAILbFAN5_FAILbFAN4_FAILbFAN3_FAIL 01 bFAN2_FAILbFAN1_FAIL 0 bANT_DL_SW_FAILbUSER_INP2bUSER_INP1 01 bUSER_INP8bUSER_INP7bUSER_INP6bUSER_INP5bUSER_INP4bUSER_INP_3 01 bFRNT_PANEL_FAILbPIO_FAILbID_ROM_FAILbNETWORK_FAILbPFWD_DET_FAILbPREFL_DET_FAIL 01 bMODULE_DISABLEDbLOCAL_MODEbMAINT_MODEbPWR_UPbDUMMY_LDbNEW_FAULT 01 bUSER_INP_R6bUSER_INP_R5bUSER_INP_R4bUSER_INP_R3bUSER_INP_R2bUSER_INP_R1 01 0 0 0 0 bUSER_INP_R8bUSER_INP_R7 ] [ , BNEW_FAULT_CODE_1 BNEW_FAULT_CODE_2 ] [ , BNEW_FAULT_CODE_1 BNEW_FAULT_CODE_2 ] is returned when bNEW_FAULT is set None None None ⇒ [BLOC_LOCKOUT_ON] ⇐ [BLOC_LOCKOUT_ON] 16 28 Get NIC Firmware Version (3.7.4.2.1) BLOC_LOCKOUT_ON = 31 if Yes (on), 30 if No (off) ⇒ None ⇐ “mask_number version_number” 16 50 16 51 Forward Power (3.7.1.2.2) Module Temperature (3.7.1.2.8) A 3F (“?”) will be returned if something is wrong with the NIC ⇒ None ⇐ [±]NPFWD ⇒ IMODULE_NUMBER ⇐ ±NMODULE_TEMP , IMODULE_NUMBER 16 54 Amplifier Output (RF) Status (3.7.1.2.1) 16 57 16 58 Logic Board Firmware Info (3.7.4.2.1) Total Module Current (3.7.1.2.6) 16 59 Get Specific Fault Codes (3.7.2.2.4) NMODULE_TEMP = 3F if unavailable or invalid module number specified. ⇒ None ⇐ 01 bNTWRK_MUTE bPARIO_MUTEbSERIO_MUTEbLOCAL_MUTE00 01 bALL_DISABLEDbALL_OFF 0 bPOWER_SAVE 0 bRF_INHIBIT 01 bNO_MODULESbSTARTING_UP 0 0 0 bSELF_CHECK ⇒ None ⇐ “mask_number version_number” ⇒ IMODULE_NUMBER ⇐ NCURRENT , IMODULE_NUMBER NCURRENT = 3F if requested current unavailable. If the measured current on a module is above the measurable range for that module, IMODULE_NUMBER is “>XXX.XX” (where XXX.XX is the top limit of the current range), or “>MAX” (if the top limit cannot be determined). Note that this condition is highly unlikely, since the module should shut down if it is drawing enough current to max out the reading. ⇒ None ⇐ BFAULT_CODE_1_BYTE_1 BFAULT_CODE_1_BYTE_2 … [ 7F ] If there are no faults, the two byte code 30 30 is returned. If there are more faults than can fit in the serial IO buffer, the byte 7F will be the last byte in the message body. Operation 3-29 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Table 3-4 Instr 16 SubInstr 5A Message Table Name (Section) Hardware Options (3.7.4.3.1) Data Values ⇒ Sent to Amplifier ⇐ Returned by Amplifier ⇒ None ⇐ BPARALLEL_IO BREMOTE_PARALLEL_IO BANT_DL_SW BTWO_PS_RACKS 30 30 30 30 , INUMBER_OF_MODULES BPARALLEL_IO = 31 if present, 30 if not present (PIO in SSPA) BREMOTE_PARALLEL_IO = 31 if present, 30 if not present (PIO in RCP-2000) BANT_DL_SW = 31 if present, 30 if not present (Antenna/Dummy Load switch) BTWO_PS_RACKS = 31 if present, 30 if not present (dual redundant PS option) 16 5B 16 5C Reflected Power (3.7.1.2.3) Parallel IO Inputs (3.7.3.3.1, 3.7.3.3.2) The 30 bytes in this message are reserved for future options. ⇒ None ⇐ [±]NPREFL ⇒ None ⇐ [ 01 bA6bA5bA4bA3bA2bA1 01 bAR4bAR3bAR2bAR1bA8bA7 01 0 0 bAR8bAR7bAR6bAR5 01 bL6bL5bL4bL3bL2bL1 01 bLR4bLR3bLR2bLR1bL8bL7 01 0 0 bLR8bLR7bLR6bLR5 ] [ 3F ] if no parallel IO present bAn = Input n is in its ACTIVE state bLn = Input n has been HIGH since you last checked (inputs set to NONE) bARn , bLRn = Inputs for RCP-2000 Parallel I/O, if present. ⇒ IMODULE_NUMBER ⇐ IMODULE_NUMBER , “VG” ±NGATE_VOLTAGE , “VI” NINPUT_VOLTAGE [ , “VR” NREGULATED_VOLTAGE ] 16 60 Module Internal Voltage Measurements (3.7.1.2.7) 16 61 16 62 16 63 16 64 Operation Time (3.7.4.2.3) Module Firmware Info (3.7.4.2.1) Get Fault Text (3.7.2.2.2, 3.7.2.2.4)) Module Output Power (3.7.1.2.5) NGATE_VOLTAGE, NINPUT_VOLTAGE, NREGULATED_VOLTAGE = 3F if unavailable ⇒ None ⇐ IDAYS , IHOURS , IMINUTES , ISECONDS ⇒ IMODULE_NUMBER ⇐ IMODULE_NUMBER , “mask_number version_number” ⇒ BFAULT_CODE_BYTE_1 [ BFAULT_CODE_BYTE _2 ] ⇐ BFAULT_CODE_BYTE_1 [ BFAULT_CODE_BYTE_2 ] , “Fault text” ⇒ IMODULE_NUMBER ⇐ IMODULE_NUMBER , [±]NMODULE_POUT 16 65 Module Status (3.7.1.2.4) NMODULE_POUT = 3F if unavailable ⇒ IMODULE_NUMBER ⇐ IMODULE_NUMBER , BSTATUS BYTE BSTATUS BYTE = 16 66 Get Event Log Entry (3.7.2.2.3) ⇒ [ ⇐ [ [ [ 30 31 32 33 34 35 36 37 OK, operating 38 OK, Muted Module missing 39 Off, RF Inhibit Disabled 3A Off, no reason given Disabled, plug-in 3B Faulted Off, External Inhibit 3C Off, Overcurrent Shutdown Off, Thermal Shutdown 3F Unknown Off, Fast Mute input low 40 Disabled, SMFC Off, Gate voltage shutdown ±ISEQUENCE_NUMBER ] ±ILATEST_SEQUENCE_NUMBER , IN_ENTRIES ] ±ISEQUENCE_NUMBER , [ 3F ] [ IDAYS , IHOURS , IMINUTES , ISECONDS , BTYPE , BFAULT_CODE_BYTE1 BFAULT_CODE_BYTE2 ] ] ] IDAYS , IHOURS , IMINUTES , ISECONDS represent the operation time at which the event occurred. 33 Logic board power-up BTYPE = 31 Fault 32 Log initialization 34 Logic board reset If the TYPE of entry is a fault (31), a two byte fault code is returned (see message 16 59). 3-30 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Table 3-4 Message Table Instr SubInstr 16 6B Gain Range (3.7.4.2.4) Data Values ⇒ Sent to Amplifier ⇐ Returned by Amplifier Each entry in the log is assigned a unique and consecutive sequence number. The most recent event has the highest sequence number. If the message is sent to the amplifier with no sequence number, the latest event sequence number and number of log entries is returned. If a sequence number is specified, and the number exists in the log, information on the log entry corresponding to that sequence number is returned. If the specified sequence number is 0, or if there is no entry in the log with the specified sequence number, it will be returned followed by a 3F. The host can start by requesting the log entry for the latest sequence number, and repeatedly send this message, decrementing the number each time. The number 0 should be skipped, but the sequence number CAN be negative. ⇒ None ⇐ NGAIN_RANGE 17 1E Set/Get IP Address (3.7.3.1.1) NGAIN_RANGE = 20 dB when SMFC is disabled; 18.8 dB when SMFC is enabled. ⇒ [ IIP_ADDR_1 . IIP_ADDR_2 . IIP_ADDR_3 . IIP_ADDR_4 ] ⇐ [ IIP_ADDR_1 . IIP_ADDR_2 . IIP_ADDR_3 . IIP_ADDR_4 ] 17 1F Set/Get Subnet Mask (3.7.3.1.2) Note that the separator between the parts of the IP address is a period (2E). ⇒ [ IIP_MASK_1 . IIP_MASK_2 . IIP_MASK_3 . IIP_MASK_4 ] ⇐ [ IIP_MASK_1 . IIP_MASK_2 . IIP_MASK_3 . IIP_MASK_4 ] 17 20 Set/Get Gateway Address (3.7.3.1.3) Note that the separator between the parts of the Subnet mask is a period (2E). ⇒ [ IGATEWAY_IP_1 . IGATEWAY_IP_2 . IGATEWAY_IP_3 . IGATEWAY_IP_4 ] ⇐ [ IGATEWAY_IP_1 . IGATEWAY_IP_2 . IGATEWAY_IP_3 . IGATEWAY_IP_4 ] 17 51 17 56 Name (Section) Power Fault Limits (3.7.2.3.1, 3.7.2.3.2) Parallel I/O Input Assignments (3.7.3.3.3) 17 58 Power-Up State (3.7.1.1.4) 17 59 Parallel I/O Output Assignments (3.7.3.3.4) 17 5A 17 5B 17 5F Forward Power Calibration Offset (3.7.1.3.1) Reflected Power Calibration Offset (3.7.1.3.2) Remote/Local Settings (3.7.2.3.4, 3.7.5.2.3) Note that the separator between the parts of the Gateway IP address is a period (2E). ⇒ [ [<][ [±]NPFWD_LOW ] [ , [>][ [±]NPFWD_HIGH ] [ , [>][ [±]NPREFL_HIGH ] ] ] ] ⇐ [ [<][±]NPFWD_LOW , [>][±]NPFWD_HIGH , [>][±]NPREFL_HIGH ] ⇒ [ BIN1 [ BIN2 [ BIN3 [ BIN4 [ BIN5 [ BIN6 [ BIN7 [ BIN8 ] ] ] ] ] ] ] ] [ , [ BINR1 [ BINR2 [ BINR3 [ BINR4 [ BINR5 [ BINR6 [ BINR7 [ BINR8 ] ] ] ] ] ] ] ] ] ⇐ [ BIN1 BIN2 BIN3 BIN4 BIN5 BIN6 BIN7 BIN8 ] [ , BINR1 BINR2 BINR3 BINR4 BINR5 BINR6 BINR7 BINR8 ] BINX = Function code (see reference) for input X (SSPA); BINRX = function code for input RX (RCP-2000 Parallel I/O, if present). Send 3F to leave input function unchanged. ⇒ [BPOWER_UP] ⇐ [BPOWER_UP] BPOWER_UP = 30 for MUTE, 31 for OPERATE, 32 for LAST ⇒ [ BOUT1 [ BOUT2 [ BOUT3 [ BOUT4 [ BOUT5 [ BOUT6 [ BOUT7 [ BOUT8 ] ] ] ] ] ] ] ] [ , [ BOUTR1 [ BOUTR2 [ BOUTR3 [ BOUTR4 [ BOUTR5 [ BOUTR6 [ BOUTR7 [ BOUTR8 ] ] ] ] ] ] ] ] ] ⇐ [ BOUT1 BOUT2 BOUT3 BOUT4 BOUT5 BOUT6 BOUT7 BOUT8 ] [ , BOUTR1 BOUTR2 BOUTR3 BOUTR4 BOUTR5 BOUTR6 BOUTR7 BOUTR8 ] BOUTX = Function code (see reference) for output X (SSPA); BOUTRX = function code for output RX (RCP-2000 Parallel I/O, if present). Send 3F to leave output function unchanged. ⇒ [[±]NPFWD_CAL_OFFSET] ⇐ [±NPFWD_CAL_OFFSET] ⇒ [[±]NPREFL_CAL_OFFSET] ⇐ [±NPREFL_CAL_OFFSET] ⇒ [ BLOCAL_MODE_WARN [ BREMOTE_DISABLES_LOCAL ] ] ⇐ [ BLOCAL_MODE_WARN BREMOTE_DISABLES_LOCAL ] Operation 3-31 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Table 3-4 Message Table Instr SubInstr 17 60 Power-Up Warning (3.7.2.3.3) 17 65 Single Module Failure Compensation (3.7.2.4) 18 50 Mute Control (3.7.1.1.1) BSMFC = 30 for DISABLED, 31 for ENABLED ⇒ [ BRF_OUTPUT ] ⇐ [ BRF_OUTPUT ] Gain (3.7.1.1.5) BRF_OUTPUT = 30 for MUTE (Output off), 31 for OPERATE (Output on). A 3F is returned if the output state cannot be determined (i.e. no modules) ⇒ [ [±]NGAIN ] ⇐ [ ±NGAIN ] 18 18 52 53 Name (Section) Unused Parallel I/O Output Control (3.7.3.3.5) 54 Power Units (3.7.1.2.9) 18 55 Reflected Power Measurement Type (3.7.1.2.10) 18 56 Module Disable (3.7.1.1.2) 20 54 Switch Ant/DL (3.7.1.1.6) Unit Status BPOWER_UP_WARN = 30 for DISABLED, 31 for ENABLED ⇒ [ BSMFC ] ⇐ [ BSMFC ] NGAIN = -20.0 to 0.0 dB when SMFC is disabled; -18.8 to 0.0 dB when SMFC is enabled. A 3F is returned if the gain cannot be determined (i.e. no modules) ⇒ [ BOUT1 [ BOUT2 [ BOUT3 [ BOUT4 [ BOUT5 [ BOUT6 [ BOUT7 [ BOUT8 ] ] ] ] ] ] ] ] [ , [ BOUTR1 [ BOUTR2 [ BOUTR3 [ BOUTR4 [ BOUTR5 [ BOUTR6 [ BOUTR7 [ BOUTR8 ] ] ] ] ] ] ] ] ] ⇐ [ BOUT1 BOUT2 BOUT3 BOUT4 BOUT5 BOUT6 BOUT7 BOUT8 ] [ , [ BOUTR1 BOUTR2 BOUTR3 BOUTR4 BOUTR5 BOUTR6 BOUTR7 BOUTR8 ] ] BOUTX or BOUTRX = 31 to set output X (SSPA) or RX (RCP-2000) to N.C. 32 to set output X (SSPA) or RX (RCP-2000) to N.O. or you can send 30 to leave output X or RX unchanged Outputs default to being energized (in the N.O. position) ⇒ [ BPOWER_UNITS ] ⇐ [ BPOWER_UNITS ] 18 19 Data Values ⇒ Sent to Amplifier ⇐ Returned by Amplifier BLOCAL_MODE_WARN = 30 for DISABLED, 31 for ENABLED, 3F for no change BREMOTE_DISABLES_LOCAL = 30 for NO, 31 for YES, 3F for no change ⇒ [ BPOWER_UP_WARN ] ⇐ [ BPOWER_UP_WARN ] BPOWER_UNITS = 30 for dBm, 31 for dBW, 32 for Watts ⇒ [ BMEAS_TYPE ] ⇐ [ BMEAS_TYPE ] BMEAS_TYPE = 30 for Power, 31 for Ret Loss (dB), 32 for VSWR (volts/volt) ⇒ IMODULE_NUMBER [ , BMODULE_DISABLE ] ⇐ [ IMODULE_NUMBER , BMODULE_DISABLE ] BMODULE_DISABLE = 30 for DISABLED, 31 for ENABLED If the Module Number is invalid, or the module is not connected, a 3F will be returned. ⇒ BANT_DL = 30 Antenna 31 Dummy Load ⇐ None ⇒ None ⇐ 01 0 bRF_ONbMUTED 0 bWARNINGbFAULT 01 0 0 bDUMMY_LDbANTENNA 0 bUNIT_ONLINE 01 0 bLOCAL_OR_MAINTbREMOTE_OR_MAINT 0 0 0 Note that N+1 amplifers are always considered “On-Line”. 3.5.5 Accessing Fault Information Using Serial I/O All fault and warning information for the amplifier may be obtained using Serial I/O messages. 3-32 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA A brief summary of faults and warnings is reported by the Get Faults message, 08. This short message should be used when repeatedly polling for system faults. When a fault is detected using the Get Faults message, detailed fault or warning information can be obtained using Serial I/O message 16 59. That message returns a list of two-byte fault codes, which are described in Table 3-5 (see Section 3.7.2.2.4). The amplifier can also supply an additional text string describing a particular fault code, by using Serial I/O message 16 63 (see Section 3.5.4). 3.6 Parallel I/O Parallel I/O is normally supplied in the main ModuMAX SSPA unit. This is referred to as “Local” Parallel I/O. It consists of 8 inputs, 8 outputs, and an analog voltage output that is proportional to amplifier output power. When an optional RCP-2000 Remote Control Panel equipped with Parallel I/O is added to the SSPA, additional “Remote” Parallel I/O is available. The Remote Parallel I/O consists of another 8 inputs, 8 outputs, and an analog voltage output that is proportional to amplifier output power. Functions for Remote inputs and outputs are programmed the same way the Local ones are, but are independent, giving a full complement of up to 16 inputs and 16 outputs. 3.6.1 Interface The Parallel I/O module contains a 37-pin D connector which contains 8 Form ‘C’ relay-contact status outputs, 8 opticallyisolated control inputs, a common ground pin for the inputs, and a differential analog output scaled to the output power of the amplifier in dBm. ModuMAX uses solid-state relays for Parallel I/O outputs. For most applications, the solid-state relays should work just like conventional reed relays. Relay on-resistance is higher than conventional reed relays and may reach 35 ohms at higher load currents (~50 mA). Off-resistance should always be at least 100 Mohms with 100 V applied, and substantially higher with lower applied voltage. Off-state leakage current is also higher than reed relays, and may reach 1 µA with load voltage of 100 V. The pin-out of the Parallel I/O connector is shown in Table 2-6. Areas marked in gray show the 8 Form ‘C’ relay contacts and the 2-pin differential analog output. Operation 3-33 DMAN-14563 Rev. H 3.6.2 Ku-Band ModuMAX SSPA Digital Inputs The 8 inputs on the Parallel I/O module can be programmed to perform any function from the list presented in Table 3-7, Section 3.7.3.3.3. When an RCP-2000 Remote Control Panel equipped with Parallel I/O is added to the SSPA, the additional 8 parallel inputs may also be programmed to perform any of these same functions. The inputs are considered “HIGH” when they are open, or driven to 5 volts or higher. They are considered “LOW” when connected to the INPUT GROUND reference. No more than 5 mA steady-state current will flow out of the input pin when it is connected to INPUT GROUND, but there are 100 pF filter capacitors on the inputs that will discharge upon the initial transition. Input signals are digitally filtered to eliminate glitches from crosstalk or a noisy environment. Inputs pulses less than 0.5 ms in duration should be avoided, as they may not be recognized. See Section 3.7.3.3.3 for more information on programming the Parallel I/O input functions. 3.6.3 Digital Outputs The eight Form ‘C’ relay contacts on the Parallel I/O module can be programmed to perform any function from the list presented in Table 3-8, Section 3.7.3.3.4. When an RCP-2000 Remote Control Panel equipped with Parallel I/O is added to the SSPA, the additional 8 “Remote” Parallel Outputs may also be programmed to perform any of these same functions. The Form ‘C’ relay contacts consist of a common pin that may be connected (via the relay) to either a “Normally Open” or “Normally Closed” pin. “Normally Open” refers to the contact that is NOT connected to the common pin when the relay is de-energized. “Normally Closed” refers to the contact that is connected to the common pin when the relay is de-energized. The relay contacts report their status by either energizing or de-energizing the relay. The polarity of the relay contacts was chosen to make the most sense (as much as possible) when the power was removed, since all relays would then be de-energized. For example, all of the Form ‘C’ relays that report faults will indicate a fault in their deenergized state. See Section 3.7.3.3.4 for more information on programming the output functions. 3.6.4 Analog Output A differential analog output provides a voltage proportional to the amplifier output power. When an RCP-2000 Remote Control Panel 3-34 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA equipped with Parallel I/O is added to the SSPA, a second differential analog output is available. (They each need to be calibrated to provide correct outputs; see Section 5.4.4) The Analog Output is scaled to produce 0.1 volts for every 1 dBm of output power. Thus, an amplifier transmitting +50 dBm of power would show 5 volts across the terminals of the analog output. See Section 3.7.1.2.2 for more information. The analog output is adjusted at the factory. If you change a Parallel I/O module in the SSPA or in an attached RCP-2000 Remote Control Panel, it may be necessary to re-adjust the analog output for that module. See Section 3.7.3.3.6 for information on adjusting the analog output. 3.7 Function Reference 3.7.1 Amplifier This section describes controls, measurements, and settings that affect the amplifier RF path. 3.7.1.1 RF Path Controls 3.7.1.1.1 Mute There are several functions that can shut off individual modules or the entire amplifier. One of these is the Mute Control. The Mute Control can be set to one of two states: Mute or Operate. • Mute: When the Mute Control is set for Mute, the entire amplifier is shut down. This function is implemented internally by commanding each individual module to shut off. • Operate: When the Mute Control is set for Operate, all modules are turned on, unless they are supposed to be off for another reason. The Mute Control can be operated from the front panel, via Serial I/O, or via Parallel I/O. Other conditions may automatically mute the amplifier. The following is a complete list of conditions that may mute the amplifier. The bold text shows how each condition will be indicated on the front panel display. • Muted:Local: The amplifier has been muted from the front panel or upon power-up, with Power Up State set to Mute or Prev (see Section 3.7.1.1.4). • Muted:SerIO: The amplifier has been muted by a Serial I/O command. • Muted:ParIO: The amplifier has been muted by a Parallel I/O input, or when RF Inhibit inputs are turned off in Maintenance mode. Operation 3-35 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA • Muted:Netwk: The amplifier has been muted by a command via the Ethernet. The Mute Control may be changed from any source. For example, it may be set to Mute by a Parallel I/O input, and then returned to Operate from the front panel. The Mute Control may be set to Mute even if the output is already off due to another condition (such as RF Inhibit), in which case the amplifier will remain off even if the other condition goes away. The Mute Control can be controlled from the front panel RF ON or MUTE buttons. Pressing MUTE will set the control to Mute. Pressing RF ON will set the control to Operate. The current screen shown in the display is not changed in response to presses of these buttons. The Mute Control is also available by selecting Oper / Mute. The top line shows the reason the amplifier is muted (from the above list). If the amplifier is not muted, the top line will show one of the following: • Operating: The amplifier is on. • RF Inhibit: The amplifier is off because one or more Parallel I/O RF Inhibit inputs is in its active state. • ? No Modules: No modules are presently installed in the system. • All Mods Disbl: All modules are presently disabled. • All Mods Off: All modules are off for some reason. • Startup...: The system is starting up and has not yet determined the RF status. The bottom line allows the Mute Control to be changed locally. Pressing MODIFY or will toggle the Mute Control between Mute and Operate. The MUTE indicator on the front panel illuminates if the Mute Control has been set to Mute by any source. The Mute Control may be changed by the Serial I/O 18 50 message. Parallel I/O inputs may be configured to change the Mute Control. Any input may be programmed to: • Mute: Change Mute Control to Mute on a falling edge. • Un-Mute: Change Mute Control to Operate on a falling edge. • Mute/UnMut Tog: Mute Control toggles on a falling edge. • Mute.L/UnMut.H: Change Mute Control to Mute on a falling edge, and to Operate on a rising edge. Note that all Parallel I/O input choices for the Mute Control are edge sensitive. Even if they are held in a certain state, they will not lock out other control sources. 3-36 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Any Parallel I/O output may be configured to monitor the Mute Control. The Form ‘C’ output indicates Mute in its de-energized state and Operate in its energized state. 3.7.1.1.2 Module Disable Any module may individually be enabled or disabled. You may manually disable a module to observe the effect on the output of the amplifier, if you suspect that the module has failed or is oscillating. Also, modules are automatically disabled when they are plugged into the system, and must then be manually enabled. If you believe that an amplifier module may be causing a problem on your system, first disable SMFC if it is enabled (see Section 3.7.2.4). Then, disable one module at a time. If disabling a module does not alleviate the problem, re-enable it, and try the next one. (The loss of a single module in an eight-module amplifier normally results in only about 1.2 dB loss in power and gain.) Once you find the module that is causing the problem, you may leave it disabled until you are able to replace it. This setting is preserved even through a power loss, so the module will continue to be disabled even if amplifier power is lost. A disabled module is also not affected by the Mute Control (i.e., setting the Mute Control to Operate will not turn on a disabled module). You should manually disable a module prior to removing it from the system. This should prevent noise from being introduced into your signal as you disconnect or reconnect the RF input cable for that module. For the same reason, when a module is installed in an already operating system, it will automatically be disabled, and you will have to enable it after installing it. When SMFC is enabled, a module will also be disabled when a fault is reported on that module, and no other module is disabled. A module which is disabled due to SMFC can be re-enabled by the operator. If a module is re-enabled in this way, it will NOT automatically be disabled again, unless it fails again. The fact that a module is disabled due to SMFC is NOT stored in non-volatile memory. So, if a module is disabled due to SMFC, and the amplifier is power-cycled or the logic is reset, the module status will be reported as DISABLED (not Dis-SMFC) afterwards. When any module is disabled, a Module Disabled Warning will occur. This will be listed in the Active Fault List (Section 3.7.2.2.1), and will cause the Warning lamp to illuminate. This warning will cease when all modules are enabled. From the front panel, the Module Disable screen is available by selecting Oper / Module. The top line lists the module numbers (1 through 8). The bottom line shows the current state of the amplifier: Operation 3-37 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA • 9 The amplifier is enabled. • X The amplifier is disabled. • ? The amplifier is not installed, or not communicating. Using Serial I/O, you can determine if any module is disabled by using the Get Faults message, 08. The Get Faults message will indicate a Module Disabled warning if any module is disabled. You may also use Serial I/O message 18 56 to read and control the disable state of individual RF Modules. 3.7.1.1.3 RF Inhibit RF Inhibit is a Parallel I/O feature that allows implementation of interlock switches, or a level-sensitive RF on/off control. Any Parallel I/O input may be programmed for the RF Inhibit function. The active level may be set for HIGH or LOW. If any RF Inhibit input is in its active state, all modules will be held off, regardless of any other controls. Setting the Control Mode for LOCAL or MAINTENANCE does not prevent RF Inhibit inputs from functioning. When all active RF Inhibit inputs are returned to their inactive state, all modules will be turned on unless another function (e.g., Mute Control, or Module Disable, or Maintenance Mode [see below]) dictates that they be left off. If all active RF Inhibit inputs return to their inactive state while in Maintenance Mode, the output will not be turned on. Instead, the Mute Control will be set to MUTE, and can then be set to OPERATE from the local control panel (which will turn the amplifier on). This behavior is to guarantee the integrity of Maintenance Mode, in which nothing changes unless commanded by the front panel of the amplifier. A Parallel I/O output may also be programmed to indicate when RF Inhibit is active. This Form ‘C’ output is de-energized to indicate inhibit, and energized when the output is not inhibited. WARNING: 3.7.1.1.4 Since RF Inhibit inputs are located on the Parallel I/O board, this feature depends on a reliable communications link between the Parallel I/O board, Logic Board, and RF Modules. Use caution if using this function for safety related interlocks. It may not work if there is a failure in communications between Parallel I/O Board and Logic Board, or Logic Board and RF Modules. Power-Up State The amplifier system may be programmed to start up with all modules muted (Mute), not muted (Oper), or to remember the previous state in which it was powered down (Prev). 3-38 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA This setting might not be effective if it is overridden by another control (e.g., RF Inhibit, or Module Disable). The current Mute Control setting must be stored in EEPROM when the Power-Up State is set to Prev. Since EEPROM memory can wear out if it incurs too many write cycles, Prev is not recommended in systems where the amplifier will frequently be turned on and off using the Mute Control (e.g., where the amplifier is used to turn the carrier on and off). On the front panel, you may change this setting by selecting Set / PwrUp. The top line shows the current setting, and the bottom line allows the setting to be changed. Also, pressing MODIFY or toggles through the three available settings. Via Serial I/O, the Power-Up State setting is controlled using the 17 58 message. 3.7.1.1.5 Gain This setting is used to control the gain of the amplifier in dB, relative to the maximum possible gain setting (0.0 dB). The range of this control depends on the Single Module Failure Compensation (SMFC) setting (see Section 3.7.2.4). When SMFC is disabled, the gain of the amplifier is controlled over a range of -20.0 to 0.0 dB, in 0.1 dB increments. When SMFC is enabled, the gain control range is reduced to -18.8 to 0.0 dB. In either case, a gain setting of 0.0 dB represents maximum gain of the amplifier. This setting is stored in non-volatile memory, and is set to 0.0 dB at the factory. The gain can be controlled most conveniently from the front panel using the GAIN or buttons. Pressing either of these buttons once will take you immediately to the gain control screen. Further presses of these buttons will either increment or decrement the gain. If you press any other button, or wait about 5 seconds, you will be returned to the screen you were in before pressing the GAIN button. The gain control screen is also accessible from the menus, by selecting GAIN from the OPERATE menu. When viewing this screen from the menu, pressing either the MODIFY and or GAIN and buttons will adjust the gain. The gain screen (whether accessed from the menu, or by pressing one of the GAIN buttons) shows the amplifier’s forward power (Section 3.7.1.2.2) on the top line. If the amplifier is operating in saturation, decreasing the gain may appear to have no effect on the Forward Power, until the amplifier is no longer saturated. If the current gain setting is 0.0 dB, pressing the MODIFY or GAIN Operation 3-39 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA buttons will have no effect, since 0.0 dB is the maximum setting. Via Serial I/O, gain can be controlled using the 18 52 message. 3.7.1.1.6 Antenna/Dummy Load Switch (Optional) If your system is equipped with an Antenna/Dummy Load Switch, also called a Maintenance Switch, it can be controlled and monitored either remotely, or through the front panel menus. This switch can be set for one of two positions: RF output connected either to the Antenna (for normal operation), or to a Dummy Load (for maintenance). In addition, the system can detect other conditions with the switch, such as it being disconnected from the control system, being stuck, the switch driver being shorted, or being changed by hand. While the switch is in the Dummy Load position, your system will be off the air, so a Dummy Load Warning will be issued. This warning will automatically clear when the switch is returned to the Antenna position. In a system consisting of two phase-combined ModuMAX amplifiers, a single Antenna/Dummy Load switch can be controlled in parallel by both amplifiers. However, due to hardware limitations, one amplifier cannot detect that the other is changing the switch. The Antenna/Dummy Load switch is treated as an option by the amplifier system. When connected, the switch will be automatically detected, and the appropriate menu screens will appear. If the switch is later disconnected, a fault will be reported, unless you remove the option using the OPTIONS screen in the Setup Menu. To control or view the status of the switch, go to the Operate Menu, and select the AntDL choice. This screen will show you the current status of the switch on the top line. This line will read one of the following: 3-40 Operation • Antenna: The output of your amplifier is connected to the Antenna. • DummyLd: The output of your amplifier is connected to the Dummy Load. • Missing: The switch is not connected to the amplifier (a fault will also be reported). • : The switch is in the middle, usually moving from one state to another. • ?ANTDL: The state of the switch cannot be determined, due to a failure of the switch driver circuitry (a fault will also be reported). DMAN-14563 Rev. H Ku-Band ModuMAX SSPA The bottom line of the screen offers you two choices, Antenna and DummyLd. Choose one, and press SEL , or press MODIFY or to control the switch. The Antenna/Dummy Load switch may be controlled via Parallel I/O. Any input may be programmed for: • Antenna: Switch to the Antenna on a falling edge. • Dummy Ld: Switch to the Dummy Load on a falling edge. • Ant-DL Tog: Change to the opposite state on a falling edge. The switch may also be monitored via Parallel I/O. Any output may be programmed for “Antenna/DL” which causes the Form ‘C’ relay to indicate the switch position. Note that an error, or the switch moving between states, will be indicated on this contact as being “Dummy Load.” The Antenna/Dummy Load switch may also be controlled and monitored via Serial I/O. Two bit flags in the Unit Status message (20) indicate the switch position. One indicates Antenna, the other indicates Dummy Load. Both will be set if the switch is changing, and neither will be set if the switch is disconnected, or if an error prevents the switch position from being determined. To control the switch, use the 19 54 message. A one-byte parameter should be sent in the message: 30 — Switch to the ANTENNA. 31 — Switch to the DUMMY LOAD. Example: Send a command, with a request for acknowledgement, to switch to the ANTENNA: TX: 02 08 01 59 54 30 DE 03 RX: 02 06 01 3F 40 03 (Acknowledgement) 3.7.1.2 Measurements 3.7.1.2.1 RF Status RF status refers to the RF output state of the entire amplifier: • Whether the RF is ON (capable of emitting RF) or OFF (the entire amplifier is shut down). • The reason that the RF is OFF, or any modules are OFF. • The reason any modules are ON when they are supposed to be OFF. There are many functions that can control the state of the modules, or of the entire amplifier. If one or more of these functions result in all eight modules being turned off, the RF Operation 3-41 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Status will be OFF. If one or more modules are on, the RF Status will be ON. When the RF status is ON, the display shows the following: • Operating: All modules are ON. When the RF status is OFF, it may be in one of these states: • RF Inhibit: The amplifier is off because one or more Parallel I/O RF Inhibit inputs is in its active state. • Muted:Local: The amplifier has been muted from the front panel or upon power-up, with Power Up State set to Mute or Prev (see Section 3.7.1.1.4). • Muted:SerIO: The amplifier has been muted by a Serial I/O command. • Muted:ParIO: The amplifier has been muted by a Parallel I/O input, or when RF Inhibit inputs are turned off in Maintenance mode. • Muted:Netwk: The amplifier has been muted by a command via the Ethernet. • ? No Modules: No modules are presently installed in the system. • All Mods Disbl: All modules are presently disabled. • All Mods Off: All modules are off for some reason. • Startup...: The system is starting up and has not yet determined the RF status. If you wish to quickly determine the state of the amplifier RF Output, simply observe the RF ON indicator on the front panel. If it is lit, then one or more modules are ON. If it is dark, then all modules are off. In the front panel menus, the RF output status information is available from two screens. On the default screen, the top line shows the Forward Power if there are no faults, and all modules are on. If any module is off, the RF Output Status is shown as one of the states from the above two lists. To request the Amplifier Output (RF) Status via Serial I/O, send the 16 54 message with no other parameters: TX: 02 07 01 16 54 6B 03 RX: 02 0A 01 16 54 40 40 40 2B 03 (no flags are set, so RF is ON) RF Status can also be indicated by Parallel I/O outputs. Refer to Section 3.7.3.3.4. 3-42 Operation DMAN-14563 Rev. H 3.7.1.2.2 Ku-Band ModuMAX SSPA Forward Power Forward Power is a measurement of the power out of the entire multi-module system. This measurement can be read on the front panel, requested via Serial I/O, and is available as a scaled voltage output on the Parallel I/O connector. On the front panel, and via Serial I/O, the reading can be requested in any of the following power units: • dBm • dBW • Watts A fault may be programmed to occur if the output power exceeds or drops below a user programmable threshold. The range of this measurement depends upon two factors: • The nominal output power of the amplifier. • The Forward Power Calibration offset. The top end of the measurement range is equal to the nominal output power of the amplifier system (in dBm) plus the calibration offset plus 2 dB. The bottom end is equal to the nominal output power of the amplifier system (in dBm) plus the calibration offset minus 30 dB. The total measurement range is 32 dB. To view the forward power reading from the front panel, select Srvc / Pfwd. The top line of the screen will show the power reading in the currently selected measurement units. It may display one of the following: • A decimal number for a normal in-range power reading. • A decimal number preceded by a greater than (>) or less than (<) symbol for an out-of-range high or low reading, respectively. • A question mark (?) for an error, such as a failure of the detector circuitry. • A non-decimal number if the calibration data for the detector has been lost. The bottom line allows the power units to be changed. This setting affects both forward and reflected power readings. To request the forward power reading via Serial I/O, send the 16 50 message with no parameters: TX: 02 07 01 16 50 67 03 RX: 02 0C 01 16 50 2B 36 30 2E 35 5B 03 (+60.5 dBm [assuming units set for dBm] ) The forward power reading is also presented on Parallel I/O in the form of a differential analog voltage. This voltage is scaled to be 0.1 volts for every 1 dBm of output power. Thus, an output power of +50 dBm would produce 5.0 volts on the analog output. Out-ofOperation 3-43 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA range LOW values are represented by a 0-volt output, and out-ofrange HIGH values by a 6.8-volt output. 3.7.1.2.3 Reflected Power Reflected Power is a measurement of the power reflected back into the amplifier from its load. Note that ModuMAX amplifiers are capable of operating into any load without damage. This measurement can be displayed (or requested via Serial I/O) as a raw power reading (in currently selected power units), or it may be combined with the Forward Power reading to compute return loss, or VSWR. A fault may be programmed to occur if the reflected power exceeds a user programmable threshold. The range of this measurement depends upon two factors: • The nominal output power of the amplifier. • The Reflected Power Calibration offset. Normally the top end of the measurement range is equal to the nominal output power of the amplifier system (in dBm) plus the calibration offset plus 2 dB. The bottom end is equal to the nominal output power of the amplifier system (in dBm) plus the calibration offset minus 30 dB. The total measurement range is 32 dB. When the reflected power and forward power are combined to compute Return Loss or VSWR, the range and resolution depend upon the measured output and reflected power. If the measured output power is out-of-range on the low side, it is not possible to calculate the Return Loss/VSWR, and an “Undefined” value is returned. If the measured reflected power is out-of-range on the low side, all that can be said is that the Return Loss is higher than a certain value (or that the VSWR is less than a certain value). Return loss is displayed as a dB value, and VSWR is displayed as a ratio. To view the reflected power reading, select Srvc / Prefl. The top line will show the reflected power measurement as one of the following: 3-44 Operation • A decimal number for a normal, in-range measurement. • A decimal number preceded by a greater than (>) or less than (<) symbol. If the measurement type is set for Power, this means that the reflected power reading is out-of-range low or high, respectively. If the measurement type is Return Loss or VSWR, this means that the actual measurement is lower than or higher than the displayed value. • A “U” meaning that the return loss or VSWR cannot be computed, since the forward power is too low. DMAN-14563 Rev. H Ku-Band ModuMAX SSPA • A question mark (?) for an error, such as a failure of the detector circuitry. The bottom line allows the reflected power measurement type to be selected. Pressing MODIFY or toggles the selection between Power, Return Loss, and VSWR. To request the reflected power measurement via Serial I/O, send the 16 5B message with no other parameters: TX: 02 07 01 16 5B 72 03 RX: 02 0C 01 16 5B 2B 32 35 2E 32 64 03 (+25.2 dBm of reflected power) 3.7.1.2.4 Module Status The module status indicates whether or not a module is present, and whether any problems have been detected with the module. To view the status of the modules, select Srvc / Module. The top line will show the module number and its status. Normal status messages are: • OK: Module is present and operating properly. • OK,Muted: Module is present and functional, but is muted. • Disabled: Module is currently disabled. • Dis-PlugIn: Module is disabled because it has just been inserted in the system. • Dis-SMFC: Module is disabled by SMFC because it has reported a Fault (and no other modules are disabled). • Missing: Module is not installed in system, or not detected by the main Logic Board (not communicating). • GateVSht: Module is shutdown due to missing gate voltage on FETs. • ThermShtdwn: Module is shutdown due to over-temperature. • OvrCurrSht: Module is shut off because it was drawing too much current. • RF Inhibit: All modules are off due to the assertion of at least one parallel I/O RF Inhibit input. • Fault: Module has reported a fault. There are also a number of messages that are very unlikely to be seen: • ?MODST: Module is present, but RF status has not yet been obtained. • ExtInh: Module is currently disabled due to assertion of its External Inhibit pin. This could result if the module is not fully inserted into the amplifier. Operation 3-45 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA • EMCONMute: Module is currently disabled due to assertion of its Fast Mute pin (special firmware only). • OFF: RF output is off for an unknown reason The bottom line allows you to select a display of the module’s power output, temperature, voltages, or currents, and to scroll through the list of modules. Via Serial I/O, the status for a single module can be returned using message 16 65. 3.7.1.2.5 Module Output Power The RF output power of each amplifier module is measured and is available via the front panel and by Serial I/O. From the front panel, select Srvc / Module / Po. The screen will show the output power for the selected module on the top line. The bottom line allows you to choose the measurement units for the output power. Press the or MENU buttons to switch between dBm, dBW, and Watts. Continuing to press the or MENU buttons will scroll through output power measurements for all modules. If the module is not present, or not detected for some reason, its power will be displayed as a question mark (?). Via Serial I/O, the output power for a module can be returned using the Module Output Power message, 16 64. 3.7.1.2.6 Module Currents The current drawn by the amplifier FETs in each module are available for display on the front panel and by Serial I/O command. From the front panel, select Srvc / Module / I. The display screen will show the total current measurement from the selected module on the bottom line. Press the or MENU buttons to scroll through the list of modules. To request the total module current for any module via Serial I/O, send the 16 58 message with the requested module number: TX: 02 08 01 16 58 38 A7 03 (module number 8) RX: 02 0E 01 16 58 35 33 2E 32 32 2C 38 CD 03 (53.22 amps, module 8) If the measured current on a module is above the measurable range for that module, it will be reported as “>XXX.XX” (where XXX.XX is the top limit of the current range), or “>MAX” (if the top limit cannot be determined). Note that this condition is highly 3-46 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA unlikely, since the module should shut down if it is drawing enough current to max out the reading. 3.7.1.2.7 Module Voltages Three internal module voltage measurements are available. • Gate Voltage: A negative voltage applied to the gate of each amplifier stage. • Input Voltage: The supply voltage entering the module. • Regulated Voltage: The regulated supply voltage (nominal 10 volts) supplied to the amplifier stages in the module. These voltage measurements are available via the front panel and by Serial I/O. From the front panel, select Srvc / Module / V. The screen will show the Module Number, Input Voltage (Vi), Gate Voltage (Vg), and Regulated Voltage (Vr) (if available) for the selected module. (Some older modules do not have the capability of making the regulated voltage measurement; for those modules, no Vr value is displayed.) Use the or MENU buttons to scroll through the displayed module voltages. To request the internal voltage measurements from any module via Serial I/O, send the 16 60 message with the desired module number: TX: 02 08 01 16 60 32 A9 03 (module number 2) RX: 02 20 01 16 60 32 2C 56 47 2D 34 2E 38 38 2C 56 49 31 30 2E 39 35 2C 56 52 31 30 2E 30 32 FE 03 (module number 2, “VG-4.88” [gate voltage is -4.88 V], “VI10.95” [input voltage is 10.95 V], “VR10.02” [regulated voltage is 10.02 V] ) 3.7.1.2.8 Module Temperature The internal module temperature of the amplifier is measured, and is available from the front panel and by Serial I/O. This reading can range from –55 to +125 °C. From the front panel, select Srvc / Module / Temp. Use the MENU buttons to scroll through the displayed module temperatures. or To request the temperature of any module via Serial I/O, send the 16 51 message with the desired module number: TX: 02 08 01 16 51 32 9A 03 (module number 2) RX: 02 0E 01 16 51 2B 39 34 2E 30 2C 32 BC 03 (+94.0 degrees C, module number 2) Operation 3-47 DMAN-14563 Rev. H 3.7.1.2.9 Ku-Band ModuMAX SSPA Power Level Units All power measurements may be displayed in units of dBm, dBW, or Watts. The Power Level Units setting applies to both Forward and Reflected Power measurements, whether viewed from the front panel or returned via Serial I/O. The power units may be set for: • dBm: A decibel scale referenced to 1 milliwatt (mW) of power. • dBW: A decibel scale referenced to 1 watt of power. • Watts: The raw power measurement in watts. To view or change the power units, select Srvc / Pfwd. The screen will show the amplifier output power on the top line, and allow you to select the units on the bottom line. Pressing MODIFY or will cycle between the three settings. Via Serial I/O, power units can be controlled using message 18 54. 3.7.1.2.10 Reflected Power Measurement Type The reflected power measurement may be displayed as: • Power: The raw reflected power reading, in the currently selected Power Units (dBm, dBW, or Watts). • Return Loss: The ratio of output power to reflected power expressed as a decibel value. • VSWR: The ratio of the impedance of the amplifier’s output to the impedance of the load on the amplifier, always expressed as a value greater than or equal to 1. To view or change the measurement type, select Srvc / Prefl . The top line of the display will show the current reflected power measurement. The bottom line will allow you to select the desired measurement type. Pressing MODIFY or will cycle through the three choices. Via Serial I/O, reflected power measurement type can be controlled using message 18 55. 3.7.1.2.11 Fan Status The amplifier monitors both the speed of cooling fans and their supply voltage. If either the speed or voltage drops below a minimum, a fault is reported. The Fan Status screen allows you to quickly view the detected state of all 8 fans on one screen. To view fan status from the front panel, select Srvc / Fan. The top line lists the fan numbers (1 through 8). The bottom line shows the current state of each fan: 3-48 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA • 9 The fan rotation speed and supply voltage are within defined limits. • X The fan appears to have failed. Rotation speed and/or supply voltage are outside defined limits. • ? The fan status is unknown. Via Serial I/O, fan status can be monitored with message 08. 3.7.1.2.12 Power Supply Status The amplifier detects the status of the external power supply modules. In installations with only one power supply, status is reported for each of the three power supply modules. In installations with two redundant power supplies, all six modules are reported. The amplifier will automatically detect how many supplies are connected and alter the information displayed. To view power supply status from the front panel, select Srvc / PS. The power supply modules are numbered 1, 2, 3 from left-to-right (as viewed from the front of the chassis). If you have two power supplies, the modules in the upper tray are 1A, 2A and 3A and those in the lower tray are 1B, 2B and 3B. If the power supply monitor cable becomes disconnected from the SSPA or from the power supply chassis, a fault will occur and the screen will show “Not Connected.” Via Serial I/O, power supply status can be monitored using message 08. 3.7.1.3 Calibration 3.7.1.3.1 Forward Power Calibration Offset Power readings within the amplifier use a detector that is calibrated with a single frequency, CW signal. The detectors are very accurate at the calibration frequency, with a CW signal, but frequency, modulation, and signal bandwidth all affect the absolute accuracy of the power reading. You can adjust the power readings to agree with a power meter using the calibration offset. You can also use the offset to compensate for losses due to couplers, waveguide, etc. in your system to get a better reading of the power level being delivered to the antenna. The offset has a range of -6.0 dB to +6.0 dB, and a resolution of 0.1 dB. The offset is always represented as a dB value, even if the power units are set for Watts. The forward power measurement range is related to the calibration offset by the following formulas: Operation 3-49 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Maximum forward power measurement = Nominal amplifier power rating [in dBm] + Calibration offset + Minimum forward power measurement = Nominal amplifier power rating [in dBm] + Calibration offset – 30 dB 2 dB Thus the calibration offset effectively shifts the range window up or down. Fault limits are not changed when this offset is adjusted, but if the fault limit falls outside the detector range after this offset is changed, that limit will be disabled. If you are using the Forward Power High or Low fault, you may wish to re-check your fault limits after adjusting this offset. To calibrate the output power readings, select Set / PwrCal / Pfwd. The top line of the display will show you the current power reading. Pressing MODIFY or will change the offset shown on the bottom line, and you can watch the power reading change on the top line. Via Serial I/O, Forward power offset can be controlled using message 17 5A. 3.7.1.3.2 Reflected Power Calibration Offset Power readings within the amplifier use a detector that is calibrated with a single frequency, CW signal. The detectors are very accurate at the calibration frequency, with a CW signal, but frequency, modulation, and signal bandwidth all affect the absolute accuracy of the power reading. The offset has a range of -6.0 dB to +6.0 dB, and a resolution of 0.1 dB. The offset is always represented as a dB value, even if the power units are set for Watts. You can adjust the reflected power readings by shorting the output of the amplifier (after the reflected power detector’s coupler). This will reflect all of the output power of the amplifier back into the internal load, and allow you to adjust the offset until the reflected power and output power are equal. Note that it is safe to reflect the full output power of the amplifier back into itself since the amplifier is protected by an output circulator. The reflected power measurement range is related to the calibration offset by the following formulas: 3-50 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Maximum reflected power measurement = Nominal amplifier power rating [in dBm] + Calibration offset + Minimum reflected power measurement = Nominal amplifier power rating [in dBm] + Calibration offset – 30 dB 2 dB Thus the calibration offset effectively shifts the range window up or down. The fault limit is not changed when this offset is adjusted, but if the fault limit falls outside the detector range after this offset is changed, that limit will be disabled. If you are using the reflected power fault, you may wish to re-check your fault limit after adjusting this offset. To calibrate the reflected power readings, select Set / PwrCal / Prefl. The top line of the display will show you both the current forward power reading and the current reflected power reading. The reflected power is shown as a power level reading, regardless of the setting of the Reflected Power Measurement Type. Pressing or will change the offset shown on the bottom line, MODIFY and you can watch the reflected power reading change on the top line. Via Serial I/O, Reflected power offset can be controlled using message 17 5B. 3.7.2 Faults and Warnings The primary purpose of the amplifier's microprocessor hardware is to detect and report problems. Problems detected in this amplifier are divided into two major categories—Faults and Warnings. • A Fault is any condition or event detected in any part of the amplifier's hardware, including the microprocessor circuitry, that indicates a component failure. • A Warning indicates that either some setting or control has been changed that will prevent normal operation of the amplifier, or some condition exists that needs attention by the operator. For example, a fault would occur if the regulated voltage (measured inside one of the modules) deviated too far from its normal value of 10 volts. A warning would occur if you left the amplifier in Maintenance Mode, which would prevent any remote controls or automatic features of the amplifier from operating. Operation 3-51 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA The ModuMAX amplifier consists of a number of replaceable components, such as the eight RF Amplifier modules. A variety of failures can occur in each of these components. Among all the components in the amplifier, there are over 260 conditions that can be detected by the micro-processor as being faults or warnings. In most cases, when one of these conditions are detected, you only need to know which component needs to be replaced. Thus, the fault conditions and warnings have been divided up into the following general classes that will point to the failed component. • Component Failures Logic Board Forward Power Detector Reflected Power Detector Parallel IO Board ID ROM (Amplifier Motherboard) Front Panel RF Modules 1-8 Fans 1-8 Power Supply Modules (1-3, or 1A-3A and 1B-3B) Power Supply Monitor Cable Disconnected Antenna/Dummy Load Switch • User Faults Forward Power Low Forward Power High Reflected Power High User Input Faults (1-8, R1-R8) • NIC Faults (if NIC is installed) NIC Disconnect NIC CommLost • Warnings New Fault Module Disabled Maintenance Mode Local Mode Power Up Dummy Load To see a list of Faults and Warnings that are currently detected on your amplifier, access the Active Fault List (Section 3.7.2.2.1). Many of the Component Failures have several conditions that indicate the component has failed. For example, the Forward Power Detector will be reported as failed either if it is disconnected, or if the calibration memory inside the detector is corrupted. This information is usually not helpful to the operator, because in either case, he only needs to know that the detector is bad, and that it needs to be replaced. 3-52 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA However, there may be times when it is useful to know what problems have been detected within that component. To do so, you would access the Fault Information (Section 3.7.2.2.2). The information may be helpful when tracking down a recurring problem, and technical support people may ask you for this information when helping you to solve a problem. The User Faults are conditions that don't necessarily indicate a problem with the amplifier. For example, the Forward Power Low fault is reported when the amplifier’s measured output power drops below an operator-set threshold. It could indicate a loss of signal at the input of the amplifier. If any of the Warning conditions occur, the amber WARNING lamp will be lit on the front panel. If any of the Component Failures or User Faults are detected, the red FAULT lamp will be lit. When any of the FAULT conditions are first detected, a New Fault Warning will be issued, which will also result in the amber WARNING lamp being lit. Most Fault and Warning conditions are not latched. The fault will be reported (and the red FAULT lamp lit) only as long as the condition exists. Exceptions to this are: • Any Fault that is based on an event, instead of a condition. An example of an event-based fault is a Spurious Interrupt, or a Spurious Reset of the micro-processor circuitry. These faults will persist until you issue a Fault Reset command. • The New Fault Warning. It is reported any time a new fault is detected, and persists until you issue a Fault Reset command. When the New Fault Warning is reported, it records the Fault, and Fault Information, which you can read in the Fault List. • The Power-Up Warning. If enabled, it is reported any time the amplifier is powered up, and persists until you issue a Fault Reset command. • An Antenna/Dummy Load Switch Stuck fault. It is reported when the switch fails to move in response to an attempt to switch, and persists until the system is able to successfully change the switch. Because faults are not latched, a fault can occur, and go away while nobody is around to see it. Two mechanisms exist to report faults that have occurred while you are not present—the New Fault Warning, and the Event Log. As stated previously, every time a new fault condition is detected, a New Fault Warning is issued. The New Fault Warning is latched until you issue a Fault Reset command, even if the original fault condition has cleared. The fault list shows the New Fault Warning, along with a description of the original fault condition. Operation 3-53 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA The Event Log keeps a detailed list of every fault that occurs in the amplifier, and the Operation Time at which it occurred. Other events, such as the system being powered up, are recorded as well. For fault events, the Fault Information is recorded as well. Warnings are not recorded in the Event Log. See Section 3.7.2.2.3 for more information on the Event Log. 3.7.2.1 Summary Fault Conditions Summary Faults summarize amplifier faults into related groups. A Summary Fault condition is considered active if any of the faults in its group are active. They are mostly used for parallel I/O outputs, but two of them (Any Fault and Any Warning) are used to light the front panel Fault and Warning indicators. 3.7.2.1.1 Any Fault or Warning “Any Fault or Warning” is a summary of all fault and warning conditions. It is available only as a Parallel I/O output. 3.7.2.1.2 Any Fault “Any Fault” is the summary of all of the fault conditions, but does not include warnings. It illuminates the red front panel indicator labeled “FAULT”. It is also available as a Parallel I/O output. 3.7.2.1.3 Any Warning “Any Warning” is the summary of all of the warning conditions. It lights the amber front panel indicator labeled “WARNING”. It is also available as a Parallel I/O output. Warnings are: 3.7.2.1.4 • Local Mode Warning (see Section 3.7.2.3.4) • Maintenance Mode Warning (see Section 3.7.5.1.1) • Module Disabled Warning (see Section 3.6.1.1.2) • New Fault Warning (see Section 3.7.2.2.4) • Power-Up Warning (see Section 3.7.2.3.3) • Dummy Load Warning (see Section 3.7.1.1.6) Fan Fault The Fan Fault is a summary of all fan faults in the system. It means that the Logic Board detects a fan not operating. It is available as a Parallel I/O output. 3-54 Operation DMAN-14563 Rev. H 3.7.2.1.5 Ku-Band ModuMAX SSPA Module Fault The Module Fault indicates that a problem has been detected in one or more RF amplifier modules. It is available as a Parallel I/O output. 3.7.2.1.6 Power Supply Fault The Power Supply Fault indicates that a problem has been detected in one or more power supply modules. It is available as a parallel I/O output. 3.7.2.2 Reading Fault Information Three features provide you with information on fault currently or previously detect by the amplifier. They are accessible from the front panel, or via Serial IO. 3.7.2.2.1 • The Active Fault List displays all faults and warnings currently detected by the amplifier logic. While you view the list, faults and warnings are latched in the list, allowing you to view intermittent faults. • The Fault Info function provides more specific failure information for most faults. These details may help you isolate faulty components within the amplifier. • The Event Log maintains a list of faults and other events (such as power-on) which have occurred. Each entry indicates the time at which it occurred. Event Log contents are retained even when amplifier power is off. The Event Log does not store warnings. Active Fault List A list of currently active faults and warnings is available from the front panel by selecting Flt / Active. If there are currently no faults or warnings, the bottom line will read “None”. Otherwise, the bottom line will show the fault list. If there is more than one fault, a right arrowhead will appear on the right hand side of the display. Use the or MENU buttons to scroll through the faults. All faults or warnings that are active upon entering the Active Fault List menu, or that occur while you are in the menu, will be latched until you exit the Active Fault List or press the FAULT RESET button on the front panel. This permits you to view information about a fault or warning, even if it becomes inactive while you are viewing the list. Each fault or warning in the list will be preceded by a check symbol ( 9 ) if it is currently active. For those component failures that are detected by more than one condition, the word "[Inf]" will appear (in selection brackets). This indication means that you can access the Fault Information (list of Operation 3-55 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA conditions that indicate the component has failed) by pressing the SEL button (see Section 3.7.2.2.2, below). Using Serial I/O, the equivalent of the Active Fault List can be obtained using the Get Active Faults message, 08. This message returns a bit indicating the state of each fault or warning in the Active Fault List. This message should be used when polling the amplifier for faults, as it is intentionally kept to a reasonable length. Bit flags in the 08 message are latched, to make sure that you don't miss transient faults due to polling rate. These bits are latched until: 1) The fault condition clears, and is reported in the 08 message. - OR 2) The fault condition clears, and a SERIAL FAULT RESET command is issued. When the New Fault Warning bit is active, message 08 will append a specific two-byte fault code to the end of the message, representing the most recent fault that has occurred. See section 3.7.2.2.4 and Table 3-5 for a list of serial I/O fault codes. To get the active fault list via serial I/O, simply send the 08 message with no parameters: TX: 02 06 01 08 09 03 RX: 02 12 01 08 40 40 40 42 40 40 40 40 41 2C 31 45 EF 03 In this example, the first underlined byte (42) has a bit flag set that represents a Module 2 fault. The next underlined byte (41) has a bit set that represents a New Fault Warning. The code of the New Fault warning is 31 45, which is Module 2 Temperature High. 3.7.2.2.2 Fault Information Fault Information lists which conditions have been detected that indicate that a particular component has failed. It is available for some of the COMPONENT FAILURES. Faults which have additional information available will display [Inf] at the right side of the bottom line. Press the SEL button to view the additional fault information. You may exit the fault information screen and return to the Active Fault List by pressing the PREV button. Using Serial I/O, you can obtain Specific Fault Info using the Get Specific Faults message, 16 59. This message returns a series of two-byte fault codes representing each active fault or warning. This list can quickly become longer than the maximum Serial I/O message length. In that case, the list will be terminated by code 3-56 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA 7F, indicating there are more codes than can be sent in one message. The two-byte fault codes are listed below in Section 3.7.2.2.4, Table 3-5. To request the specific fault codes (Fault Info) via Serial I/O, send the 16 59 message with no other parameters: TX: 02 07 01 16 59 70 03 RX: 02 0B 01 16 59 22 30 11 30 03 03 (fault codes 22 30 [Fan 2 failure] and 11 30 [forward power low] ) Once you have retrieved Specific Fault codes via Serial I/O, you can obtain corresponding descriptive text strings using the Get Fault Text message, 16 63. You must supply a one- or two-byte specific fault code when sending the message. The first byte refers to the component; the second byte, if included, refers to the specific fault for that component (see Table 3-5). The reply will return the one- or two-byte fault code, followed by a text string containing any available description of the component or fault. If no description is available, the fault code will be returned with a question mark (“?”, or 3F). 3.7.2.2.3 Event Log The Event Log maintains a list of faults, and other events (such as power-on) that the amplifier's logic has detected. The event log is maintained in non-volatile memory. Events that are logged are: • Power-Up — Every time the Logic Board is powered up from an un-powered state. • Logic Board Reset — Every time the microprocessor on the logic board is RESET, whether due to some failure, or due to a command. • Log Initialized — When the non-volatile fault log is initialized at the factory. • Fault — Any fault condition that occurs. To prevent a rapidly repeating Fault from quickly filling the log, any particular Fault will be logged only once in a 15 minute interval, no matter how often in actually occurs. For example, if an Output Power Low Fault occurs once per minute for 16 consecutive minutes, it will be logged only twice—once when it first occurs, and then again at 15 minutes. Power-On or Logic Board Reset events are always logged, no matter how often they occur. The Event log has a limited capacity. After the Log fills up, a new event will cause the oldest event to be dropped. The Log Initialized event will always be the first one recorded, but once it "drops off" the end of the log, you will know that the log has become full. The Operation 3-57 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Event Log is available for your use, but it is also used at the factory when equipment is returned, so for this reason, it cannot be cleared. The maximum number of entries in the Event Log may vary with software revisions, but it will generally be at least 80 events. Each log entry includes the time at which it occurred. When viewing the Event Log from the front panel, the time given is relative to the present Operation Time value (see Section 3.7.4.2.3). Times will therefore always be negative, indicating the event occurred before the present time. When accessing Event Log information via Serial I/O, times will be given as absolute times based on the Operation Time. The Event Log is stored in non-volatile memory on the Logic Board, and its contents are therefore retained even when amplifier power is off. That also means that if the main Logic Board is removed from the amplifier, the Event Log goes with it. If the main Logic Board is replaced with a board that was used in another amplifier, the event log from that other amplifier will appear when queried. Using Serial I/O, you can obtain Event Log entries using the Get Event Log Entry message, 16 66. The procedure is: 1. Send the Get Event Log Entry message with no parameters. 2. The reply will contain an integer “Sequence Number” for the latest event logged, and another integer reflecting the current number of log entries. 3. For each entry you wish to retrieve, send the Get Event Log Entry message with the Sequence Number as a parameter. The Sequence Number must be decremented to get each earlier entry in the log. Sequence Number 0 is invalid and must be skipped, but Sequence Numbers can be negative. If the Sequence Number you sent represents a valid log entry, the reply will contain the absolute operation time the event occurred, followed by a type code indicating the type of event. If the type code is for a fault, a two-byte fault code will then end the message reply. (See Table 3-5.) If the Sequence Number you sent was invalid, the reply will contain only the Sequence Number and an ASCII “?”. When log entries are retrieved via Serial I/O, the time of each event is returned in absolute Operation Time. In contrast, when viewing the Event Log from the front panel, the time of each event is shown relative to current Operation Time. To convert absolute to relative time, use the Get Operation Time message, 16 61, to retrieve the current Operation Time. Then apply the formula: Relative time = Absolute Time – Current Operation Time 3-58 Operation DMAN-14563 Rev. H 3.7.2.2.4 Ku-Band ModuMAX SSPA List of Specific Fault and Warning Codes Table 3-5 contains a list of all conditions detected by the amplifier that are reported as a fault, as of the firmware version associated with this manual. The two byte fault codes (used in several serial I/O messages) are listed as well. In the table, an ellipsis “...” indicates that a byte will come before (ellipsis in left column) or after (ellipsis in right column) the byte listed. The two-byte fault codes use the following numbering scheme: The first byte represents the General Fault (Component Failure, User Fault, or Warning, from Section 3.7.2) that is reported when a particular condition occurs. If there is only one condition that defines the fault, the second byte will be 30. For those Component Failure faults where more than one condition causes the fault, the second byte will represent the specific condition. Table 3-5 Fault and Warning Codes SIO Fault Code Byte 1 Byte 2 10 30 11 30 12 30 13 … … 31 Screen Name; Description and Debugging Pfwd Hi System output power exceeds the operator-defined high limit. The input level may be too high, or one of the modules may be oscillating. Check the input level. If it is not too high, use the Module Disable function to disable each amplifier module one at a time. If disabling one module causes output power to drop more than expected (about 1.2 dB), that module may be oscillating. Try replacing that module. This fault will not be checked while the amplifier RF output is off. Pfwd Lo System output power is below the operator-defined low limit. The input level may be too low, or something may have failed in the amplifier. Check the input level. If it is ok, check for faults on each module. It may be useful to use Module Disable to disable and enable each amplifier module one at a time. If disabling and enabling one module causes no significant change in output power, that module may have failed. Try replacing that module. This fault will not be checked while the amplifier RF output is off, and there will be a 1-second delay after Mute, Inhibit, or other condition that turns RF off is removed before it is checked. Prefl Hi System reflected power exceeds the operator-defined high limit. This fault indicates power reflected back into the amplifier from its load has become too high. This could be due to a shorted or broken wave-guide or damage to the antenna. This fault will not be checked while the amplifier RF output is off. Logic Board A failure has occurred on the Logic Board. Logic Board faults may indicate a hardware problem, but could also indicate a programming error. If a Logic Board error occurs once, try resetting the Logic Board and running the Self Test (see Sections 3.7.4.1.2 and 3.7.4.1.1). If the Self Test fails, replace the Logic Board. If the test passes but the problem recurs, it tends to indicate a programming error. This is especially true if the problem occurs in response to a certain sequence of actions. If this is the case, try another Logic Board. If it also exhibits the problem, please contact the factory. This byte will be followed by one of the bytes below to indicate specific failure information. CPU:ROM (Logic Board Fault) Program memory has a bad checksum. This usually means the memory has become corrupt. If this fault occurs, or the amplifier becomes unresponsive to controls, try the firmware reload procedure described in Section 3.7.4.4. If the reload fails or does not solve the problem, replace the Logic Board. This fault will occur only in response to a Self Test command (Section 3.7.4.1.1). If a Logic Board detects bad program memory on power-up, the board will not run. Operation 3-59 DMAN-14563 Rev. H Table 3-5 Ku-Band ModuMAX SSPA Fault and Warning Codes SIO Fault Code Byte 1 Byte 2 … 32 Screen Name; Description and Debugging CPU:RAM (Logic Board Fault) Temporary memory used to store settings and variables during operation has failed. Reset the Logic Board. If the fault occurs again, replace the Logic Board. … 33 CPU:EEData (Logic Board Fault) Non-volatile memory used to store permanent program settings and calibration information did not contain any valid data on power-up. If this fault occurs, you should check all of your settings and controls, as they may have reverted to default values. If this fault occurs repeatedly, replace the Logic Board. … 34 CPU:EEWrite (Logic Board Fault) Every write to non-volatile memory is verified. If the non-volatile memory does not match the data that was supposed to be stored in it, this fault occurs. If this fault cannot be cleared, or if it occurs repeatedly, replace the offending Logic Board. … 35 CPU:InvInt (Logic Board Fault) An invalid interrupt to the CPU occurred. This will also result in the CPU being reset. It could be caused by a hardware problem on the board, or it may be a programming error. If this fault occurs repeatedly, try replacing the Logic Board. If it occurs in response to a repeatable sequence of actions or events, report it to the factory. … 36 CPU:IllglOp (Logic Board Fault) The CPU attempted to execute an unrecognized instruction. This will result in a CPU reset. Either a hardware problem on the board or a programming error could cause this fault. If this fault occurs repeatedly, try replacing the Logic Board. If it occurs in response to a repeatable sequence of actions or events, report it to the factory. … 37 CPU:SpurRst (Logic Board Fault) The CPU was unexpectedly reset. A power supply problem, a hardware problem on the Logic Board, or a programming error could cause this. If this fault occurs repeatedly, try replacing the offending Logic Board. If it occurs in response to a repeatable sequence of actions or events, report it to the factory. If this fault occurs on several modules and the Logic Board simultaneously, suspect a power supply problem. … 38 CPU:StkOvfl (Logic Board Fault) The CPU attempted to execute too many functions at once. Normally this would only be caused by a programming error, but some hardware failures might also result in this fault being reported. If this fault occurs, report it to the factory. … 39 … 3A … 40 … 50 15 30 16 17 18 30 CPU:A/D (Logic Board Fault) The A/D converter built into the CPU has failed. This A/D converter is used to make many of the amplifier measurements in this system, so its failure may prevent other faults from being detected. Reset the Logic Board. If the fault occurs again, replace the Logic Board. NVRAM Fail Non-volatile memory used to hold amplifier operation time and the Event Log cannot be accessed. NVRAM Data Non-volatile memory used to hold amplifier operation time and the Event Log is blank or its data is corrupted. Switch Drv The system has detected a problem with circuitry used to drive the Antenna/Dummy Load Switch (Maintenance Switch). There may be a short in the switch wiring, or a defect in the Logic Board that will require its replacement. PS Disc The monitor cable between the Power Supply and the SSPA has become disconnected or is damaged. Check the cable connected to J9 on the rear panel of the amplifier. PS Mod1 PS Mod2 PS Mod3 The indicated power supply module is reporting a failure. Try replacing the module. If the problem persists, there may be a fault in the status wiring between the power supply and Logic Board. 3-60 Operation DMAN-14563 Rev. H Table 3-5 Ku-Band ModuMAX SSPA Fault and Warning Codes SIO Fault Code Byte 1 Byte 2 30 19 1A 1B 1C 1D 1E Screen Name; Description and Debugging PS Mod 1A (Only in systems with dual redundant Power Supplies.) PS Mod 2A PS Mod 3A PS Mod 1B PS Mod 2B PS Mod 3B The indicated power supply module in Power Supply A or Power Supply B is reporting a failure. Try replacing the module. If the problem persists, there may be a problem with status wiring between the Power Supply and Logic Board connector J9. Fan1 Fan2 Fan3 Fan4 Fan5 Fan6 Fan7 Fan8 Indicates a possible cooling fan failure. This fault means the fan’s rotation speed has dropped to below its specified rate. Power to the fans is protected with self-resetting fuses. If a fan fails because the fuse tripped, it could be that the fan has failed internally, or cabling to the fan may have shorted. If a fan becomes jammed, a fan motor fails, or a fan is disconnected, you will get a fan speed fault. Mod Pwr Dif The system will report this fault if any two or more modules installed in the unit are of different RF output power ratings. Module 1 Module 2 Module 3 Module 4 Module 5 Module 6 Module 7 Module 8 A problem has been detected with one of the amplifier modules. Normally this fault indicates that the indicated module should be replaced. This byte will be followed by one of the bytes below to indicate specific failure information. 21 22 23 24 25 26 27 28 30 29 30 31 32 33 34 35 36 37 38 … … 31 ROM (Module Fault) Memory used to store the CPU program has a bad checksum. This usually means the memory has become corrupt. Amplifier modules can be reprogrammed via the serial port of the Logic Board. If this fault occurs, try the module firmware reload procedure described in Section 3.7.4.4. If the reload fails, or does not solve the problem, you must replace the offending module. This fault will occur only in response to a Self Test command (3.7.4.1.1). If a module detects bad program memory on power-up, it will indicate a fault and will not operate. … 32 RAM (Module Fault) Temporary memory used to store settings and variables during operation has failed. Try resetting the module. If the fault occurs again, you must replace the offending module. … 33 EE Data (Module Fault) The non-volatile memory used to store permanent program settings and calibration information did not contain any valid data on power-up. If this fault occurs, you should check all settings and controls, as they may have reverted to default values. If this fault occurs repeatedly, replace the module. … 34 EE Wrt (Module Fault) Every write to non-volatile memory is verified. If the non-volatile memory does not match the data that was supposed to be stored in it, this fault occurs. If this fault cannot be cleared, or if it occurs repeatedly, replace the offending module. Operation 3-61 DMAN-14563 Rev. H Table 3-5 Ku-Band ModuMAX SSPA Fault and Warning Codes SIO Fault Code Byte 1 Byte 2 … 35 Screen Name; Description and Debugging InvInt (Module Fault) An invalid interrupt to the CPU occurred. This will also result in the CPU being reset. It could be caused by a hardware problem, or it may be a programming error (bug). If this fault occurs repeatedly, try replacing the module. If it occurs in response to a repeatable sequence of actions or events, report it to the factory. … 36 IllglOp (Module Fault) Similar to an invalid interrupt, the CPU attempted to execute an instruction that is not recognized. This will also result in the CPU being reset. Either a hardware problem or a programming error could cause this fault. If this fault occurs repeatedly, try replacing the module. If it occurs in response to a repeatable sequence of actions or events, report it to the factory. … 37 SpurRst (Module Fault) The CPU was unexpectedly reset. A power supply problem, a hardware problem on the Logic Board, or a programming error could cause this to happen. If this fault occurs repeatedly, try replacing the offending module. If it occurs in response to a repeatable sequence of actions or events, report it to the factory. If this fault occurs on several modules and/or the Logic Board simultaneously, suspect a power supply problem. … 38 StkOvfl (Module Fault) The CPU attempted to execute too many functions at once. Normally this would only be caused by a programming error, but some hardware failures might also result in this fault being reported. If this fault occurs, report it to the factory. … 39 AD Conv (Module Fault) The A/D converter built into the module CPU has failed. This A/D converter is used to make many of the amplifier modules measurements, so its failure may prevent other faults from being detected. If this fault occurs, you should replace the module. … 3A GainCal (Module Fault) The table telling the module how to control gain and temperature-compensate gain is either missing or corrupted. … 3B Det Cal (Module Fault) The calibration memory for the output power detector is not operating correctly. … 3C Det A/D (Module Fault) The high resolution A/D converter used to make forward and reflected power readings has failed. Replace the module if this fault occurs. … 3D TempSns (Module Fault) The module temperature sensor is not responding. If this fault occurs, the module probably needs to be replaced, or it will be unable to warn about and protect itself from excessive internal temperature. … 41 InpVLo (Module Fault) Input voltage to the amplifier module is below a programmed limit. … 42 InpVHi (Module Fault) Input voltage to the amplifier module is above a programmed limit. … 43 Ext Inh (Module Fault) The amplifier module is disabled because the external inhibit pin is asserted. … 44 TmpShdn (Module Fault) The module has been shut down because its temperature has become too high. This shutdown protects the module from damage due to high temperatures. Check the cooling fans closest to this module. Make sure you are operating your equipment within the specified operating temperature range. … 45 TempHi (Module Fault) The temperature of the module exceeded a factory-programmed limit. Check the cooling fans closest to this module, they may have become blocked. This fault will also occur if the amplifier is operated above its specified operating temperature range. … 56 GateSht (Module Fault) The module has been shut down because the negative voltage generator that supplies the gates of the amplifier FETs has failed. If this happens, the module should be replaced and returned to the factory for repair. 3-62 Operation DMAN-14563 Rev. H Table 3-5 Ku-Band ModuMAX SSPA Fault and Warning Codes SIO Fault Code Byte 1 Byte 2 … 57 Screen Name; Description and Debugging HiCrSht (Module Fault) The module has been shut down because it is drawing excessive supply current. If this happens, the module should be replaced and returned to the factory for repair. … 58 ComLost (Module Fault) The Logic Board is unable to communicate with the module. Remove and replace the indicated module. Remove the Logic Board, verify there are no bent pins on the connector, and replace the Logic Board. Try replacing the indicated module. Try replacing the Logic Board. … 59 Pout Lo (Module Fault) Module output power is 5 dB or more below the average of the other modules; or is otherwise lower than expected. Try swapping the module. … 5A Curr Lo (Module Fault) Module total current is lower than expected. Try swapping the module. … 5B 41 42 43 44 45 46 47 48 30 49 30 4A … … 31 … 32 4B … … 31 … 32 4C 30 4D 30 Vr Adj (Module Fault) Module regulated voltage is out of tolerance. Try swapping the module. Input1 Input2 Input3 Input4 Input5 Input6 Input7 Input8 The indicated user input of the Parallel I/O board has been asserted. These faults do not indicate a hardware problem internal to the SSPA. See Section 3.7.3.3.3 for information on assigning Parallel I/O input functions. ID ROM Fail There is a problem with the ID ROM memory used to hold system data and calibration information. If this fault occurs, assume that system calibration (if any) may be incorrect and report this failure to the factory. Pfwd Det Indicates a problem with the forward power detector for the system. This byte will be followed by one of the bytes below to indicate specific failure information. Pfwd Cal The detector calibration memory appears corrupted. Replace the detector module. PfwdFail The detector has failed or become disconnected. Check the detector cabling. If it is ok, replace the detector module. Prefl Det Indicates a problem with the reflected power detector for the system. This byte will be followed by one of the bytes below to indicate specific failure information. Prefl Cal The detector calibration memory appears corrupted. Replace the detector module. PreflFail The detector has failed or become disconnected. Check the detector cabling. If it is ok, replace the detector module. ParIO Bd The Parallel I/O board has become disconnected or has failed. If you have intentionally removed the Parallel I/O board, you should remove the option (see Section 3.7.4.3.2) and reset faults. Otherwise, remove the Parallel I/O board, check its connector for bent pins, and reinstall the board. If the problem persists, try replacing the board. Frnt Pnl The front panel board has become disconnected or has failed. Remove the front panel and check its cable to the Motherboard. If all connections are intact, try replacing the front panel assembly. 4E … Ant/DL Switch (Only in systems with Antenna/Dummy Load switch.) This group of faults indicates a problem with the Antenna/Dummy Load switch, for systems that contain one. Operation 3-63 DMAN-14563 Rev. H Table 3-5 Ku-Band ModuMAX SSPA Fault and Warning Codes SIO Fault Code Byte 1 Byte 2 … 31 … 32 50 30 51 30 52 30 53 30 54 30 55 30 61 62 63 64 65 66 67 68 30 3-64 Operation Screen Name; Description and Debugging Ant/DL Disc The Antenna/Dummy Load switch is not correctly detected by the system. Check wiring between the switch and J7 on the Logic Board. If no problem is found, there may be a defect in the switch or Logic Board. Ant/DL Stuck The system has attempted to switch the Antenna/Dummy Load switch, and it appears to be stuck in the wrong position. Check the switch for a mechanical problem. Try switching it manually if possible. Check wiring between the switch and J7 on the Logic Board. If no problem is found, there may be a defect in the Logic Board circuitry used to drive the switch. New Fault This warning occurs whenever a new fault occurs. It illuminates the WARNING indicator on the front panel to alert an operator that a new fault has occurred, even if the fault is not currently active. It is cleared by resetting faults. Maint Mode This warning occurs when the SSPA is in Maintenance Mode. This warning illuminates the WARNING indicator on the front panel to remind an operator to exit Maintenance Mode before leaving the site. When Maintenance mode is exited, this warning will automatically clear. Maintenance Mode suspends many fault detection and remote control mechanisms in the amplifier system. The logic system will not function properly if left in Maintenance Mode. Local Mode This warning occurs when the SSPA is placed in Local Mode from the front panel controls. It illuminates the WARNING indicator on the front panel to remind an operator to exit Local Mode before leaving the site. When Local mode is exited, this warning will automatically clear. Local Mode prevents remote (Serial I/O or Parallel I/O) operation of the amplifier. In most installations, you probably will not wish to operate in Local Mode at all times. If you do wish to permanently run your system in Local Mode, this warning may be disabled. See Section 3.7.2.3.3. Power Up This warning is generated each time the amplifier is powered-up. This may be useful to indicate whether power to the amplifier has been interrupted while an operator is not present. It illuminates the WARNING indicator until cleared by resetting faults. This warning may be disabled. See Section 3.7.2.3.4. Mod Disable This warning occurs when one or more amplifier modules are disabled. The Module Disable warning will light the WARNING indicator on the front panel to remind the operator that some action needs to be taken. When all amplifier modules are re-enabled, this warning will automatically clear. Dummy Load (Only in systems with Antenna/Dummy Load switch.) This warning is generated when the system output is directed to the Dummy Load. This may help prevent the amplifier from being left in an undesired offline state. This warning cannot be disabled. It illuminates the WARNING indicator on the front panel until it is cleared by resetting faults or putting the amplifier back online. Remote Input 1 Remote Input 2 Remote Input 3 Remote Input 4 Remote Input 5 Remote Input 6 Remote Input 7 Remote Input 8 When an RCP-2000 Remote Control Panel with Parallel I/O is connected, these faults indicate the corresponding user input of the RCP-2000 Parallel I/O board has been asserted. These faults do not indicate a hardware problem internal to the SSPA or RCP-2000. See Section 3.7.3.3.3. DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Table 3-5 Fault and Warning Codes SIO Fault Code Byte 1 Byte 2 6A … Screen Name; Description and Debugging Network Fault Indicates a problem with the Ethernet network interface. This byte will be followed by one of the bytes below to indicate specific failure information. … 31 The NIC has become disconnected or has failed. Remove the NIC, check its connector for bent pins, and reinstall the board. If the problem persists, try replacing the board. … 32 Lost communications with the NIC. This fault may indicate a hardware problem, but could also indicate a programming error. If this error occurs once, try resetting the Logic Board. If the problem recurs, it may indicate a programming error. This is especially true if the problem occurs in response to a certain sequence of actions. If this is the case, try another NIC. If it also exhibits the problem, please contact the factory. 3.7.2.3 Fault Settings and Controls The following settings and controls affect the reporting of faults in the amplifier system. 3.7.2.3.1 Forward Power Limits You may set both a HIGH and a LOW forward power fault limit. Separate faults are reported for the forward power being too high or too low, because each of these conditions implies a different kind of failure. The high limit should be set slightly above the maximum power that you expect your system to put out. If this power level is exceeded, it may indicate that one of the modules is oscillating, or that a failure in the equipment supplying the signal to the amplifier has caused the input level to be too high. The low limit should be set about 1 dB lower than the minimum output power you expect from the system. If you are switching your carrier on and off, or if your modulation scheme causes extreme dips in the measured signal level, you probably will not be able to use the low limit, so you should disable it. If set properly, this fault will be able to detect module failures that are not detected by the other measurements in the amplifier system. The forward power low limit is not checked (and no Pfwd Lo fault is reported) when RF is turned OFF by a mute or inhibit command. The firmware delays 1 second after RF has been restored before checking this limit. To control the forward power fault limits, select Set / Faults / Limits / Pfwd. The top line will show the current power units setting. Two numbers will be shown on the bottom line. These will be the LOW (left) and HIGH (right) limits for the forward power, in the currently selected power units. A greater than (>) or less than (<) symbol indicates that the limit is disabled. Operation 3-65 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Use the or MENU buttons to select either limit, and the MODIFY (increase) and (decrease) buttons to change them. Set the LOW limit for the minimum acceptable power level (a fault will occur only if the measured power is less than this number). Set the HIGH limit for the maximum acceptable power level (a fault will occur only if the measured power is greater than this number). If you adjust the Forward Power Calibration Offset, remember to re-check these fault limit settings. If a fault limit falls outside the measurement range after the offset is adjusted, that limit will be disabled. You can read and control the Forward Power Limit via Serial I/O, using message 17 51. 3.7.2.3.2 Reflected Power Limit You may set a HIGH limit on reflected power. If the measured reflected power rises above this limit, a fault will occur. To set the reflected power fault, select menu Set / Faults / Limits / Prefl. The screen will show the current reflected power limit. Press MODIFY or to edit the limit. The reflected power limit is always set as a power level in dBm, never in Return Loss or VSWR. If you adjust the Reflected Power Calibration Offset, remember to re-check these fault limit settings. If a fault limit falls outside the measurement range after the offset is adjusted, that limit will be disabled. You can read and control the Reflected Power Limit via Serial I/O, using message 17 51. 3.7.2.3.3 Power-Up Warning Enable/Disable When the Power-Up Warning is enabled, a warning will be generated each time the amplifier is powered-up. (An entry is also made in the Event Log.) This may be useful to indicate whether power to the amplifier has been interrupted while an operator is not present. This warning may be enabled or disabled by selecting Set / PwrUp, or using Serial I/O message 17 60. (You cannot disable the Power-Up Event Log entry.) 3.7.2.3.4 Local Mode Warning Enable/Disable Most systems should be run in Remote mode, which allows Serial I/O and Parallel I/O control of the amplifier. However, if you do 3-66 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA not wish to remotely control your amplifier, you may wish to leave it in Local Mode. The Local Mode Warning exists to remind the operator to return the amplifier to Remote Mode if they change it while working on the amplifier. If you wish to use Local Mode exclusively, you should disable the Local Mode Warning. To do so, select Set / Faults / Loc. The top line of the screen will show the current setting, Enabled or Disabled. Select the desired setting from the choices on the bottom line, or press MODIFY or to change the setting. You can read and control the Local Mode warning via Serial I/O, using message 17 5F. 3.7.2.3.5 Fault Reset Faults that are based on measured parameters or conditions are not latched. Faults based on discrete events, such as a Spurious Reset, are latched; that is, they continue to be reported until reset by the operator. Also, the New Fault Warning and the Power-Up Warning are latched. In order to stop reporting of latched faults and warnings, use the Fault Reset command. This command is available from the front panel, by Serial I/O, and by Parallel I/O. Any fault that remains active will not be cleared by this command. Some faults are caused by internal self-test failures. Before clearing the fault, the system will re-run any tests associated with such faults that are currently being reported as active. Some of these tests take significant processor time, so avoid repeatedly issuing a Fault Reset command if there is a fault condition that will not clear. If no faults are being reported after a serial I/O Fault Reset command is executed, the Service Request will also be cleared. See Section 3.7.2.3.6 below for more information about the Service Request feature. To reset faults from the front panel, press the Fault Reset button. This function is also available in the menu: select Flt / Reset, and press SEL to perform the reset. Using the Fault Reset button while viewing the Active Fault List will also clear faults that have been latched in the list. Faults can also be reset using Parallel I/O if one of the inputs has been programmed as a Fault Reset input. Any high-to-low transition on this line will issue a Fault Reset command. To reset faults via Serial I/O, simply send the 0A message with no parameters: Operation 3-67 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA TX: 02 06 01 0A 0B 03 RX: none (Faults are reset) 3.7.2.3.6 Service Request The Service Request is a Form ‘C’ relay contact available on the Serial I/O interface connector. It is meant to be used to alert the monitoring system that the amplifier has detected a condition that needs attention. The monitoring system would send a Get Active Faults message, 08, to find out what is wrong, and then acknowledge the service request by issuing a Clear Service Request command (see Section 3.7.2.3.7, below). The Service Request contact will change to its fault state any time a new Fault or Warning is detected. It will remain in its fault state until one of the following occurs: • A Serial I/O Fault Reset command (Section 3.7.2.3.5) is issued that causes all latched Faults and Warnings to stop being reported. • A Serial I/O Clear Service Request command (Section 3.7.2.3.7) is issued. • The amplifier is changed to Maintenance Mode. The Service Request contact will not indicate a fault while in Maintenance Mode. Note that a front panel Fault Reset command (i.e., pressing the FAULT RESET button) will not affect the Service Request. 3.7.2.3.7 Clear Service Request When a Service Request occurs (see Section 3.7.2.3.6) the monitoring system can acknowledge it, and cause it to stop being reported by issuing the Serial I/O Clear Service Request message, 09. To reset the Service Request contact, simply send the message with no parameters: TX: 02 06 01 09 0A 03 RX: none (service request is cleared) This command will be obeyed regardless of the setting of the Control Mode. The Service Request will be cleared even if there are still active faults. If any new faults are detected, the Service Request will occur again. 3.7.2.4 Single Module Failure Compensation (SMFC) A ModuMAX amplifier consists of eight identical amplifier modules, all running in parallel. The outputs of the eight modules are phase combined to produce a composite amplifier whose power capability is 8 times that of each individual module. If any single 3-68 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA module were to be disabled, removed, or fail completely, i.e. stop providing any output at all, the gain (and output power capacity) of the composite amplifier would drop by approximately 1.2 dB. Many systems can tolerate this loss temporarily, until the defective module is replaced and re-enabled. However, for systems that are less tolerant of such loss, Single Module Failure Compensation (SMFC) is available. SMFC automatically compensates for loss of gain due to the failure of one of the eight modules in a ModuMAX amplifier by increasing the gain by 1.2 dB. SMFC may be enabled or disabled by selecting Set / Faults / SMFC at the front panel, or using Serial I/O message 17 65, or via the optional Ethernet network interface. When SMFC is activated (enabled), the actual gain of the ModuMAX amplifier will immediately drop by 1.2 dB (assuming no modules are faulted or disabled, and assuming the gain control is set higher than -18.8 dB; see below for more details). This is done to provide “headroom” to be able to increase the gain by 1.2 dB should an amplifier module failure be detected. For example, this means if the gain of the amplifier is normally 70.0 dB (with the gain control set for maximum [0.0 dB]) the gain of the amplifier will be 68.8 dB after the SMFC feature is activated. Note This gain change will affect intermodulation performance, and the end user should plan accordingly for this when setting up the system. While SMFC is activated, the gain control range of the amplifier (normally -20.0 to 0.0 dB) will be -18.8 dB to 0.0 dB, where 0.0 dB still represents the maximum possible gain setting. At the time this setting is changed, the Gain Control setting and the actual gain of the amplifier will be affected as indicated in Table 3-6. This setting is stored in non-volatile memory, and is ENABLED at the factory. The actual displayed gain control setting will not change when this feature is activated, unless it is already set below -18.8 dB, in which case it will be forced to -18.8 dB. This means that if the gain control was previously set below -18.8 dB, the actual drop in gain may be numerically less than 1.2 dB. For example, if the gain is set for -20.0 dB prior to activating SMFC, it will be set for -18.8 dB afterwards. In this example, the combination of the 1.2 dB drop in gain and the increase in the gain control setting results in no change in the observed amplifier gain. Operation 3-69 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Table 3-6 SMFC/Gain Control Logic When SMFC is ... ... and Gain Control Before (GSET-) is ... ...and any Module is Faulted or Disabled: Then Gain Control After is ... and Actual Amplifier Gain is: ENABLED ≥ -18.8 dB NO Unchanged Decreased by 1.2 dB ENABLED ≥ -18.8 dB YES Unchanged Unchanged ENABLED < -18.8 dB NO -18.8 dB Decreased by (GSET- + 20.0) dB ENABLED < -18.8 dB YES -18.8 dB Increased by (-18.8 - GSET-) dB DISABLED ANY NO Unchanged Increased by 1.2 dB DISABLED ANY YES Unchanged Unchanged While SMFC is activated, if any failure is detected in a module or if a module is disabled, and no other modules are already faulted or disabled, the gain will be increased by 1.2 dB. If all 8 modules are subsequently restored to normal operation, the gain will be dropped by 1.2 dB. Also, while SMFC is activated, when a failure is detected in a module (and no other modules are already faulted or disabled), the failed module will be disabled. If more than one module fails simultaneously, the first one detected will be disabled. This is done to insure that the failed module is not contributing to the output power, and the 1.2 dB gain increase will correctly compensate for the loss of the single failed module. Because some faults reported by modules (for example, a high current fault) will clear when the module is disabled, a module that is disabled in this way will remain disabled until re-enabled by an operator (through front panel, serial I/O, or network control). Since faults are not latched, any fault which clears while the module is disabled would no longer be reported. However, both the latched New Fault warning and the Fault Log will record the fault and identify the cause. Only one module would be disabled in this way. If any module is already disabled (even if it has been manually disabled), a module that subsequently fails will not automatically be disabled by this feature. Whenever a module is manually enabled, the automatic, SMFCinitiated disabling of a faulted module will be suppressed for that module for 3 seconds afterwards. This prevents SMFC from immediately disabling that module again, if the fault condition 3-70 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA cleared while the module was disabled, and is re-detected after it is enabled. Ideally, the gain increase and the disabling of the faulted module should keep the output signal level close to constant. However, there are some issues that the end user should be aware of: 3.7.2.5 • If your system is running close to saturation before a module fails, the 1.2 dB increase in gain after a module failure may drive the amplifier further into saturation, increasing spurious outputs. • There may be a delay in the response between the actual module failure and the gain adjustment. In most cases this delay should be less than 100 ms. These delays will result in transient gain discontinuities. • If the module failure results in or is due to a loss of communications between the module and the main logic board, then the module cannot be disabled. If that module is still contributing to the output, the gain may actually increase by as much as 1.2 dB. Audible Alarm The amplifier front panel is equipped with an Audible Alarm. The alarm can be configured to sound if any Fault is detected in the amplifier, or if either a Fault or Warning is detected. The alarm may also be disabled entirely. To stop the audible alarm from sounding, simply press any button on the front panel. The alarm will also stop sounding if a Serial I/O or Parallel I/O command results in all faults being reset. 3.7.2.5.1 Audible Alarm Setting The audible alarm can be configured to sound on Faults, Faults and Warnings, or not sound at all. This setting is available through the front panel only. To configure the audible alarm, select Set / Faults / AudAlarm. The top line will show the current state of this setting: Off, Fault, or All. Use the menu choices on the second line to alter this setting. Pressing MODIFY or will also cycle the setting. The last menu choice allows the audible alarm to be tested (see Section 3.7.2.5.2, below). 3.7.2.5.2 Audible Alarm Test To test the audible alarm, select Set / Faults / AudAlarm. Press the right arrow to change to the last menu choice, Test, then press SEL . Operation 3-71 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA The audible alarm will sound immediately. Once you are satisfied that it is working, press any button to stop it. 3.7.3 Remote Control Three methods exist to remotely control and monitor the amplifier: the network, Serial I/O, and Parallel I/O. This section describes the settings and controls that are used to set up the remote control interfaces. The network interface is not available if your ModuMAX SSPA is equipped with support for an RCP-2000 remote control panel. 3.7.3.1 Ethernet Network The network interface supports simple network management protocol (SNMP) and allows control of a sub-set of firmware functions through a Management Information Block (MIB). The MIB uses a subset of the serial I/O protocol instruction and subinstruction codes as part of the MIB address, or Object Identifier (OID). Network setup (IP Address, Net Mask, and Gateway Address cannot be accomplished via the network interface itself, but can only be done from the front panel or through serial I/O commands. 3.7.3.1.1 Network IP Address This setting determines the IP address of the network interface. It consists of four integers, each of which can range from 0 to 255, representing a traditional IP address. This setting defaults to 192.168.1.100, and is stored in nonvolatile memory. From the main menu, select Set / Net / IP Address. Note that, due to space limitations on the screen, the four parts of the Network IP address are shown not separated by the traditional periods. The Network IP Address can be set using serial I/O message 17 1E. 3.7.3.1.2 Network Net Mask This setting represents the Subnet Mask for the IP address. You increment or decrement the entire mask. The Subnet Mask must consist of values where the bits are all “1”, followed by bits that are all “0”. There are only 23 valid Subnet Masks for ModuMAX. INC/DEC steps through all possible masks. This setting defaults to 255.255.255.0, and is stored in nonvolatile memory. 3-72 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA From the main menu, select Set / Net / NetMask. Note that, due to space limitations on the screen, the four parts of the Network Net Mask are shown not separated by the traditional periods. The Network IP Mask can be set using serial I/O message 17 1F. 3.7.3.1.3 Network Gateway IP Address This setting determines which IP address network traffic should be sent to, if the IP addresses are not on the network, according to the combination of Network IP Mask, and the IP address. This setting defaults to 192.168.1.1, and is stored in non-volatile memory. From the main menu, select Set / Net / Gateway. Note that, due to space limitations on the screen, the four parts of the Gateway address are shown not separated by the traditional periods. The Gateway address can be set using serial I/O message 17 20. 3.7.3.2 Serial I/O Serial I/O allows the amplifier to be remotely controlled and monitored via a serial port. The following controls must be set to match your computer’s serial port. If an RCP-2000 Remote Control Panel will be used with your ModuMAX SSPA, it will connect to the ModuMAX’s Serial I/O port, and you will connect your computer’s serial port to the RCP2000’s Serial I/O port. In this case, the serial settings described below will transfer to the RCP-2000. See the RCP-2000 Manual Supplement for more information. 3.7.3.2.1 Interface The serial port can be programmed to use RS-232, RS-485 (2- or 4- wire), or RS-422. To set the serial port interface from the front panel, select Set / Ser / Intfc. The top line of the screen will show you the current serial interface setting. The bottom line allows selection of the four interface types: • • • • RS-232 RS-485 (2 wire) RS-485 (4 wire) RS-422 Pressing MODIFY or will cycle through the four settings. The interface selection cannot be changed via Serial I/O. Operation 3-73 DMAN-14563 Rev. H 3.7.3.2.2 Ku-Band ModuMAX SSPA Baud Rate The serial baud rate can be selected from the front panel. It should be set to match the baud rate of your M&C computer. To control the baud rate, select Set / Ser / Baud. The top line of the screen will show the current baud rate setting. The bottom line allows selection from among several commonly used baud rates, from 300 to 28800. The BAUD RATE selection cannot be changed via Serial I/O. 3.7.3.2.3 Address In a serial bus structure where more than one amplifier can “hear” messages sent to other amplifiers (or other ModuMAX equipment), each amplifier must be assigned a unique, non-zero address. The Serial I/O protocol contains an address in the message header that determines which amplifier should obey the message. Address 0 is reserved for messages you wish to send to ALL amplifiers at once. However, address 0 is safe to use where there is only one amplifier on the bus. To assign an address, select Set / Ser / Adr. Press MODIFY to change the address of the amplifier. or The address setting cannot be changed via Serial I/O. 3.7.3.2.4 SIO Relay The serial I/O interface includes a programmable relay output that can be utilized to alert the host status monitoring system of faults or warnings in the SSPA. The Form ‘C’ contact set can be programmed for one of two functions: • Service Request – The contact set indicates a fault as soon as any condition is detected by the amplifier that requires attention, including any warning or fault. The contacts will be cleared when one of the following occurs: 1. The user initiates a Get Active Faults request via serial I/O (message 08), the reply is successfully sent, and there are no active faults or warnings; or 2. All faults are successfully cleared by a Fault Reset command (0A); or 3. A Clear Service Request serial I/O command (09) is issued (even if faults or warnings are currently active). • Active Fault – The contact set indicates a fault only for as long as a fault condition is detected by the amplifier. When the condition clears, the contact set reverts to its non-fault state. This is the recommended setting if the amplifier is used in a 1:1 or 1:2 system with an external redundancy controller. 3-74 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA To choose a setting, select Set | Ser | Relay. The top line of the screen will show the current relay setting. The bottom line allows selection of the setting. This setting is stored in non-volatile memory, and is set to Service Request at the factory. 3.7.3.3 Parallel I/O Parallel I/O is normally supplied in the main ModuMAX SSPA unit. This is referred to as “Local” Parallel I/O. It consists of 8 inputs, 8 outputs, and an analog voltage output that is proportional to amplifier output power. When an optional RCP-2000 Remote Control Panel equipped with Parallel I/O is added to the SSPA, additional “Remote” Parallel I/O is available. The Remote Parallel I/O consists of another 8 inputs, 8 outputs, and another analog output that is proportional to amplifier output power. Functions for Remote inputs and outputs are programmed the same way the Local ones are. 3.7.3.3.1 Input Active State The current state of all 8 Local Parallel I/O inputs can be determined at any time via the front panel, or by Serial I/O. When an RCP-2000 Remote Control Panel equipped with Parallel I/O is added to the SSPA, the state of the additional 8 Remote Parallel Inputs may also be determined from the front panel or by Serial I/O. From the front panel, select Srvc / Inp. The top line shows the input number, and the function for which that input is programmed. The bottom line shows the current state of the input. This will be: • HIGH: The input is high or open. • LOW: The input is pulled to ground. • ?INP: There is a problem with the Parallel I/O board. Use the or MENU buttons to scroll through the list of inputs. To request the state of the parallel I/O inputs via Serial I/O, send the 16 5C message with no other parameters: TX: 02 07 01 16 5C 73 03 RX: 02 0D 01 16 5C 7F 42 40 40 40 40 34 03 In the above example, the underlined bytes 7F 42 indicate that all inputs are active, except input number 7 (least significant bit of the second byte). The underlined bytes 40 40 are bit flags with no bits set, and they indicate that either none of the inputs are set to NO FUNCTION (None), or none of them that are set to None have Operation 3-75 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA been high since you last checked. (The intervening 40 bytes are reserved for Parallel I/O in an attached Remote Control Panel.) 3.7.3.3.2 Input Latched State Inputs that are not assigned any function may be latched. An input is considered latched if it has been high since the last time its state was checked via Serial I/O. Inputs that are assigned any function are not latched. Using Serial I/O, both the latched and active state of Parallel I/O inputs can be obtained using message 16 5C. 3.7.3.3.3 Input Functions The operator may program the functions of the 8 inputs on the Local Parallel I/O module. These settings may be changed from the front panel, or via Serial I/O. When an RCP-2000 Remote Control Panel equipped with Parallel I/O is added to the SSPA, the functions of the additional 8 Remote Parallel Inputs may also be programmed from the front panel or by Serial I/O. Table 3-7 lists the functions available. Table 3-7 Screen Title Input Functions Serial I/O Code Function Activ e On See Section None 30 No function H 3.7.3.3.1, 3.7.3.3.2 Fault.H 31 User Fault (active HIGH) H 3.7.2.2.4 Fault.L 32 User Fault (active LOW) L 3.7.2.2.4 Mute 33 Mute 3.7.1.1.1 Un-Mute 34 Un-mute 3.7.1.1.1 Mute/UnMut Tog 35 Mute/Un-mute toggle 3.7.1.1.1 Mute.L/UnMut.H 36 Mute Un-mute 3.7.1.1.1 RF Inhibit.L 37 RF Inhibit (active LOW) L 3.7.1.1.3 RF Inhibit.H 38 RF Inhibit (active HIGH) H 3.7.1.1.3 Fault Reset 39 Resets Faults 3.7.2.3.4 Antenna 3A Switch to Antenna 3.7.1.1.6 DummyLd 3B Switch to Dummy Load 3.7.1.1.6 Ant-DL Tog 3C Ant/Dummy Load toggle 3.7.1.1.6 Note 3-76 Operation In Local Mode or Maintenance Mode, Parallel I/O inputs that are programmed to generate a Fault still function normally. DMAN-14563 Rev. H Ku-Band ModuMAX SSPA In Table 3-7, “Screen Title” shows how the function will be shown on the input function selection screen. The “Serial I/O Code” is the hexadecimal value of the byte that must be sent in the message to select a particular input function. “Function” is a description of the operation that the input will perform. “Active On” shows the edge ( , ) or level (L,H) which will cause the function to be executed. “See Section” refers to the section of this manual where the input function is described. To set the input functions from the front panel, select Set / Par / Inp. Press the or MENU buttons until the desired input is shown. The top line shows the input number, and the current function setting for that input. The bottom line allows the function to be changed. Press MODIFY or to step through the list of available input functions, which are presented in alphabetical order. When the function you want is shown, press SEL . Note that you MUST press SEL to change the input function to the one you want, otherwise it will be left unchanged. Using Serial I/O, the input functions for Parallel I/O inputs can be read and controlled using message 17 56. 3.7.3.3.4 Output Functions The operator may control the functions of the eight outputs on the Local Parallel I/O module. These settings may be changed from the front panel or by Serial I/O. When an RCP-2000 Remote Control Panel equipped with Parallel I/O is added to the SSPA, the functions of the additional 8 Remote Parallel Outputs may also be programmed from the front panel or by Serial I/O. The list of functions available for Parallel I/O outputs is shown in Table 3-8. In Table 3-8, “Screen Title” shows how the selected function will appear on the output function selection screen. “Serial I/O Code” is the hexadecimal value of the byte that must be sent in the message to select the function. “Function” describes the overall meaning of the Parallel I/O output. “Contacts” shows the meaning of the two positions of the Form ‘C’ contact set; the relays are shown in their de-energized position. “See Section” refers to the section where the function is described. To set the output functions from the front panel, select Set / Par / Outp. Press the or MENU buttons until the desired output number is shown. Operation 3-77 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Table 3-8 Screen Title None Pfwd Fault Prefl Fault Any Fault Remote/Local Maint Mode RF Inhibit RF On/Off Mute/Operate Fan Fault Module Fault Any Warning Temp Fault Any Flt/Wrn PS Mod Fault Antenna/DL Output Functions Serial I/O Code 30 31 32 33 34 35 36 37 38 39 3A 3B 3C 3D 3E 40 Function Contacts N.C. No function (may be controlled via SIO) Forward Power Fault (high or low) 3.7.3.3.5 N.O. FAULT 3.7.2.2.4 NO FAULT FAULT 3.7.2.2.4 Reflected Power Fault NO FAULT FAULT 3.7.2.1.2 Any Fault NO FAULT LOCAL 3.7.5.1.1 Remote/Local REMOTE MAINT 3.7.5.1.1 Maintenance Mode NORMAL INHIBIT 3.7.1.1.3 RF Inhibit NOT INH RF OFF 3.7.1.2.1 RF On/Off RF ON MUTE 3.7.1.1.1 Mute or Operate OPERATE FAULT 3.7.2.1.4 Fan Fault NO FAULT FAULT 3.7.2.1.5 Module Fault NO FAULT WARNING 3.7.2.1.3 Any Warning NO WARN FAULT 3.7.2.2.4 Temperature Fault NO FAULT FAULT 3.7.2.1.1 Any Fault or Warning NO FAULT FAULT Power Supply Module Fault 3.7.2.1.6 NO FAULT Dummy Load 3.7.1.1.6 Antenna/Dummy Load Antenna 3-78 Operation See Section DMAN-14563 Rev. H Ku-Band ModuMAX SSPA The top line shows the output number, and the current function setting for that output. The bottom line allows the function to be changed. Press MODIFY or to step through the list of available output functions, which are presented in alphabetical order. When the function you want is shown, press SEL . Note that you MUST press SEL to change the output function to the one you want, otherwise it will be left unchanged. Using Serial I/O, the output functions for Parallel I/O outputs can be read and controlled using message 17 59. 3.7.3.3.5 Unused Output Control Parallel I/O outputs that are not assigned any function may be independently controlled remotely via Serial I/O. You may switch the contact to either its normally-open or its normally-closed position. These controls only affect outputs that are not assigned to any function. These outputs will default to their normally-open state upon power-up if no control message is issued. Unused output controls are not stored in non-volatile memory. Using Serial I/O, the functions for unused Parallel I/O outputs can be read and controlled using message 18 53. 3.7.3.3.6 Analog Output Adjustment The Parallel I/O interface includes a voltage output that is proportional to the output power in dBm. This voltage is adjusted at the factory to be exactly 0.1 volts/dBm, so a +50 dBm output power would be represented by 5 volts. This output might need to be adjusted if: • It drifts with aging. • A Parallel I/O module is replaced or installed in the field. The gain of the differential amplifier on the board varies from part to part, so you will definitely need to adjust the analog output if you replace or install the module in the field. This adjustment is handled by the microprocessor, and is stored in non-volatile memory after it is complete. This adjustment can only be carried out from the SSPA front panel (or RCP-2000 front panel, if present). To adjust the analog output: 1. Connect a DVM across the analog output terminals on the Parallel I/O module to be adjusted. Position it where you can see it from the front panel. Operation 3-79 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA 2. On the front panel, select Set / Par / AnAdj. This will take you to the Analog Adjust screen for the SSPA Parallel I/O module. (If you want to adjust the analog output on the RCP-2000 Parallel I/O module, press the MENU button to move to the Remote Adjust screen.) At this time, the analog output is controlled by this screen, and does not represent the output power. 3. Press MODIFY or to raise or lower (as necessary) the voltage on the analog output, until the DVM reads 5.00 volts. 4. Press the PREV button . You will exit the Analog Adjust (or Remote Adjust) screen and be back in the Setup Parallel IO menu. At this time, the analog output will again represent output power. 3.7.4 Hardware and Firmware Several functions exist to test the amplifier, get information about the amplifier, or to install and remove optional hardware (such as Parallel I/O). You will probably not use these functions very often. 3.7.4.1 Commands 3.7.4.1.1 Self Test A built-in self-test allows you to check operation of much of the digital hardware and microprocessor circuitry in the amplifier. Running the self test should not disturb the RF path of your amplifier. To run the Self Test from the front panel, select Srvc / Test. The screen will then read “Testing…” for several seconds and then display either “Test Passed!” or “Test Failed”. If any test fails, a fault will be generated. You should go to the Active Faults List menu to determine what failed. To run the Self Test via Serial I/O, simply send the 0B message with no parameters: TX: 02 06 01 0B 0C 03 RX: none (Self test is run) About 5 seconds after sending this command, send a Get Faults (08) or Get Fault Code (16 59) message to see whether any test failed. 3.7.4.1.2 Microprocessor Reset Issuing a microprocessor reset command will reset the Logic Board processor and RF module processors. This will clear any faults being reported, clear all memory, and reload all settings and 3-80 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA calibration information from non-volatile memory. It will not disturb the RF path of the amplifier. Issuing this command will not result in a Spurious Reset fault. Normally, it is not necessary to use the reset function. If you observe unusual behavior of the amplifier’s controls, you can try this to see if the problem goes away. To reset the processor, select Srvc / Reset. The screen will read “Press SELECT to reset Processor”. Press SEL , and the microprocessors will be reset. Press the PREV button if you decide not to do so. To reset the microprocessor via serial I/O, simply send the 04 message with no parameters: TX: 02 06 01 04 05 03 RX: none (microprocessor resets) 3.7.4.2 Information 3.7.4.2.1 Firmware Versions and Mask Number If you call the factory for technical support, they may need to know both the firmware version and mask number to help you. The firmware version identifies what level of firmware is in your amplifier. The mask number identifies any special hardware support, or custom features that may have been installed in your amplifier. To obtain the firmware version and mask information, select Srvc / Ver. Then select LogicBrd, or Modules, or Ethernet. If you select LogicBrd, the screen will show the firmware name, mask number and version number on the top line, and a copyright notice on the bottom line. Similarly, the Ethernet mask and version numbers are obtained by selecting Ethernet. If you select Modules, pressing the or MENU buttons will scroll through the list of modules. The firmware in all modules should be the same. If any are different, record each module’s serial number and version and contact the factory. Using serial I/O, you can obtain the Logic Board version using message 16 57, the Module version using message 16 62, and the Ethernet firmware version using message 16 28. The Logic Board firmware version can also be obtained via the network. For example, to request the logic board firmware version via Serial I/O, send the 16 57 message with no other parameters: TX: 02 07 01 16 57 6E 03 RX: 02 0F 01 16 57 30 30 30 20 31 2E 30 32 DF 03 (Mask 000, version 1.02) Operation 3-81 DMAN-14563 Rev. H 3.7.4.2.2 Ku-Band ModuMAX SSPA Unit Type The unit type is a one-byte code available via Serial I/O that identifies the type of unit you are communicating with. To request the unit type, simply send message 07 with no parameters: TX: 02 06 01 07 08 03 RX: 02 07 01 07 35 3D 03 (Unit type code 35, ModuMAX N+1 Series) The return message will contain the unit type code. Unit type code 35 is assigned to the ModuMAX N+1 Redundant Solid State Power Amplifier family. 3.7.4.2.3 Operation Time Operation Time is a measurement that indicates the cumulative amount of time the amplifier main Logic Board has been powered since final factory test. To obtain Operation Time, select Srvc / Timer. The display consists of four integer values representing days, hours, minutes, and seconds. For example: 67d,13:09:01 represents 67 days, 13 hours, 9 minutes, and 1 second The Serial I/O message to return Operation Time is 16 61. Note that there is no real time clock in the amplifier. The operation time counter is retained in non-volatile memory on the Logic Board. If the Logic Board is replaced, the Operation Time value will change. 3.7.4.2.4 Gain Range To request the gain range of the SSPA, simply send message 16 6B. The return message will contain the gain range of the SSPA in dB. For this product line, the gain range is 20 dB when SMFC is disabled, or 18.8 dB when SMFC is enabled. (See Section 3.7.2.4.) On the front panel, the gain range is displayed to the right of the gain setting on the second line in the Gain control screen (Oper / Gain). 3.7.4.3 Optional Hardware Optional hardware may be installed in your amplifier at any time. When installed, it will automatically be detected by the system, and screens that support the hardware will be added to the menus. 3-82 Operation DMAN-14563 Rev. H 3.7.4.3.1 Ku-Band ModuMAX SSPA Detection of Optional Hardware You can determine whether or not optional hardware is installed in your amplifier from either the front panel or via Serial I/O. From the front panel: To Check For: Do This: Local (SSPA) Parallel I/O or Remote (RCP-2000) Parallel I/O Go into the Service Menu. Use the MENU button to scroll through the choices in the menu. If the choice “Inp” (Inputs) appears, then you have either Local Parallel I/O (parallel board installed in your ModuMAX amplifier), or Remote Parallel I/O (parallel board in an RCP-2000). Enter the Inp Menu. If the first input number listed is not preceded with an “R”, then Local Parallel I/O is installed. Use the MENU button to scroll to the end of the listed inputs. If the last input number is preceded with an “R”, then Remote Parallel I/O is installed. Antenna/Dummy Load Switch Go into the Operate Menu. Use the MENU button to scroll through the choices in the menu. If the choice “AntDL” appears, then you have an Antenna/Dummy Load Switch installed. Two Power Supply Racks Go into the Service Menu. From here, select “PS” (Power Supply). If you see power supply labels "123", then only one power supply rack is connected to your system. If you see power supply labels “A123 B123”, then two power supply racks are connected to the system. You can also retrieve the status of optional hardware via Serial I/O using message 16 5A. Simply send the message with no other parameters: TX: 02 07 01 16 5A 71 03 RX: 02 11 01 16 5A 31 30 30 30 30 30 30 30 2C 38 56 03 In the above example, the first underlined byte, 31, indicates that this amplifier has Parallel I/O installed. The next underlined byte, 38, indicates that the amplifier has 8 modules (whether or not all 8 are plugged in). 3.7.4.3.2 Remove Optional Hardware Optional hardware such as a Parallel I/O board is not required for normal operation. If you wish to remove optional hardware after operating the SSPA with it in place, you must reconfigure the SSPA so it does not expect the hardware. If you do not, the SSPA will report an error since it expects the hardware. To remove an option, first disconnect the physical hardware. Then, select Set / Opts from the menus. The screen will read “Press SEL Operation 3-83 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA to remove:” on the top line, and the bottom line will list hardware that is removable. Press the or MENU buttons to scroll through the list. If there is no removable hardware, the bottom line will read “None”. In order to be removable the option must have been installed at some point, and now must be disconnected. When you press SEL , the indicated hardware will be removed from the amplifier configuration. Any screens associated with the option will no longer appear in the menu structure. The fault may still be reported, but you’ll be able to clear it by pressing FAULT RESET. Removal of options can only be done from the front panel. 3.7.4.4 Reloading Firmware Firmware in the Logic Board or RF modules may be reloaded via the SSPA Serial I/O port. To do so, obtain the loader software from the factory for the new version you wish to load. The loader software requires Windows 3.0 or higher to run. Connect the RS-232 serial port from your computer to the SSPA serial port, and follow the instructions provided with the loader to start the reload process. 3.7.5 Security The menus and Serial I/O protocol allow several mechanisms to restrict access to the system controls. If your amplifier site is unmanned, you may wish to lockout control via the menus, so that someone cannot wander in and change anything. If you are an operator working at the site, you may wish to disable remote control of the system while you are working on it. The security mechanisms are: • Control Mode: The control mode determines whether Local controls (the front panel), Remote Control (Serial and Parallel I/O), or both are able to control the amplifier. • Local Lockout: A Serial I/O command can lockout the front panel from changing anything. At your discretion, the operator can bypass Local Lockout with a password, or not. • Screen password: You can program a password that the operator MUST enter if he intends to change anything from the front panel. These controls and settings can be used individually, or combined to produce whatever level of security you wish on changes to the controls and settings of the amplifier. 3-84 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA 3.7.5.1 Controls 3.7.5.1.1 Control Mode The control mode can only be changed from the front panel. It controls whether or not Remote Control of the amplifier is possible. The front panel is considered “Local” control, and Serial and Parallel I/O are both considered “Remote” control. Note Do not confuse the Remote Control mode described here, which involves controlling the SSPA “remotely” via Serial I/O or Parallel I/O, and the use of an optional RCP-2000 Remote Control Panel. Front panel controls on the RCP-2000 are also considered “local” controls in this sense. The control mode can be set for one of three states: Note: • Remote: Serial and Parallel I/O can control the amplifier system. Local control is also possible, unless either Remote Disables Local is set to YES, or Serial I/O issues a Local Lockout command. • Local: Serial and Parallel I/O cannot control the amplifier system. Serial I/O can still request information, and the Parallel I/O outputs (Form ‘C’ and analog output) still function. Only the Parallel I/O RF Inhibit inputs can shut the amplifier off. Local controls function normally. In Local Mode, any parallel I/O inputs that are programmed to generate a fault will do so if asserted. • Maintenance: Nothing changes on the amplifier unless directly commanded from the front panel. However, if a fault condition such as Thermal Shutdown or Overcurrent Shutdown occurs, or an RF Inhibit occurs, the amplifier will be muted. If the amplifier is off due to RF Inhibit, it will not turn on again if RF Inhibit goes inactive (see Section 3.7.1.1.3). Faults are not reported on Parallel I/O; likewise, Serial I/O Service Request will not report a fault. Serial I/O can still request information, and the non-fault Parallel I/O outputs will still function. To change the control mode, select Oper / Ctrl. The top line shows the current control mode setting, and the bottom line allows the mode to be changed. Pressing MODIFY and will toggle between Remote and Local, but the only way to enter Maintenance Mode is to move the selection to Maint with the MENU button, and then press SEL . Although Control Mode can only be changed from the front panel, you can obtain the Control Mode setting using Serial I/O message 20. Operation 3-85 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA 3.7.5.1.1.1 Maintenance Mode Warning In many installations, the amplifier is normally operated in Remote mode so it can be monitored and controlled by an M&C system. In this situation, it is undesirable to leave the amplifier in either Maintenance Mode or Local mode, as it will prevent remote control. This could happen, for example, if service personnel change the control mode from the front panel and then do not restore it to Remote mode. For this reason, the amplifier will generate a Maintenance Mode warning as long as it is in Maintenance Mode. The front panel Warning indicator will therefore be lit, reminding the operator to return the amplifier to Remote mode. 3.7.5.1.1.2 Local Mode Warning In a similar way, the Local Mode warning can help prevent leaving the amplifier in Local Mode. When Local Mode warning is enabled in the Setup menu, a warning will be generated when the amplifier is in Local Mode. The front panel Warning indicator will therefore be lit, reminding the operator to return the amplifier to Remote mode. 3.7.5.1.1.3 Screen “Flash” Messages There are some messages which will appear on the display for a few seconds if you try to execute a function that is currently not allowed. These are referred to as “flash” messages. Three of these may appear in a system whether or not it has an RCP-2000 Remote Control Panel installed: 3-86 Operation • The ***REMOTE*** flash message will appear if you try to change a setting or control from the front panel while the SSPA is in Remote Mode and Remote Disables Local is set to Yes. You will not be able to change controls or settings from the front panel while this is the case. The one exception is the Control Mode. You can change Control Mode to Local (using Oper / Ctl /Local), which will re-enable all front panel functions. See Section 3.7.5.2.3 for more information. • The **LOCAL LOCKOUT** flash message will appear if you try to change a setting or control from the front panel while the front panel has been disabled using the Serial I/O Local Lockout message. You will not be able to change control mode from the front panel while this is the case. See Section 3.7.5.1.2 for more information. • The ***PASSWORD*** flash message will appear if you try to change a setting or control from the front panel while the front panel is locked using a screen password. You will not be able DMAN-14563 Rev. H Ku-Band ModuMAX SSPA to change control mode from the front panel while this is the case. See Section 3.7.5.2.1 for more information. Two other flash messages will only appear if you are using an RCP-2000 Remote Control Panel with your system: 3.7.5.1.2 • The RCP CAN'T SET MAINT flash message will appear if you try to change to Maintenance Mode from the front panel of an RCP-2000 Remote Control Panel. This is not permitted. • The ***MAINT MODE*** flash message will appear if you try to change a setting or control from the front panel of an RCP2000 Remote Control Panel while the SSPA is in Maintenance Mode. This is not permitted. Local Lockout The front panel of the amplifier may be locked out remotely using the Local Lockout command. The Local Lockout command may be issued only if the amplifier is in Remote Mode. When enabled, Local Lockout prevents an operator at the site from changing anything. They may still navigate through the menu screens and view settings and measurements. However, any attempt to edit or change anything with the front panel controls results in the flash message **LOCAL LOCKOUT** temporarily being displayed on the bottom line. If you have set up a screen password, the operator may regain control of the system by entering the password in the Unlock screen. However, if the screen password is 0 0 0 0 0 0, no menu screen exists that will allow local control of the amplifier. In this case, a Serial I/O message must be issued to turn off Local Lockout. Using the password only temporarily bypasses Local Lockout. As soon as you return to the default screen, Local Lockout will again be active. Powering the amplifier off and on or resetting the CPU via Serial I/O will turn off Local Lockout. To control Local Lockout via Serial I/O, use message 0E. To request the current Local Lockout setting, send the message with no parameters: TX: 02 06 01 0E 0F 03 RX: 02 07 01 0E 30 3F 03 (30 = Local Lockout is currently OFF) To turn ON Local Lockout, send message 0E with a 31 data byte parameter: TX: 02 07 01 0E 31 40 03 RX: none (Local Lockout is now turned on, if in Remote Mode) Operation 3-87 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA To turn OFF Local Lockout, send message 0E with a 30 data byte parameter: TX: 02 07 01 0E 30 40 03 RX: none (Local Lockout is now turned off, if in Remote Mode) 3.7.5.1.3 Unlock The Unlock choice appears in the first position of the Main Menu if one of the following occurs: • A screen password is enabled. • A Serial I/O Local Lockout command is issued. The Unlock screen allows an operator at the front panel to regain control of the amplifier if he knows the password. The password is a six-digit number. Note If you lose your password, write down the six-digit number that is shown when you first enter the Unlock screen, and contact the factory for assistance. To unlock the screens, select Unlock from the Main Menu. The screen will show a random six-digit number on the bottom line. The or MENU buttons allow each of the six digits to be selected separately. Pressing MODIFY or will change the selected digit. Change all six numbers to match the preset password. Once the entire password is entered, press PREV once to get back to the Main Menu. Do not press PREV from the main menu, as it will cancel the password you entered, and you must start over again. If the Unlock choice is now gone from the Main Menu, then you have entered the correct password, and may navigate from the Main Menu to whatever settings you need to change. Once you are finished, simply press PREV enough times to get back to the default screen, and the front panel will be re-locked. If you do not use any front panel control for about 5 minutes, the timeout function will also return you to the default screen, and relock the menus. 3.7.5.2 Settings 3.7.5.2.1 Screen Password Enable You can set a screen password for more complete protection from changes through the front panel menus. In order to enable a screen password, you must set the password for something other than 0 0 0 0 0 0. 3-88 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA To enable or disable a password, select Set / Pass. The top line will show whether the password is Enabled or Disabled. The bottom line allows control of the setting. The bottom line also gives access to the Set Menu, where you can choose your screen password. If you attempt to Enable a screen password while the password is set to 0 0 0 0 0 0, nothing will happen. In this case, select the Set menu choice, and program a password in that screen. If, after enabling a screen password, you change the password to 0 0 0 0 0 0, the screen password setting will revert to Disabled. Once enabled, the screens will be locked, until someone enters the correct password in the Unlock screen. While locked, an operator can view any setting or measurement. However, attempts to change any setting are blocked, and result in the flash message ***PASSWORD*** being shown on the screen. When the screen password is enabled, you will have to enter the correct password in the Unlock screen every time you go to use the menus to change anything. Note that you have to set a password (i.e., not 0 0 0 0 0 0), but you do not have to enable the password, in order to use the password to temporarily override Local Lockout. The screen password cannot be enabled, disabled, or set via Serial I/O. 3.7.5.2.2 Screen Password Set You may set a password that allows you to gain access to the menus in two situations: • The Serial I/O Local Lockout command has been issued. • A screen password is enabled. If the screen password is set to 0 0 0 0 0 0, there will be no local control method to bypass Local Lockout, and the screen password will be automatically disabled. To set a screen password, select Set / Pass / Set. The current password will be shown as a six-digit number. The or MENU buttons allow you to select any of the six digits, and the MODIFY and buttons allow you to change the selected digit. If you enter this screen while the screens are locked (either due to Local Lockout, or to a screen password being Enabled) the password will appear as X X X X X X, and will not be editable. Set the six digits to your desired password, and then decide how you want to use the password: Operation 3-89 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA • If you just wish to have a way to temporarily override Local Lockout, press PREV and make sure that the Screen password setting is DISABLED. • If you wish to have the operator enter a password any time he is going to change anything, press PREV , and make sure that the Screen password setting is ENABLED. A screen password cannot be enabled, disabled, or set via Serial I/O. See Section 3.7.5.1.3 for information on what to do if you lose your password. 3.7.5.2.3 “Remote Disables Local” Setting You can set the amplifier so that the local controls do not function while the amplifier is in Remote Mode. This is called “Remote Disables Local”. If this setting is ON (set to “YES”), the operator may not change anything from the front panel without first setting the amplifier to Local Mode. To turn this setting on or off, select Set / R/L. The top line shows whether the setting is ON or OFF (“YES” or “NO”). The bottom line allows the setting to be changed. Pressing MODIFY or will toggle the setting. If you turn on Remote Disables Local while the amplifier is in Remote Mode, you will immediately lose the ability to change anything from the front panel. You must return to the Control Mode setting in the Operate Menu, and set Local Mode, before you can do anything else. Attempts to edit anything while this setting is ON and the amplifier is in Remote Mode will result in the flash message *** REMOTE *** being displayed for a few seconds. You can read and control the setting of Remote Disables Local using Serial I/O message 17 5F. 3-90 Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Section 4 4.1 Theory of Operation General Introduction To understand how the VertexRSI Ku-Band ModuMAX SSPA works, use the information contained in this section. The description is organized by major subassemblies, with the first section describing the overall system and the interconnection between major assemblies. 4.2 • To understand the theory from the top level, see System Level Description, Section 4.2. • To understand the operation of the Power Supply, see Power Supply Description, Section 4.3. • To understand the operation of the SSPA, see SSPA Description, Section 4.4. System Level Description For help in understanding the following description, refer to the system schematic diagram, drawing 14508, in Section 6, Drawings. The SSPA system includes a Power Supply, an SSPA, and interconnecting cables. The Power Supply converts single-phase or 3-phase AC voltage to 11.5 Vdc for use by the SSPA. #1/0 or #2/0 AWG DC power cables capable of carrying the high current connect the Power Supply output to J3 on the SSPA. The Power Supply remotely senses the SSPA input voltage so that it can adjust its output to generate a constant voltage at the SSPA input. A separate cable connects a set of relay contacts from the Power Supply to the SSPA logic. If one of the Power Supply plug-in modules fails, the contacts will de-energize, alerting the SSPA and generating a fault. If you use two Power Supplies to power the SSPA, each connected to a separate 180-264 Vac power bus, you can gain protection against failure of one power bus. In this case, an additional cable interconnects the two power supplies to ensure current sharing and synchronization. Theory of Operation 4-1 DMAN-14563 Rev. H 4.3 Ku-Band ModuMAX SSPA Power Supply Description The Power Supply consists of a shelf populated by three plug-in modules. The outputs from each module are diode-OR’ed together, which protects the 11 Vdc bus from interruption if one module fails. The SSPA will operate properly if only two of the three plugin modules are functioning. Each plug-in module has a circuit breaker on its front panel. It also has a cam-lock handle for installation and removal. If you forget to shut down a module before attempting to remove it, the mechanical construction of the front panel trips the circuit breaker off when you begin to pull it out. The modules have highcurrent, low-insertion-force connectors in the back that mate with the shelf. Each module is cooled by a fan behind its front panel. The fan takes air in at the front, blows it over the components, and exhausts it out the rear. AC power is connected to the 3-phase line filter mounted on the Power Supply’s rear panel. This filter keeps conducted emissions off the facility’s ac power lines. A set of configuration jumpers located behind the line filter allow the installer to set up the power supply for single-phase, 3-phase delta, or 3-phase wye operation. Schematic 14508 in Section 6, Drawings, shows all types of connections. The plug-in modules are high-efficiency switching power supplies. Each one has a voltage adjust and output current meter on its front panel. All module output voltages should be trimmed within 0.1 Vdc of each other to ensure proper current sharing. If the output voltages are different, the total power supply output will track the lowest voltage. The Power Supply modules are hot-swappable, which means any module can be removed from the shelf without disrupting the output voltage. 4.4 SSPA Description Refer to schematic 13538 in Section 6 to follow the discussion of the SSPA. The SSPA consists of an RF path to amplify the Ku-Band signal, a forced-convection cooling system to maintain reliable device operating temperatures, a power-distribution system, and a logic system to control and monitor the system components. These systems are described in more detail in the following sections. 4-2 Theory of Operation DMAN-14563 Rev. H 4.4.1 4.4.1.1 Ku-Band ModuMAX SSPA RF Path Overview RF input applied to J1 is routed through isolator HY1 through coupler CP1, whose coupled output appears at the RF Input sample port on the front panel. A coaxial isolator, HY2, improves VSWR at the sample port. If the SSPA is intended for use in a phase-combined system with another SSPA, phase trimmer Z9 allows adjustment of the SSPA electrical length. A power splitter network, PD1-PD3, splits the RF signal eight ways and routes each output to one of the RF modules. Phase trimmers Z1-Z8 in the eight paths allow electrical length adjustment of each path for maximum combining efficiency. The eight plug-in RF modules, A1-A8, perform the RF amplification. Each module has approximately 75 dB gain. Module output power capability depends on the SSPA rated power. See Table 4-1 for module power levels corresponding to SSPA rated power. Table 4-1 Module Power SSPA Rated Power Module Rated Power 500 Watt 140 Watt 350 Watt 100 Watt The output waveguide flanges of the eight SSPA modules butt directly against an 8-way waveguide combiner, PD4, which uses magic-T junctions. R2 terminates the isolated port of the final combiner stage. The combined output is routed through sampler CP2, whose output is split by PD5. One splitter output drives the RF Output sample port on the front panel through coaxial isolator HY4. The other output drives detector module A9. A high-power waveguide circulator, HY3, provides protection against total reflected power. R1, the 500-watt circulator termination, is capable of dissipating full reflected power of a 500 watt SSPA. Detector module A10, connected to sampler CP3, measures any power reflected back from the output. 4.4.1.2 SSPA Modules The plug-in SSPA modules provide all the RF gain in the SSPA system. They have SMA Female RF input connectors, and WR75G waveguide output flanges. Each module includes a microprocessor to control its functions and communicate with the system logic. Each module has 75 dB maximum gain. When you adjust SSPA gain from the front panel, a PIN-diode attenuator inside each module adjusts all module gains simultaneously over a 20 dB range. Theory of Operation 4-3 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Each module’s electrical length has been matched to a standard so that a spare SSPA module can be substituted into any position with minimal effect on combining efficiency. Each SSPA module can measure its internal temperature, input voltage, gate voltage, total current, and output power. Newer models can also measure regulated voltage. These measurements are available on the SSPA front panel. The temperature sensor inside the module controls the PIN-diode attenuator to perform temperature compensation of gain. This sensor also shuts down the module if it gets too hot (> 95 °C). If an over-temperature shutdown occurs, the module will automatically restart when the temperature decreases to 90 °C. The module stores its own temperature compensation calibration data. A/D converters in the microprocessor measure the input voltage and gate voltage. A current-sensing circuit measures the total module current. A detector built in to each module measures its own output power. The SSPA module is built from GaAs MESFETs. Two or four devices are combined in the final stage of each module to produce the module’s rated power. To keep junction temperatures as low as possible, the higher-power modules are mounted on bonded-fin heat sinks that incorporate heat pipes to dissipate the heat generated by the FETs. A sheet-metal enclosure around the module protects the heat sinks from damage, and prevents accidental operator contact with the power supply input pin. Power pins on the module rear panel mate with sockets on the bus bar system to pick up the +11 Vdc bus. The power pins float to accommodate mechanical tolerance build-up. Each module is internally fused to protect the bus in case of a module short circuit. Data from the logic system enters the module through a 4-pin combination D-connector pair. A guide pin and socket built into these connectors assures reliable alignment. The chassis half of this pair is float-mounted. Pins 1 and 3 of this connector are connected together on the chassis half. When the module is installed, these pins allow the module to un-mute itself. If you forget to turn off the module before removing it from the chassis, the module will mute itself before the power pins disengage, preventing arcing. The waveguide output flange on the module presses against a vertical partition inside the chassis, which is mounted directly to the combiner. Guide pins installed in two of the SSPA module’s waveguide mounting holes align the module as you insert it into the chassis. A conductive flat gasket on the module waveguide output provides good contact around the flange. The two long hold-down bolts screw into the vertical partition, providing a secure connection at the waveguide flanges. 4-4 Theory of Operation DMAN-14563 Rev. H 4.4.1.3 Ku-Band ModuMAX SSPA Combining Theory ModuMAX N+1 SSPAs use phase combining, a technique where the outputs from multiple amplifier modules are combined in equal magnitude and phase to generate high output power. This series of SSPAs uses eight modules. For efficient power combining, the phase difference between each path must be minimized. To operate effectively over the entire uplink bandwidth, the insertion gain and electrical delay through each path must be equal. If they are not, excessive insertion loss will occur at the combiner, causing a drop in combining efficiency and total output power. To achieve these requirements, each of the eight SSPA module paths is made equal in delay, and phase trimmers in each path allow fine adjustment by the operator. All plug-in SSPA modules are set to the same nominal gain and insertion phase at the factory. This guarantees that a failed module can be field-replaced with a spare at any time, and the spare will combine efficiently with the other modules in the chassis. Figures 4-1 and 4-2 show that, with closely matched amplitudes between SSPA modules, the excess insertion loss through the combiner greatly depends on phase match between modules. Figure 4-1 shows a wide range of amplitude imbalance between modules; Figure 4-2 is a close-up view of the first few dB of amplitude imbalance. To achieve less than 0.1 dB of excess insertion loss through the combiner, the phase mismatch must be less than 15° with an amplitude imbalance less than 1.4 dB. There is a trade-off, of course; a greater amplitude imbalance requires a smaller phase imbalance to achieve the same insertion loss. Figures 4-1 and 4-2 demonstrate the results of a single combining stage, where two modules are combined. Figure 4-1 shows that, when the amplitude imbalance is very large, corresponding to one module out of two failing, the excess insertion loss is 3 dB. This means that the total output power is 3 dB less than the output power of the remaining functional module, or 6 dB less than the original power generated when both modules were functional. So, a failure of one module out of two causes an output power reduction of 6 dB. Combining more than two modules mitigates the drop in output power caused by a single module failure. In general, for an efficient phase-combined system of n modules, the output power drop caused by one module failure is described by the following equation: ( ) ⎡ Loss in dB = 10 log ⎢ ⎣⎢ 1- 1n 2 ⎤ ⎥ ⎦⎥ Theory of Operation 4-5 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Figure 4-1. Combining Loss vs. Amplitude and Phase Imbalance (0-40 dB) Figure 4-2. Combining Loss vs. Amplitude and Phase Imbalance (0-4 dB) 4-6 Theory of Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Table 4-2 tabulates the effect of a module failure for various numbers of combined modules: Table 4-2 Power Loss # of modules Pout drop with 1 module failure 2 6 dB 4 2.5 dB 8 1.2 dB 16 0.6 dB Table 4-2 shows that combining more modules reduces the effect of a single module failure, producing a more fault-tolerant system. The ModuMAX SSPAs combine eight modules, so a single module failure causes the SSPA output power to decrease only by about 1.2 dB. This is within the acceptable margin of most links. Removing a module from the SSPA open-circuits one of the waveguide combiner ports. The combiner has approximately 30 dB port-to-port isolation, so up to +20 dBm of power could appear at this open port when an SSPA is operating at full power. To prevent human exposure to this level, a hinged metal door drops down into the vacant cavity. This door is lined with absorber, and reduces the amount of RF to a level that is safe for continuous exposure. This door also assists the cooling system, as described in Section 4.4.2 below. 4.4.1.4 Detector Module The SSPA contains two detector modules, one to measure forward power, and one for reflected power. These detectors are based on Schottky diodes, which are envelope detectors. As such, they can give erroneous results compared to a thermal-based sensor such as a power meter when the detected RF signal includes multiple tones, or modulation. Do not interpret the SSPA’s displayed forward or reflected power as the actual total power when operating with multiple carriers or modulated signals. The detectors have approximately 32 dB of dynamic range, capable of displaying power reasonably accurately from 2 dB greater than rated power to 20 dB below rated power. Below this point, the detectors lose resolution and accuracy. The detector’s video output voltage is converted to a digital word and sent to the SSPA’s Logic Board. At low power levels, the A/D step size becomes significant compared to the power being measured, so accuracy degrades below about 20 dB below rated power. Theory of Operation 4-7 DMAN-14563 Rev. H 4.4.2 Ku-Band ModuMAX SSPA Cooling System The SSPA contains eight reverse-curved impeller fans to cool the active components. Four fans, B1-B4, on the rear panel intake air and force it through the modules’ heatsinks. In front of the SSPA modules, the air turns downward through 180° and enters an exhaust plenum, where four more fans, B5-B8, move it to the exhaust port on the rear panel. The air can intake and exhaust into the room, or be ducted from an outside location. The SSPA can operate indefinitely with any one of the fans failed. For maximum reliability, however, you should replace any defective fan as soon as possible. When an SSPA module has been removed, a hinged door closes off the vacant cavity. Without this door, the available air would flow through this low-resistance path, robbing the other modules of cooling air and causing them to overheat. The SSPA can operate indefinitely with a missing module without overheating. PC boards attached to each fan convert the 11 Vdc bus voltage to approximately 28 Vdc to run the fans. Each fan has a built-in tachometer output that sends two pulses per revolution to the Logic Board, which monitors the fan speed to detect fan faults. 4.4.3 Power Distribution System The SSPA operates solely from the 11.5 Vdc generated by the Power Supply. The incoming dc voltage enters the SSPA through a pair of bus bars at the rear panel. Once inside, heavy wires route some of the current to the SSPA Motherboard, which distributes power to the logic system and the fans. A bus bar system inside the SSPA routes most of the current to the SSPA modules. 4.4.3.1 Bus Bar System The SSPA operates on a low-voltage (11.5 Vdc) bus, but at high current (up to 450 A for the 500 Watt ModuMAX SSPA). The SSPA therefore includes a robust bus bar system for power distribution to minimize voltage drops. Low-insertion force sockets on the bus bars mate with the power pins on the SSPA modules. Each pin/socket connection is capable of handling 100 A with minimal voltage drop. Since the highestcurrent module in the ModuMAX series consumes 55 A, the design includes a safety factor of almost 2. The internal bus bars are nickel-plated to inhibit corrosion, and are insulated everywhere possible to minimize risk of a short circuit. 4-8 Theory of Operation DMAN-14563 Rev. H 4.4.3.2 Ku-Band ModuMAX SSPA Motherboard The Motherboard, mounted under the chassis top cover, distributes power to all other SSPA components except the SSPA modules, and connects signals between all components of the amplifier. It also provides connectors into which the Logic Board, Parallel I/O board, and Expansion board slide. The Motherboard is the one component of the SSPA that cannot easily be accessed for service without taking the SSPA off-line. For this reason, it is designed with very few components, and the components used are very simple. It is highly unlikely that you will ever need to access the Motherboard. Resettable fuses on the Motherboard protect the 11 Vdc bus from short circuits in other components. In case of a short or faulted component, the fuses reduce current to a safe level. Once a fault goes away, the fuses reset within a minute or two. Motherboard connections to the Logic Board, Parallel I/O board, and Expansion Board slot are made with gold-plated DIN connectors. These connectors are used in many industrial control computers, as they provide reliable, gas-tight connections. 4.4.4 Logic System The Logic System consists of the Logic Board, Front Panel, Parallel I/O Board, and Ethernet board. 4.4.4.1 Logic Board The Logic Board performs the primary monitoring and control functions of the amplifier. Its main functions are as follows: • It communicates with the RF modules to control them and report measurements they make and faults they have detected. • It monitors supply voltages and fan speeds. • It monitors the forward and reflected power detectors. • It stores non-volatile configuration data and an Event Log. • It communicates with the Front Panel to report status and accept commands. • It communicates with the Parallel I/O board to read its inputs and controls its outputs. • It provides a Serial I/O interface to remotely monitor and control the SSPA. The core of the Logic Board is a microcontroller chip. Most of the support logic for the microcontroller is implemented in a programmable logic device (PLD). Firmware for the microcontroller, as well as the PLD, is stored in FLASH memory, which can be reprogrammed on the board. Theory of Operation 4-9 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA The combination of FLASH memory and a PLD means the Logic Board can easily be reprogrammed via its Serial I/O port. Upgrades and firmware corrections can usually be done in the field, without opening the chassis or disturbing RF operation of the SSPA. The Logic Board contains power-on circuitry that limits inrush current to a very low value. This allows the board to be inserted into an operating SSPA with no effect on the RF signal path. The Logic Board can be removed from the SSPA without affecting RF operation. Fault detection will be seriously impaired without the Logic Board, but the individual RF modules can still perform temperature compensation of their gain and can shut down in case of over-temperature, over-current, or other serious problem. 4.4.4.2 Front Panel The Front Panel assembly provides the user interface. It includes a text display, control buttons, indicator lamps, and an audible alarm beeper. The communication interface between the SSPA Logic Board and Front Panel is a synchronous serial link controlled by the Logic Board. As long as Front Panel power is present, fault detection circuitry will light the red FAULT lamp if it receives no communications from the Logic Board for approximately 1 second. Front Panel logic is mostly implemented in a programmable logic device (PLD). At power-up, or when a Front Panel is plugged into the SSPA, the SSPA Logic Board sends a program to the PLD, defining its operation. From that point on, the Logic Board can send serial messages to the PLD, controlling the display and lamps, querying the pushbuttons, and driving the audible alarm beeper. Because the PLD program is transferred from the main Logic Board, revisions to Front Panel logic can be done in the field, without opening the chassis or disturbing RF operation of the SSPA. The Front Panel contains power-on circuitry that limits inrush current to a very low value. This allows the board to be inserted into an operating SSPA with no effect on the RF signal path or logic. The Front Panel can be removed from the SSPA without affecting RF or Remote Control operation. 4.4.4.3 Parallel I/O Board The Parallel I/O board adds opto-isolated inputs, relay outputs, and an analog voltage output to the SSPA. The inputs can control 4-10 Theory of Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA features of the SSPA, and the outputs can indicate status of various SSPA features. The inputs and outputs can also be read and controlled by Serial I/O, to implement user-specific functions. The analog voltage output is scaled to represent SSPA output power. The communication interface between the SSPA Logic Board and Parallel I/O board is a synchronous serial link controlled by the Logic Board. Fault detection circuitry will return all relay outputs to their faulted (de-energized) state if the Parallel I/O board receives no communications from the Logic Board for approximately 1 second. Parallel I/O board logic is mostly implemented in a programmable logic device (PLD). At power-up, or when a Parallel I/O board is plugged into the SSPA, the SSPA Logic Board sends a program to the PLD, defining its operation. From that point on, the Logic Board can send serial messages to the PLD, querying the Parallel input status, or controlling the Parallel output relays. Because the PLD program is transferred from the main Logic Board, revisions to Parallel I/O logic can be done in the field, without opening the chassis or disturbing RF operation of the SSPA. Parallel I/O inputs are opto-isolated. They are digitally filtered by the PLD to avoid false input activation caused by noise glitches. Parallel I/O outputs use solid-state relays, which are more reliable than conventional reed relays. For most applications, the solidstate relays work just like reed relays. Note that relay onresistance is somewhat higher than conventional reed relays; relay off-resistance may be less than conventional reed relays; and leakage current may be higher than reed relays. These effects are of little concern to most users, as they are mainly seen when solid state relays are operated near their upper voltage and current limits. The Analog Output is created by a 12-bit digital-to-analog converter and buffered by a differential line driver. The Parallel I/O board contains power-on circuitry that limits inrush current to a very low value. This allows the board to be inserted into an operating SSPA with no effect on the RF signal path or logic. The Parallel I/O board can be removed from the SSPA without affecting RF operation. 4.4.4.4 Ethernet Board The Ethernet Board provides a network port that allows the user to control and monitor the unit using SNMP or HTTP protocol. It Theory of Operation 4-11 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA uses a Rabbit microprocessor core module to facilitate conversion between the Logic Board and the user Ethernet port. The Ethernet Board can be removed from the SSPA without affecting RF operation. A NIC fault will be reported in this case. 4-12 Theory of Operation DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Section 5 5.1 Maintenance General Introduction To maintain, repair or verify performance of the VertexRSI KuBand ModuMAX SSPA, use the information contained in this section. 5.2 • For a list of test equipment and accessories required for maintenance, see Recommended Equipment, Section 5.2. • Preventive Maintenance Procedures are in Section 5.3. Follow these regularly to keep the equipment in peak operating condition. • Instructions for alignment and adjustments are in Adjustments, Section 5.4. • To verify that the equipment is operating properly, see Performance Verification, Section 5.5. • To determine the cause of a particular problem, see Troubleshooting, Section 5.6. • For instructions on repairing the SSPA, see Assembly Replacement, Section 5.7. Recommended Equipment Equipment recommended for use during maintenance and alignment procedures is listed below. Alternate items may be substituted if a listed item is unavailable. • • • • • • • 5.3 35 dB WR75 cross-guide coupler 500 W WR75 termination Scalar network analyzer with appropriate detectors and bridge Digital multimeter (DMM) Signal generator Power meter and sensor Screwdriver, 1/8" flat blade Preventive Maintenance Procedures The following procedures keep the equipment in top working order and should be performed at least every 12 months, except for fan replacement, which should be done every 5 years. It is recommended that a log be kept. Maintenance 5-1 DMAN-14563 Rev. H 5.3.1 Ku-Band ModuMAX SSPA Power Supply Module Cleaning The cooling fans and grills on the Power Supply plug-in modules can become clogged by dirt and should be cleaned periodically. Because the Power Supply modules are hot-swappable and redundant, they can be cleaned one at a time without taking the equipment out of service. The SSPA system requires two of the three Power Supply modules to be on simultaneously to operate properly. When removing Power Supply modules for cleaning, take care to avoid turning off more than one module at a time. Note 1. Make sure all modules are turned on and functioning. 2. Turn off the circuit breaker on one of the modules and release its locking mechanism to remove it from the Power Supply shelf. 3. Inspect the plug-in module’s fan and grills for accumulation of dirt, and clean it. 4. Slide the module back into the shelf and secure it with its locking mechanism. 5. Turn on the circuit breaker. 6. Repeat the process with each of the other modules in turn. 5.3.2 SSPA Module Cleaning Like those on the Power Supply modules, cooling fins on the SSPA modules can become clogged and require cleaning. SSPA modules are hot-swappable and redundant, and can be cleaned without taking the SSPA system out of service. 1. Remove the SSPA front panel by loosening its captive fasteners. 2. Select Oper / Mod from the menu, then press SEL to disable Module 1. The LED on Module 1 (top left) will turn amber. 3. Disconnect the flexible RF input cable from Module 1 with a 5/16" open-end wrench. Push the cable out of the way so it won’t be damaged when you remove the module. 4. Loosen the two module hold-down bolts on the top and bottom of Module 1 with a ½" nut driver. 5. Make sure the flexible RF input cable is out of the way, and pull on the plug-in module’s handle to slide the module out. 6. Examine the heatsink fins. If they are dirty, remove the module and heatsink covers by removing the six flat-head screws that secure the module cover. Then remove the eight sets of panhead hardware that secure the heatsink cover to the front and 5-2 Maintenance DMAN-14563 Rev. H Ku-Band ModuMAX SSPA rear module panels, and remove the heatsink cover. Clean the accumulated dirt off the heatsink fins, then replace the covers. 7. Re-install the heatsink and module covers using the hardware removed in the previous step. 8. Slide the SSPA module back into its slot. Do not pinch the flexible RF input cable. Make sure it seats firmly, and that its front panel is flush with adjacent ones. 9. Tighten the two module hold-down bolts with a ½" nut driver. Tighten to 8 in-lb (90 N-cm). This is finger-tight; do not overtighten. 10. Re-connect the flexible RF input cable to the module input with a 5/16" wrench. Tighten to 8 in-lb (90 N-cm). 11. Select Oper / Mod from the menu, then press SEL to enable Module 1. The LED on Module 1 (top left) will turn green. 12. Repeat the cleaning process with each of the other modules. 5.3.3 Air Cooling System Maintenance For maximum SSPA system life, keep the SSPA air cooling system clean and free of obstructions. The intake fans on the rear panel and the exhaust fans in the bottom of the SSPA must all be serviced. As fans age, their bearings eventually wear out, and the fans must be replaced. • SSPA rear intake fans – Clean the finger guards on the rear intake fans periodically to keep them clean. If dirt has entered the fan assembly, remove and clean it. To do so, shut the fan off using its switch. Wait for it to spin down. Remove the four captive panel fasteners on the corners and slide it out. Disconnect the 4-pin Molex connector at the end of the fan assembly’s cable. Clean the impeller blades and motor housing. Re-install the fan and switch it on. Repeat for the other fans. • SSPA exhaust fans – The exhaust fan assembly is accessed by removing the SSPA front cover. Clean the finger guards periodically. If dirt has entered the fan assembly, remove it and clean the fans. To do so, disconnect the two 6-pin Molex connectors at the front of the fan assembly. Loosen the two captive fasteners on the bottom of the fan assembly, then slide it out. If the fans are dirty, remove each assembly by disconnecting the Molex connectors going to it, then loosening the four captive fasteners that hold each one to the top and bottom of the enclosure. Clean the impeller blades and motor housing. Re-install by reversing the removal procedure. • SSPA fan replacement – Fan bearings eventually wear out. To prevent unexpected fan failure, replace the eight fan assemblies in the SSPA every five years. Maintenance 5-3 DMAN-14563 Rev. H 5.3.4 Ku-Band ModuMAX SSPA DC Power Cable Maintenance The high-current power cables connecting the Power Supply to the SSPA are critical links in the power transfer chain. If loose connections develop in the power cable system, heat will be generated at the loose joints, and the SSPA may be starved of power. Periodically check the bus voltages at the points listed in Table 51. The SSPA Module Vin measurements are made through the menu by selecting Srvc / Mod / V. If voltage drops are higher than expected, disconnect the cable at any suspect point, then reconnect it. Use a new lock washer when re-working the connection, and tighten to the recommended torque given in Section 2.5.3. Table 5-1 Voltage measurement 5.3.5 Bus Voltages Expected value Power Supply output bus bars +11.8 Vdc maximum SSPA 11.5 Vdc input bus bars +11.5 +/- 0.05 Vdc SSPA module Vin +10.5 Vdc minimum Adjustments Check and adjust the power supply voltages and output power measurement using the procedures in Section 5.4. 5.4 Adjustment Procedures The following adjustment procedures are contained in this section: WARNING 5.4.1 • Power Supply Voltage Adjustment, Section 5.4.1 • Output Power Measurement Adjustment, Section 5.4.2 • Analog Output Adjustment, Section 5.4.3 Adjustments described in this section are performed with power applied. Always be careful not to come into contact with dangerous voltages while performing these procedures and never work alone. Power Supply Voltage Adjustments The Ku-Band ModuMAX SSPA system’s Power Supply contains three plug-in units. Their output voltages should be checked every 12 months. Set the Power Supply output voltages as follows: 1. Set the DMM to measure voltage. 5-4 Maintenance DMAN-14563 Rev. H Ku-Band ModuMAX SSPA 2. In turn, plug the DMM test leads into the VREF test points on the front panel of each of the power supply plug-in modules and record the three voltage readings. 3. If all three power supply module voltages are within a 0.004 V (4 mV) window, proceed to step 4 below. Otherwise, use a small flat-blade screwdriver to adjust the recessed VADJ pot on the two plug-in modules with the lowest voltages to match their VREF measurements (to within 4 mV) with that of the highest voltage module. 4. Measure the voltage at the SSPA’s 11.5 Vdc bus bar inputs on the rear panel (J3). If the voltage is 11.5 +/- 0.05 V, the power supply is adjusted properly; skip the remaining steps. 5. Calculate the difference between 11.5 V and the actual measured voltage at the SSPA bus bar inputs. This difference is the amount by which each plug-in module must be adjusted. Divide the difference by 10 to calculate how much each module’s VREF must be changed, and add or subtract that amount to the original VREF measured in step 2. For example: If the measured SSPA bus bar voltage is 11.3 V, it needs to be increased by 0.2 V. Therefore, the VREF of all three modules needs to increase by 0.02 V. If the original VREF readings are all 1.142 V, each needs to be increased by 0.02 V to 1.162 V. 6. In turn, plug the DMM test leads into the VREF test points on the front panel of each of the power supply plug-in modules, and adjust that module’s VADJ pot to achieve the desired value calculated in step 5. 7. Again measure the voltage at the SSPA’s 11.5 Vdc bus bar inputs on the rear panel. If the voltage is 11.5 +/- 0.05 V, the power supply is adjusted properly. If the input voltage is still not within 0.05 V of 11.5 V, repeat steps 5 through 7. 5.4.2 RF Phase Adjustments This procedure describes how to adjust the phase trimmers to achieve maximum combining efficiency. The phase trimmers are set at the factory for maximum output power. If you ever replace an SSPA module or flexible RF input connector, you can adjust the phase trim on its path to optimize the system for the new component. You can also adjust all the phase trimmers to peak the entire system. Note Adjusting the RF phasing may require taking the SSPA out of service. To avoid traffic interruption, you should perform this adjustment during scheduled system downtime. Maintenance 5-5 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA 1. Make sure the SSPA is terminated in a suitable load capable of handling the rated SSPA power. 2. Remove the SSPA front panel by loosening its captive screws. 3. Connect a power meter to the Output Sample port on the SSPA front panel. Set the power meter to read output in dBm or dBW with two digits of precision after the decimal point. 4. Connect a signal generator to the SSPA RF Input. Set it for an unmodulated CW signal at 14.25 GHz. Set its RF level to achieve maximum possible SSPA output power. Or, connect a spectrum analyzer set to 1 dB/div to the Output Sample port and observe actual carriers. 5. Set a reference on the power meter. 6. Find the phase trimmer corresponding to the module you want to adjust. • For modules in the top row, the trimmers are connected to the flexible RF input cables, and are located above the modules. Their screwdriver adjustments are accessible from below the trimmers. • For modules in the bottom row, the trimmers are installed under the shelf below the row of modules. Look at the underside of this shelf to determine which trimmer connects to the module you want to adjust. 7. Watch the power meter or spectrum analyzer while slowly adjusting the phase trimmer. Adjust the phase trimmer to obtain the maximum power meter reading. Or, if using a spectrum analyzer, observe the effect on carriers at both ends of the band while adjusting. Adjust the phase trimmer to obtain maximum response across the band. 8. If you wish to peak the entire system, repeat the phasing procedure on each trimmer. 9. Replace the SSPA front cover, disconnect the signal source, and return the SSPA system to service. 5.4.3 Power Measurement Adjustments Because the SSPA uses Schottky-diode based RF detectors, the forward and reflected power they measure may differ from measurements made by a thermal-based sensor such as a power meter. If you need to fine-tune the forward or reflected power displayed on the control panel to agree with measurements made by a power meter or other equipment, use the offset provided in the PwrCal screen under the Setup Menu, as described below. You can adjust the offset in 0.1 dB increments from -6 dB to +6 dB. 5-6 Maintenance DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Forward power measurement adjustment: 1. Select Set / PwrCal / Pfwd from the SSPA front panel menu. 2. Use the MODIFY and buttons to adjust the offset to make the forward power (Pfwd) reading agree with your power meter or other equipment. Reflected power measurement adjustment: The reflected power measurement adjustment should be set to agree with the forward power measurement when the SSPA is operating into a load of infinite VSWR. To make this adjustment, follow the steps below: Note Adjusting the reflected power measurement requires taking the SSPA out of service. To avoid traffic interruption, you should perform this adjustment before the SSPA is put into service, or during scheduled system downtime. 1. Shut off the SSPA system by turning off the front-panel circuit breakers on all three Power Supply modules. 2. Disconnect the facility waveguide from the SSPA RF Output port. 3. Terminate the SSPA RF Output port with a short circuit, such as a metal plate. To prevent RF leakage, make sure that the short is securely attached. 4. Disconnect the facility RF input cable from the SSPA RF Input connector, and connect a signal generator. Set it for approximately –20 dBm at 14.25 GHz. 5. Turn on the Power Supply. 6. Select menu Srvc / Pfwd from the SSPA front panel. Note which measurement units are currently selected (dBm, dBW, or Watts). Set the measurement units to dBm, if they are not already. 7. Select menu Set / PwrCal / Prefl from the SSPA front panel. The top line of the resulting display will display the forward and reflected power levels in dBm. 8. Use the MODIFY and buttons to adjust the reflected power offset until the displayed reflected power equals the displayed forward power. 9. Select menu Srvc / Pfwd from the SSPA front panel. Set the measurement units back to their previous selection, if it was something other than dBm. 10. Turn off the Power Supply. 11. Remove the short circuit from the SSPA RF Output and reconnect the facility waveguide. Maintenance 5-7 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA 12. Disconnect the signal generator from the SSPA RF Input and re-connect the facility input cable. 13. Turn on the Power Supply and return the SSPA system to service. 5.4.4 Analog Output Adjustment A differential signal is provided on the parallel I/O port that represents the measured RF output level in dBm. The voltage of this signal is adjusted at the factory to provide a scale of 0.1 volts per dB. To verify the accuracy of this circuit, set the output power of the amplifier to a convenient level, as measured on the control panel display. Measure the dc voltage obtained at pin 27 (positive) and pin 9 (negative) of the 37-pin D connector, J5. As an example, set the power output to +40 dBm, as read from the control panel. Measure the voltage at pins 27 and 9. This voltage should read 4.0 Vdc. If not, select Set / Par / AnAdj from the menu choices. This will output a 5.00 Vdc signal at pins 27 (+) and 9 (-). Use the MODIFY and buttons to adjust the output as near as possible to 5.00 Vdc. If the system is used with an RCP-2000 Remote Control Panel with parallel I/O, its analog output can be adjusted in a similar manner. While on the local analog adjust screen, press the MENU button to move to the remote analog adjust screen. While measuring the dc voltage obtained at pin 27 (positive) and pin 9 (negative) of the RCP-2000’s 37-pin D connector, use the MODIFY and buttons to adjust the output as near as possible to 5.00 Vdc. 5.5 Performance Verification Use the procedures in this section to verify that the SSPA is operating within specifications. This is the procedure used at the factory for outgoing inspection. The procedures should be used as a tool for incoming inspection before initial installation or whenever any problems are detected and the SSPA system is suspected as a source of the problems. Use a copy of the Measured Test Data form in Section 8 as a checklist and to record results of the measurements. The procedures used are: • • • • 5-8 Maintenance Power Supply Tests RF Tests Control Panel/Display Test Microprocessor Test 5.5.1 5.5.2 5.5.3 5.5.4 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA • • • LED Test Mute/Operate Test Parallel I/O Tests 5.5.5 5.5.6 5.5.7 These tests cannot be performed with the SSPA on-line. Certain procedures will interrupt service to the SSPA. Disconnect from service before doing performance verification tests. Note The RF tests require laboratory microwave test equipment such as sweepers and power meters. Do these tests only if the proper test equipment is available. WARNING Servicing instructions are for use by service-trained personnel only. To avoid dangerous electric shock, do not perform any servicing unless qualified to do so. Do not replace components with the power cable connected. In preparation for the tests, connect a high power waveguide termination to the RF Output at J2. A precision 35 dB cross-guide coupler is convenient for making power meter or spectrum analyzer measurements. Loads must be capable of dissipating the full rated power of the SSPA. 5.5.1 Power Supply Tests Perform the procedure described in Section 5.4.1, Power Supply Voltage Adjustment, to test Power Supply operation. If one or more of the Power Supply plug-in module voltages cannot be set to the specified window, refer to the Troubleshooting chart for possible causes. 5.5.2 RF Tests It is assumed that the reader is familiar with standard RF and microwave test techniques such as gain, power output, and intermodulation. No details of these tests are given here other than conditions and test limits. Refer to the manuals of your microwave test equipment for measurement details, if necessary. The following parameters of the Ku-Band ModuMAX SSPA are measured: • • • • • • Gain, gain flatness Input and output VSWR Power output at 1 dB compression Two-tone intermodulation suppression RF input and output sample port response Gain control adjustment range Maintenance 5-9 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Use a copy of the test data sheet in Section 8 to record measured test data. This amplifier system is capable of generating over +57 dBm (500 W) of output power. Most test equipment can be damaged by levels greater than +20 dBm. Use sufficient attenuation between the output and your test equipment to protect it against high power. Use caution at all times. CAUTION Measure gain from J1 (Input) to J2 (Output). Be sure that the electronic gain control is set to 0 dB via the control panel controls under the Operate menu. Use an input level that is in the small signal region of the amplifier (less than +45 dBm out). Plot the swept response on the test data sheet. From the plot, determine gain and gain flatness. Record values on the test data sheet. Measure VSWR (Return Loss) at both the input (J1) and at the output (J2). For input measurements, keep the test signal low enough to avoid saturation in the amplifier. Plot the swept return loss for both input and output on the same graph. Identify traces by drawing an arrow and labeling the appropriate trace. Record minimum return loss for each port on the test data sheet. For output power measurements, determine the output power when the amplifier is 1 dB compressed. Use frequencies specified on the test data sheet. Measure two-tone intermodulation suppression using the tone combinations specified on the test data sheet. Adjust input levels to produce the per-tone output level shown on the test data sheet. Measure the coupling factors of the input and output sample port couplers. For the input coupler, measure the loss from J1 to the INPUT SAMPLE port. For the output coupler, measure the difference in output levels between J2 and the OUTPUT SAMPLE port. Record the losses at the frequencies listed on the test data sheet. Use this calibration data on the calibration labels, located on the front panel. Test the gain control adjustment range by operating the amplifier in the small-signal region (< +45 dBm output), and adjusting the GAIN and buttons. You should see a minimum adjustment range of 20 dB. The following series of tests (Sections 5.5.3 through 5.5.9) require that the correct password has been entered (if enabled), and that the SSPA is in Local mode. Note 5.5.3 Control Panel/Display Test This section verifies that all of the control panel buttons operate. While performing these tests, verify that all of the characters in 5-10 Maintenance DMAN-14563 Rev. H Ku-Band ModuMAX SSPA the display look normal, and are not missing any pixels, and that no pixels are stuck on. 1. While watching the display, turn ON system power. Verify that the display backlight is lit. 2. Watch the display. You should see the copyright notice, then the display should show the status screen. 3. Press the SEL Main Menu. button. Verify that the display switches to the 4. Press the MENU button. Verify that the selection indicators move to the second choice in the menu (Operate). 5. Press the MENU button. Verify that the selection indicators move to the first choice in the menu (Faults). 6. Press the PREV button. Verify that the display goes back to the status screen. 7. Press SEL , then choose menu Srvc / Pfwd. Note whether dBm, dBW or Watts is selected. Repeatedly press the MODIFY button and verify that the unit of measure cycles through the sequence “... dBm, dBW, Watts, dBm, ...”. 8. Press and hold the MODIFY button and verify that the unit of measure first changes, then pauses, then rapidly cycles through the sequence of choices. 9. Repeatedly press the MODIFY button. Verify that the unit of measure cycles through the reverse sequence of step 7. 10. Return the unit of measure to its original value noted in step 7. (If this is a factory test, select dBm). 11. Press and hold the GAIN button and verify that the gain first drops by 0.1 dB, then pauses, then rapidly decreases in 0.1 dB steps to its minimum value, -20.0 dB. Press and hold the GAIN button and verify that the gain first increases by 0.1 dB, then pauses, then rapidly increases in 0.1 dB steps to its maximum value, 0.0 dB. 5.5.4 Microprocessor Test To run the microprocessor test, select Srvc / Test. If the microprocessor and associated hardware is operating correctly, the screen will display “TEST PASSED!” If the self-test fails, a fault will occur, and you can go to the Faults display for more information. Self-test failure indicates that the SSPA is in need of repair. Refer to the Fault Conditions chart for information on how to proceed. Maintenance 5-11 DMAN-14563 Rev. H 5.5.5 Ku-Band ModuMAX SSPA LED Test As a confidence test, all control panel LED indicators are lit for about 1 second when power is first applied, and any time the microprocessor is reset. Resetting the microprocessor from the control panel will not affect the status of the output. To test the LEDs at any time, reset the microprocessor by selecting menu Srvc / Reset. Another screen will appear that reads “Press SELECT to reset Processor”. While observing the control panel LEDs, press the SEL button again. Verify that all control panel LEDs are lit briefly. 5.5.6 Mute/Operate Test This test will confirm that the microprocessor is able to mute the output, and that all of the modules are properly shut down while muted. To perform this test, a power meter (with appropriate attenuation) should be connected to the output, and a non-saturated signal should be passed through the amplifier. 1. Verify that the RF ON indicator on the control panel is lit. 2. Press the MUTE button. 3. Verify on the power meter that the RF has indeed been muted. 4. Verify that the RF ON indicator on the control panel is unlit and that the MUTE indicator is lit. 5. Verify that the LED status indicator on each module is lit amber, indicating that RF is off. 6. Press the RF ON button. 7. Verify on the power meter that the RF is back on at its original level. 8. Verify that the MUTE indicator on the control panel is unlit and that the RF ON indicator is lit. 5.5.7 Parallel I/O Tests The Parallel I/O board is controlled by a program running in the main Logic Board. These verification tests simply check that the state of each input can be read by the system, and that each output can be controlled. These tests are designed to not interfere with the RF signal path and can be completed without taking the system out of service. 5-12 Maintenance DMAN-14563 Rev. H Note 5.5.7.1 Ku-Band ModuMAX SSPA During these tests, you will be temporarily reprogramming the functions of the Parallel I/O interface. Before beginning, make note of all the existing Parallel I/O settings, so the equipment can be returned to its original state upon completion of the tests. Input Function Tests 1. Select Set / Par / Inp, and assign all input functions (1-8) to NONE. 2. Go to menu Srvc / Inp. 3. With nothing connected to the Parallel I/O port, verify that all inputs read HIGH. 4. Go to the screen for Input 1. 5. Connect J5 pin 28 (Input 1) to pin 11 (ground). 6. On the screen, verify that Input 1 reads LOW, and that all other inputs are HIGH. 7. Disconnect J5 pin 28 from pin 11. 8. Repeat steps 4 through 7 for the following: Input 2, J5 pin 10 Input 3, J5 pin 29 Input 4, J5 pin 30 Input 5, J5 pin 12 Input 6, J5 pin 34 Input 7, J5 pin 16 Input 8, J5 pin 17 9. On the front panel, return to menu Set / Par / Inp, and restore all the inputs to their original functions. If your system includes an RCP-2000 Remote Control Panel with parallel I/O, you may repeat this test for Remote Inputs (R1-R8). Connect to the corresponding pins of the parallel I/O connector on the RCP-2000 rear panel. 5.5.7.2 Output Function Tests 1. Make sure there are no faults reported on the front panel. 2. Set the amplifier to LOCAL control mode (Oper / Ctl). 3. Go to menu Set / Par / Outp and set the functions for all 8 outputs to Remote/Local. This should de-energize all 8 relays. (Remember that after selecting the function with MODIFY or , you must press SEL to select the function.) 4. Using the DMM, verify continuity between the following pairs of pins on J5: Output 1, pins 1 and 20 Maintenance 5-13 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Output Output Output Output Output Output Output 2, 3, 4, 5, 6, 7, 8, pins pins pins pins pins pins pins 21 and 3 4 and 23 24 and 6 7 and 26 31 and 13 14 and 33 18 and 37 5. Again using the DMM, verify no continuity between the following pairs of pins on J5: Output 1, pins 2 and 20 Output 2, pins 22 and 3 Output 3, pins 5 and 23 Output 4, pins 25 and 6 Output 5, pins 8 and 26 Output 6, pins 32 and 13 Output 7, pins 15 and 33 Output 8, pins 19 and 37 6. On the front panel, change the function for Output 1 to Any Fault (but not Any Flt/Wrn). This should energize that relay (Output 1) only. 7. Using the DMM, verify that there is continuity between pins 2 and 20 of J5 (Output 1). 8. Verify that there is no continuity between the remaining pairs of pins listed in step 5 (Outputs 2-8). 9. On the front panel, set Output 1 back to Remote/Local. 10. Repeat steps 6 through 9 for each remaining output, using the pin pairs listed in step 5. 11. On the front panel, go to the menu Set / Par / Outp, and restore all outputs to their original functions. If your system includes an RCP-2000 Remote Control Panel with parallel I/O, you may repeat this test for Remote Outputs (R1-R8). Connect to the corresponding pins of the parallel I/O connector on the RCP-2000 rear panel. 5.5.7.3 Analog Output Test 1. Set the DMM to measure dc voltage. 2. Connect the DMM positive (+) lead to J5 pin 27, and the negative (-) lead to J5 pin 9. 3. On the front panel, go to the Analog Adjust screen (Set / Par / AnAdj). 4. Record the number displayed on this screen so you can restore this value when the test is done. 5-14 Maintenance DMAN-14563 Rev. H Ku-Band ModuMAX SSPA 5. The DMM should read +5.00 Vdc. If it does not, you may want to follow the procedure under Section 5.4.4, Analog Output Adjustment, when you are finished with this test. 6. Press and hold the MODIFY button. Verify that the number displayed on the screen increases, and that the voltage displayed on the DMM likewise increases. 7. Release the MODIFY button. Press and hold the MODIFY button. Verify that the number displayed on the screen decreases, and that the voltage displayed on the DMM likewise decreases. 8. Using the MODIFY or button as appropriate, restore the original displayed value recorded in step 4 above, or to achieve a reading of 5.00 Vdc on the DMM. 9. Press PREV to exit the Analog Adjust screen. Move to the screen Srvc / Pfwd, and set the power units to dBm. 10. Verify that the voltage displayed on the DMM is equal to 0.1 volts times the power reading shown on the screen in dBm. (If there is no signal, the front panel display will show 40°C above ambient at any cable-bus bar connection point Insufficiently torqued hardware (loose connection) Remove both bolts from the suspected connection. Replace the lock washer. Re-install the bolts and tighten them to the recommended torque. In systems with (2) PS shelves, modules on (1) PS shelf operating at higher current than modules on other PS shelf Sync cable missing Make sure the Sync cable is connected between PS1 J6 and PS2 J6 5.7 Assembly Replacement The major active components of the SSPA can be removed and replaced without disrupting operation. This section gives procedures for replacing each of these components. VertexRSI supplies two optional spares kits for each type of ModuMAX SSPA: • Spares Kit A includes an SSPA module, a Power Supply module, and a fan assembly; • Spares Kit B includes Spares Kit A plus a Logic Board, parallel I/O board, Ethernet board (if the ModuMAX is equipped with one), front panel assembly, and flexible RF cable assemblies. If you need to purchase spares kits, or need to return a failed assembly, contact VertexRSI as described in Section 7. 5.7.1 Power Supply Module Replacement The SSPA system requires two of the three Power Supply modules to be on and functioning. Therefore, if the third Power Supply module fails, you can replace it without disrupting service. Removing a Power Supply module: 1. Turn off the module at its front-panel circuit breaker. 2. Release the latch built into the handle at the bottom of the Power Supply module’s front panel. 5-22 Maintenance DMAN-14563 Rev. H Ku-Band ModuMAX SSPA 3. Pull the Power Supply module out of the Power Supply shelf. Re-installing a Power Supply module: 1. Slide the new Power Supply module into the Power Supply shelf. 2. Engage the latch mechanism built into the module’s handle, and press the handle closed to secure the module. 3. Turn on the Power Supply module at its front-panel circuit breaker. 4. Reset faults. 5.7.2 SSPA Module Replacement Remove the SSPA front cover by loosening its captive screws. Determine which SSPA module is defective. The control panel should show a fault on the affected module. Each module is referred to by a number. The labels on the SSPA sides indicate the location of each numbered module. They are also identified in Figure 5-1. The LED on the faulted module will be either red, amber, off, flickering or different from all of the other modules. MODULE 1 MODULE 2 ModuMAX SSPA RF ON MODIFY HOT ! ! See removal instructions below See removal instructions below Dark = O Red = F Amber = M Green = O AX Mo CAUTION HOT AX Mo CAUTION HOT AX Mo CAUTION HOT ! ! ! See removal instructions below See removal instructions below Dark = O Red = F Amber = M Green = O Mo Tighten to 8 in-lb (90 N-cm) ! See removal instructions below Dark = O Red = F Amber = M Green = O Dark = O Red = F Amber = M Green = O AX Mo MODULE 8 AX Tighten to 8 in-lb (90 N-cm) Tighten to 8 in-lb (90 N-cm) See removal instructions below AX ! See removal instructions below Dark = O Red = F Amber = M Green = O Tighten to 8 in-lb (90 N-cm) Tighten to 8 in-lb (90 N-cm) Dark = O Red = F Amber = M Green = O Tighten to 8 in-lb (90 N-cm) Dark = O Red = F Amber = M Green = O Tighten to 8 in-lb (90 N-cm) Tighten to 8 in-lb (90 N-cm) Mo Tighten to 8 in-lb (90 N-cm) Tighten to 8 in-lb (90 N-cm) ! See removal instructions below Tighten to 8 in-lb (90 N-cm) FAULT FAULT RESET SEL Dark = O Red = F Amber = M Green = O CAUTION MENU MUTE Tighten to 8 in-lb (90 N-cm) Mo WARNING PREV GAIN MPKM14500R MODULE 5 MODULE 4 MODULE 3 AX Mo MODULE 6 AX MODULE 7 CAUTION HOT CAUTION Tighten to 8 in-lb (90 N-cm) IN (dBc) -11.7 -11.6 -11.6 -11.5 -11.5 HOT Freq. (GHz) 14.000 14.125 14.250 14.375 14.500 Tighten to 8 in-lb (90 N-cm) CAUTION HOT Tighten to 8 in-lb (90 N-cm) CAUTION HOT Tighten to 8 in-lb (90 N-cm) OUT (dBc) -49.9 -49.7 -48.9 -48.5 -48.7 Figure 5-1. SSPA Module Identification (Front View of Chassis) Maintenance 5-23 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Removing a module: 1. Turn off the module by selecting Oper / Mod from the SSPA control panel, then using the or MENU buttons to select the faulted module. Press SEL to turn off the module. The check mark (9) under the module number will change to an X. (If the SSPA has lost communication with the module, a question mark (?) will be displayed instead.) The LED on the module will change to amber (module not faulted), or to alternating red and amber. 2. Disconnect the flexible RF input cable using the supplied 5/16" wrench. Position it away from the module so it won’t be damaged when the module is removed. 3. Loosen the two hold-down bolts in the corners of the module using the supplied ½" nut driver. WARNING The module may be hot. It can be as much as 40 °C above room temperature. 4. Pull the module forward to remove it. Re-installing a module: 1. Inspect the module’s output flange to be sure its gasket is in place. Slide the module in, being careful not to pinch the RF input cable. Push in until the module is firmly seated and flush with other modules. 2. Use the supplied 1/2" nut driver to tighten the two hold-down bolts on the face of the module until they just start to get snug. Then alternately tighten first one, then the other, in small steps until they are tightened to 8 in-lb (90 N-cm). This is approximately finger-tight. Do not overtighten. 3. Re-connect the flexible RF input cable to the module’s RF input connector and tighten to 8 in-lb (90 N-cm). 4. Turn on the module by selecting Oper / Mod from the SSPA control panel, then using the or MENU buttons to select the newly replaced module. Press SEL to turn ON the module. If the replacement has been successful, the X under the module number will change to a check mark (9), and the module LED will turn green. 5. Reset faults. 6. If practical, adjust the module’s phase trimmer to maximize combining efficiency by following the adjustment procedure in Section 5.4.2. However, if you are unable to take the SSPA system out of service, the combining efficiency will still be very high, so you can immediately restore service without adjusting the trimmer. 5-24 Maintenance DMAN-14563 Rev. H 5.7.3 Ku-Band ModuMAX SSPA Flexible RF Input Cable Assembly Replacement The eight SSPA modules each have a flexible cable assembly attached to their input connectors. If care is taken when installing and removing the modules, these flexible cables should last indefinitely. If they sustain damage, you can replace them. The flexible RF input cables on the top row of modules are 5.5" (140 mm) long, and those on the bottom row are 9.5" (240 mm) long. Spares Kit B includes one of each type. Removing a flexible RF input cable: 1. Turn off the module connected to the cable by selecting Oper / Mod from the SSPA control panel, then using the or MENU buttons to select the correct module. Press SEL to turn off the module. The check mark (9) under the module number will change to an X. The LED on the module will change to amber. 2. Disconnect the flexible RF input cable from the SSPA module using the supplied 5/16" wrench. 3. Disconnect the other end of the flexible RF input cable. a. The cables on the top row are connected to phase trimmers above the top shelf. Reach into the access hole with the 5/16" wrench and disconnect the cable from the trimmer. b. The cables on the bottom row are connected either directly to a phase trimmer, or to an intermediate semi-rigid cable. Disconnect the cable from whichever component it is connected to. Re-installing a flexible RF input cable: 1. Select the RF input cable of the proper length: 5.5" (140 mm) for the top row; 9.5" (240 mm) for the bottom row. 2. Connect the straight SMA male connector on one end of the new flexible RF input cable to either the trimmer or the semirigid cable from which the old cable was disconnected. Tighten with the 5/16" wrench. 3. Connect the right-angle SMA male connector on the flexible RF input cable to the module’s RF input connector. Tighten. 4. Turn on the module by selecting Oper / Mod from the SSPA control panel, then using the or MENU buttons to select the module. Press SEL to turn on the module. The X under the module number will change to a check mark (9), and the module LED will turn green. 5. Reset faults. 6. If practical, adjust the module’s phase trimmer to maximize combining efficiency by following the adjustment procedure in Maintenance 5-25 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Section 5.4.2. However, if you are unable to take the SSPA system out of service, the combining efficiency will still be very high, so you can immediately restore service without adjusting the trimmer. 5.7.4 Intake Fan Assembly Replacement (Fan 1–4) The Fan Fault message displays the number corresponding to the faulted fan. Fans 1 through 4 are the intake fans on the SSPA rear panel. See Figure 5-2 to determine the location of the faulted fan. A fan assembly consists of a reverse-curved impeller fan and fan PC board, both of which are mounted on a metal bracket. This fan assembly is the replaceable unit for both the intake and exhaust fans. FAN 2 Turn fan OFF before removing. FAN 1 Turn fan OFF before removing. Turn fan OFF before removing. FAN 3 FAN 4 Turn fan OFF before removing. ! 2120 Old Gatesburg Road State College, PA 16803 Phone: 814-238-2700 Fax: 814-238-6589 www.tripointglobal.com WARNING: Radiation hazard when unterminated. Do not operate SSPA without a termination. EXHAUST GRILLE Figure 5-2. Rear Panel Intake Fan Identification 5-26 Maintenance DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Removing an intake fan assembly: 1. Turn off the fan’s switch. Wait for the fan to spin down. It will probably not stop entirely if the other intake fans are running. WARNING Be extremely careful when working with the fan. It spins rapidly, and can cause serious injury if its blades catch your fingers. Always allow fans to spin down before attempting to handle them. 2. Loosen the four captive fasteners in the corners of the fan’s access panel, and pull the fan assembly out until it clears the SSPA rear panel. Do not pull on the cable still attached to the SSPA interior. 3. Reach into the SSPA behind the fan assembly, and disconnect the 4-pin Molex connector at the end of the fan assembly’s cable. 4. Disconnect the 4-pin Molex connector from J1 on the fan PC board. This is the wire that does not connect to the fan. 5. Remove the four pan-head screws attaching the PCB mounting bracket to the enclosure, and remove the fan assembly. Re-installing an intake fan assembly: 1. Slide the new fan assembly inside the enclosure in the same orientation as the old one was removed. Attach it to the enclosure with the four sets of pan-head hardware previously removed. 2. Re-connect the 4-pin Molex connector previously disconnected from J1 on the fan PC board. 3. Take the fan assembly back to the SSPA and re-connect the 4pin Molex connector to its mate inside the chassis. 4. Slide the fan enclosure back into the opening and fasten the four sets of captive hardware at its corners. 5. Turn on the fan’s switch. 6. Wait a few seconds for the fan to spin up to speed. Check that the Fan Fault has cleared. 7. Reset faults. 5.7.5 Exhaust Fan Assembly Replacement (Fan 5-8) The Fan Fault message displays the number corresponding to the faulted fan. Fans 5 through 8 are the exhaust fans, located in a tray at the bottom of the SSPA, and are numbered in left-to-right sequence as viewed from the front. See Figure 5-3. Maintenance 5-27 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA CAUTION HOT IN (dBc) -11.7 -11.6 -11.6 -11.5 -11.5 FAN 5 CAUTION Tighten to 8 in-lb (90 N-cm) HOT Freq. (GHz) 14.000 14.125 14.250 14.375 14.500 Tighten to 8 in-lb (90 N-cm) CAUTION HOT CAUTION Tighten to 8 in-lb (90 N-cm) HOT Tighten to 8 in-lb (90 N-cm) OUT (dBc) -49.9 -49.7 -48.9 -48.5 -48.7 FAN 6 FAN 7 FAN 8 Figure 5-3. Exhaust Fan Identification (Front View of Chassis) A fan assembly consists of a reverse-curved impeller fan and fan PC board, both of which are mounted on a metal bracket. This fan assembly is the replaceable unit for both the intake and exhaust fans. Removing an exhaust fan assembly: 1. Remove the SSPA front cover by loosening its captive fasteners. 2. Disconnect the two cables connected to the 6-pin Molex connectors on the front of the exhaust fan assembly. Position the cables above the fan tray so they will not be damaged when you pull the tray out. Wait for the fans to spin down. WARNING Be extremely careful when working with the fan. It spins rapidly, and can cause serious injury if its blades catch your fingers. Always allow fans to spin down before attempting to handle them. 3. Loosen the two captive fasteners at the front of the exhaust fan tray, then pull the fan assembly out. Note: The SSPA will cool properly for an indefinite time with the exhaust fan tray removed, as long as the SSPA front panel is left off so that the air can exhaust out the front. 4. On the faulted fan, disconnect the 4-pin Molex connector from J1 on the fan PC board. This cable is anchored to the fan tray, and is not connected to the fan itself. 5-28 Maintenance DMAN-14563 Rev. H Ku-Band ModuMAX SSPA 5. Remove the faulted fan assembly by loosening the four captive fasteners securing its outer bracket to the fan tray, and pulling it out. 6. Remove the four pan-head screws attaching the PCB mounting bracket to the outer bracket, and remove the fan assembly. Re-installing an exhaust fan assembly: 1. Attach the new fan assembly to the outer bracket with the four sets of pan-head hardware previously removed. 2. Re-connect the 4-pin Molex connector previously disconnected from J1 on the fan PC board. 3. Install the fan assembly with its outer bracket back into the fan tray by tightening its four captive fasteners. 4. Slide the fan tray back into the SSPA and tighten the two captive fasteners at its front edge. 5. Re-connect the fan cables in the chassis to the two 6-pin Molex connectors on the front of the fan tray. The fans will come back on immediately. 6. Wait a few seconds for the fan to spin up to speed. Check that the Fan Fault has cleared. 7. Reset faults. 5.7.6 Logic Board Replacement The Logic Board should normally be present for amplifier operation; however, the RF components will operate without it. The Logic Board may therefore be removed and replaced without disturbing the RF signal path. While the Logic Board is removed, the RF modules will retain their last gain settings and status (RF on, muted, disabled). RF modules will continue to perform temperature compensation and fault detection, and display status via their front panel LEDs. If a module detects an overtemperature, gate voltage error, or high current condition, it will shut itself off. While the Logic Board is removed, the status LEDs on all RF modules will flicker (briefly turn off about once per second) to indicate that communications with the Logic Board are absent. CAUTION Before removing, handling, or installing any boards, it is vitally important that you discharge electrostatic charge from your body to the chassis. We strongly suggest you ground yourself to the chassis using a commercially available wrist strap. If precautions are not taken, damage to boards may result. Maintenance 5-29 DMAN-14563 Rev. H Note Ku-Band ModuMAX SSPA The Event Log and Operation Time counter are stored in nonvolatile memory located on the Logic Board. The record of events affecting a particular amplifier therefore follows the location of its Logic Board. If a Logic Board is removed, and a new Logic Board installed, the Event Log and Operation Time that are stored on the new board become associated with this amplifier. The actual log of this amplifier’s past events and its actual operation time, up until the change of Logic Boards, will still be stored on the Logic Board that was removed. Removing the Logic Board: 1. Connect an anti-static wrist strap to the ground stud on the rear of the chassis. Do NOT use the negative power cable/bus bar connection. 2. Disconnect the Power Supply Interface cable from J9 on the SSPA rear panel. This will cause Power Supply Module (PS Mod) faults, which are normal. 3. Disconnect any cable from J4, the Serial I/O connector. 4. Unscrew the two thumbscrews on the Logic Board’s rear panel. 5. Grasp the two thumbscrews and firmly and steadily pull the board straight out. Do not jerk the board from its socket, as that could damage the board. 6. Handle the board only by its rear panel or the edges of the board. Place the board in static-safe packaging as soon as possible. Re-installing the Logic Board: 1. Connect an anti-static wrist strap to the ground stud on the rear of the chassis. Do NOT use the negative power cable/bus bar connection. 2. Remove the new Logic Board from its static-safe packaging. Handle the board only by its rear panel or the edges of the board. 3. Inspect the board’s plug-in connector, checking for bent pins or any other damage or obstruction. 4. Place the edges of the board into the plastic card guides visible through the rear panel opening. 5. Slide the board in until resistance is felt, then firmly and steadily press the board into its mating connector. If the force required seems excessive, remove the board and again check the plug-in connector for bent pins, damage, or obstructions. 6. Evenly tighten the two thumbscrews on the board’s rear panel. 5-30 Maintenance DMAN-14563 Rev. H Ku-Band ModuMAX SSPA 7. Reconnect the Power Supply Interface cable to J9. If you disconnected a cable from J4, the Serial I/O port, reconnect it. 8. Reset faults. 5.7.7 Parallel I/O Board Replacement The Parallel IO board is not required for amplifier operation. When you remove the Parallel I/O Board, the SSPA will report a fault. If you replace the Parallel I/O Board, you can clear the fault by issuing a Fault Reset command. If you do not plan to replace the Parallel I/O Board right away, and want to clear the fault, reconfigure the amplifier so it does not expect a Parallel I/O Board. To remove Parallel I/O from the configuration, see Section 3.7.4.3.2, Remove Optional Hardware. If you install a functional Parallel I/O Board into an SSPA not configured for Parallel I/O, the SSPA will detect the board and automatically reconfigure to use it. CAUTION Before removing, handling, or installing any boards, it is vitally important that you discharge electrostatic charge from your body to the chassis. We strongly suggest you ground yourself to the chassis using a commercially available wrist strap. If precautions are not taken, damage to boards may result. Removing the Parallel I/O Board: 1. Connect an anti-static wrist strap to the ground stud on the rear of the chassis. Do NOT use the negative power cable/bus bar connection. 2. Remove any cables connected to J5, the Parallel I/O port, on the SSPA rear panel. 3. Unscrew the two thumbscrews on the Parallel I/O Board’s rear panel. 4. Grasp the two thumbscrews and firmly and steadily pull the board straight out. Do not jerk the board from its socket, as that could damage the board. 5. Handle the board only by its rear panel or the edges of the board. Place the board in static-safe packaging as soon as possible. 6. If you do not plan to replace the Parallel I/O Board right away, reconfigure the amplifier to remove the option so that the fault can be cleared. See Section 3.7.4.3.2. Maintenance 5-31 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Re-installing the Parallel IO Board: 1. Connect an anti-static wrist strap to the ground stud on the rear of the chassis. Do NOT use the negative power cable/bus bar connection. 2. Remove the board from its static-safe packaging. Handle the board only by its rear panel or the edges of the board. 3. Inspect the board’s plug-in connector, checking for bent pins or any other damage or obstruction. 4. Place the edges of the board into the plastic card guides visible through the rear panel opening. 5. Slide the board in until resistance is felt, then firmly and steadily press the board into its mating connector. If the force required seems excessive, remove the board and again check the plug-in connector for bent pins, damage, or obstructions. 6. Evenly tighten the two thumbscrews on the Parallel I/O Board’s rear panel. 7. If you disconnected a cable from J5, the Parallel I/O Port, reconnect it. 8. Reset faults. 9. Adjust the analog output of the replacement board. See Section 5.4.4. 5.7.8 Ethernet Board Replacement When you remove the Ethernet Board, the SSPA will report a fault. If you replace the Ethernet Board, you can clear the fault by issuing a Fault Reset command. CAUTION Before removing, handling, or installing any boards, it is vitally important that you discharge electrostatic charge from your body to the chassis. We strongly suggest you ground yourself to the chassis using a commercially available wrist strap. If precautions are not taken, damage to boards may result. Removing the Ethernet Board: 1. Connect an anti-static wrist strap to the ground stud on the rear of the chassis. Do NOT use the negative power cable/bus bar connection. 2. Remove any cables connected to J6, the Ethernet port, on the SSPA rear panel. 3. Unscrew the two thumbscrews on the Ethernet Board’s rear panel. 5-32 Maintenance DMAN-14563 Rev. H Ku-Band ModuMAX SSPA 4. Grasp the two thumbscrews and firmly and steadily pull the board straight out. Do not jerk the board from its socket, as that could damage the board. 5. Handle the board only by its rear panel or the edges of the board. Place the board in static-safe packaging as soon as possible. Re-installing the Ethernet Board: 1. Connect an anti-static wrist strap to the ground stud on the rear of the chassis. Do NOT use the negative power cable/bus bar connection. 2. Remove the board from its static-safe packaging. Handle the board only by its rear panel or the edges of the board. 3. Inspect the board’s plug-in connector, checking for bent pins or any other damage or obstruction. 4. Place the edges of the board into the plastic card guides visible through the rear panel opening. 5. Slide the board in until resistance is felt, then firmly and steadily press the board into its mating connector. If the force required seems excessive, remove the board and again check the plug-in connector for bent pins, damage, or obstructions. 6. Evenly tighten the two thumbscrews. 7. If you disconnected a cable from J6, reconnect it. 8. Reset faults. 5.7.9 Front Panel Assembly Replacement The Front Panel Assembly should normally be present so that a local operator can control and monitor the SSPA system; however, the SSPA will operate without it. The Front Panel Assembly may therefore be removed and replaced without disturbing the RF signal path. CAUTION Before removing, handling, or installing any boards, it is vitally important that you discharge electrostatic charge from your body to the chassis. We strongly suggest you ground yourself to the chassis using a commercially available wrist strap. If precautions are not taken, damage to boards may result. Removing the Front Panel assembly: 1. Connect an anti-static wrist strap to a ground point on the chassis. Do NOT use the negative power cable/bus bar connection. Maintenance 5-33 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA 2. Loosen the two captive fasteners that hold the Front Panel assembly to the chassis. Hold the assembly so its electrical components do not contact the chassis. 3. Release the safety latches on the header connector on the Front Panel Board, and remove the cable connected to it. 4. Handle the assembly only by its edges. Place the assembly in static-safe packaging as soon as possible. Replacing the Front Panel assembly: 1. Connect an anti-static wrist strap to a ground point on the chassis. Do NOT use the negative power cable/bus bar connection. 2. Remove the new Front Panel assembly from its static-safe packaging. Handle the assembly only by its edges. 3. Inspect the assembly’s connector, checking for bent pins or any other damage or obstruction. 4. Plug the front panel cable into the connector on the rear of the assembly, making sure the safety latches engage to prevent the cable from vibrating loose. 5. Holding the assembly so its electrical components do not contact the chassis, carefully place the front panel against the chassis. Ensure the cable is not pinched or otherwise misrouted. 6. Evenly tighten the two captive fasteners. 7. Reset faults. 5.7.10 Detector Module Replacement The forward and reflected power detectors convert samples of the RF power to digital format for display by the control system. The detectors are not necessary for system operation, and can be replaced without taking the SSPA system out of service. Both detectors are accessed through the SSPA exhaust port. Removing a detector module: 1. Gain access to the SSPA rear panel air exhaust. If the SSPA exhausts air into the room, remove the grill over the exhaust port by loosening the four captive fasteners. If the exhaust air is ducted to the outside, remove the exhaust duct, and disconnect the duct adapter. WARNING 5-34 Maintenance Opening the rear panel air exhaust port exposes the blades on the exhaust fans. The fans spin rapidly, and can cause serious injury if the blades catch your fingers. Do not reach into the rear of the SSPA farther than necessary. DMAN-14563 Rev. H Ku-Band ModuMAX SSPA 2. Refer to Figure 5-4 to locate the detector you want to replace. Use a 5/16" wrench to disconnect the coaxial attenuator attached that detector’s RF connector. ! To remove fan tray: 1. Disconnect both cables on front of tray. Position cables above tray so they won't interfere with tray motion. 2. Loosen two fasteners on floor of fan tray. 3. Pull tray forward to remove. 1. Position cables above tray opening so they won't interfere with tray motion. To reinstall: 2. Slide fan tray fully into chassis. Secure the two fasteners on floor of fan tray. 3. Connect both cables on front of fan tray. FORWARD POWER DETECTOR B1 B4 B2 B6 B3 B7 B8 Fan Reference Designators — Front View of Chassis — B5 REFLECTED POWER DETECTOR Figure 5-4. Locations of Detector Modules 3. Use a ¼" open-end wrench to remove the #4 hardware securing the detector module’s base to the studs in the chassis floor. Lift the detector off the studs, taking care not to strain the ribbon connector still attached. 4. Use a 3/32" Allen wrench to remove the two #4-40 socket-head screws that attach the mating D-connector to the detector. Unplug the D-connector and remove the detector module from the chassis. Re-installing a detector module: 1. Plug the D-connector at the end of the ribbon cable in the chassis to the new detector module. Secure the connector to the detector using the #4-40 socket-head screws removed earlier. Tighten with a 3/32" Allen wrench. 2. Attach the detector to the studs in the chassis floor using the #4 washers and nuts removed previously. 3. Reconnect the coaxial attenuator to the detector’s RF connector. Make sure the semi-rigid cable attached to the attenuator is tight. 4. Check for proper detector operation. Reset faults. 5. Reinstall the duct adapter or grill to the air exhaust port. Maintenance 5-35 DMAN-14563 Rev. H 5-36 Maintenance Ku-Band ModuMAX SSPA DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Section 6 6.1 Drawings General Introduction This section includes drawings needed to maintain and service your SSPA System. Drawing types are briefly described in Table 61 below. Table 6-1 Drawing Types Drawing Type Description Block Diagram Depicts overall signal flow through a subassembly with major circuit groups shown as blocks. Sometimes annotated with signal levels. Schematic Standard electronic schematics with appropriate reference designators on components. Assembly Drawing Pictorial view of a circuit board, subassembly or unit. Components on the assembly drawing are identified by schematic designator or by item number. Item numbers refer to the bills of materials. Bill of Materials (BOM) Shows quantities, manufacturer and manufacturer’s part number of each item of an assembly. Also lists reference designators that appear on schematics. All original drawings which were C size or larger have been reduced for inclusion in this manual. Revisions to drawings are identified in the revision block in the upper right corner of the drawing. The initial release of a drawing has no revision. The first revision is A, the second B, and so on. 6.2 Drawing Index Refer to the Drawing Index, Table 6-2, to locate a particular drawing. Drawings are inserted in the order in which they appear in Table 6-2. Drawings 6-1 DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Table 6-2 Drawing Number Drawing Index Description 14565-5 Outline, MPK_-14XXX/R w/ NIC 14508-6 Schematic, ModuMAX SSPA w/ NIC, without Cabinet 14564-4 Assembly, MPK_-14XXX/R w/ NIC 14509 Cable Assembly, PS Sense ACAB-14509-4’ BOM, Cable Assembly, PS Sense 12763 Cable Assembly, PS Monitor ACAB-12763-4’ BOM, Cable Assembly, PS Monitor 13538-3 Schematic, MPK_-14XXX/R, w/ NIC 13568-11 thru -15 Assembly, Base Assembly, Ku-Band ModuMAX w/ NIC AMAX-13568-1004 BOM, Base Assembly, Ku-Band ModuMAX SSPA … 13141-1 Assembly, Exhaust Duct Adapter Kit (Option) AMAX-13141-1 BOM, Kit, Exhaust Duct Adapter 13141-2 Assembly, Intake Duct Adapter Kit (Option) AMAX-13141-2 BOM, Kit, Intake Duct Adapter 14566-1 Assembly, Ku-Band Maintenance Switch (Option) AMAX-14566-1 BOM, Assy, Ku-Band Maintenance Switch Note 6-2 Drawings Also see Section 8, System Configuration, for information on specific options included with your SSPA system. DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Section 7 7.1 Warranty General Introduction Specific warranty policies, along with technical support, repair and return procedures, are listed in this section. 7.2 • For help installing, maintaining or servicing the unit, see Technical Support, Section 7.2. • For terms and conditions of the warranty, see Warranty, Section 7.3. • Before returning any equipment for factory service, see Return Procedures, Section 7.4. Technical Support Technical support is available by calling General Dynamics SATCOM Technologies directly at (814) 238-2700 between 8:00 a.m. and 5:00 p.m. USA Eastern time. Before calling, please have your technical manual at hand and the model and serial number of the relevant equipment. 7.3 Warranty General Dynamics SATCOM Technologies, Inc. warrants that its products will be in accordance with the written specifications, will be the kinds and quality described in the agreement, and will be free from defects in material and workmanship, under normal use and service, when correctly installed and maintained, for a period of three (3) years from the date of shipment. General Dynamics’ liability is limited solely, at its discretion, to replacing, repairing or issuing credit for products which become defective during the warranty period. General Dynamics must be notified by the buyer, in writing, of any discrepancy before any action may be taken. The buyer must provide General Dynamics with the opportunity to inspect and test the product(s) alleged to be defective. Under no circumstances shall General Dynamics be held liable for any defective product(s) if examination of the product(s) shows that the defect was caused by misuse, abuse, improper installation or application, improper maintenance or repair, alteration, accident or negligence in use, storage, transportation or handling. Warranty 7-1 DMAN-14563 Rev. H 7.4 Ku-Band ModuMAX SSPA Return Procedures Before returning any materials to General Dynamics, the buyer must complete all of the following tasks: • Contact either General Dynamics directly or the appropriate General Dynamics sales representative for issuance of a Return Materials Authorization (RMA) number. If the sales representative is contacted, they will in turn contact General Dynamics for approval to return materials. • Supply sufficient information regarding the reason(s) for return. • Supply the date and purchase order number through which the materials in question were purchased. • Supply the location to which the materials are to be returned. • Include a name and phone number of an individual to contact in case of questions regarding the return materials. Materials approved for return must be accompanied by the information requested above. All materials must have an RMA number. Note Unauthorized returned materials will not be accepted by General Dynamics and will be shipped back to the buyer at the buyer’s expense. All returned materials must arrive with postage, duties and all handling costs prepaid by the buyer. General Dynamics will evaluate the returned materials to determine responsibility and will advise the buyer of any repair or replacement charges that apply. Contact General Dynamics at voice: (814) 238-2700 fax: (814) 238-6589 Shipping Address: 60 Decibel Road, Suite 200 State College, PA 16801 USA 7-2 Warranty DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Section 8 8.1 System Configuration General Introduction This section contains specific configuration information for your system as it was shipped from the factory. Such information may include manual supplements for optional equipment ordered, outline drawings for custom configurations and information on ancillary equipment. System Configuration 8-1 DMAN-14563 Rev. H 8-2 System Configuration Ku-Band ModuMAX SSPA DMAN-14563 Rev. H Appendix A Term A AC or ac A/D BOM BUC °C CFM cm CMOS CW DAC CCW dB dBc dBm dBW DC or dc DCE DMM DTE DVM EEPROM EIA EMC FET GaAs GCM GHz Hz IC I/O in in-lb kg Ku-Band lb LED µA Ku-Band ModuMAX SSPA Glossary Definition Ampere Alternating current Analog-to-digital Bill of materials Block upconverter Degrees Celsius Cubic feet per minute Centimeter Complementary metal-oxide semiconductor Clockwise Digital-to-analog converter Counter-clockwise Decibel Decibels with reference to carrier power Decibels with reference to a power of 1 milliwatt Decibels with reference to a power of 1 watt Direct current Data Communication Equipment Digital multimeter Data Terminal Equipment Digital voltmeter Electrically erasable programmable read-only memory Electronic Industries Association Electromagnetic compatibility Field-effect transistor Gallium arsenide Gain control module Gigahertz Hertz Integrated circuit Input/output Inch(es) Inch-pound Kilogram Frequencies in the range of 12-18 GHz Pound Light emitting diode Microampere Glossary A-1 DMAN-14563 Rev. H Term µF mA MHz mm MOSFET MOV ms mV N-cm NC NEC NO ns OIP3 pF PLD p-p PREV PS RAM RF SEL SPI SSPA TEMP UV V VA Vac Vdc VPC VSWR W Ω 1:1 A-2 Glossary Ku-Band ModuMAX SSPA Definition Microfarad Milliampere Megahertz Millimeter Metal oxide semiconductor field effect transistor Metal-oxide varistor (variable resistor) Millisecond Millivolt Newton-centimeter Normally closed National Electrical Code Normally open Nanosecond Third order output intercept point Picofarad Programmable logic device Peak-to-peak Previous Power supply Random access memory Radio frequency Select Serial peripheral interface Solid-state power amplifier Temperature Ultraviolet Volt Volt-ampere Volts alternating current Volts direct current Variable phase combiner; variable phase combined Voltage standing wave ratio Watt Ohm Redundant configuration with one standby amplifier for one main or primary amplifier DMAN-14563 Rev. H Ku-Band ModuMAX SSPA Notes