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Cubic COM5000-8 Instruction And Maintenance Manual

Hf-ssb 5-kw linear power amplifier
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351804-1 Rev. 100
COM5000-8 TECHNICAL MANUAL
Instruction and Maintenance Manual
COM5000-8
HF-SSB 5-kW Linear Power Amplifier
THIS DOCUMENT CONTAINS DATA WHICH IS PROPRIETARY TO, OR A TRADE SECRET OF, CUBIC
DEFENSE APPLICATIONS, INC. THIS DOCUMENT AND THE DATA CONTAINED THEREIN SHALL
NOT BE USED, DUPLICATED, DISCLOSED OR ALTERED WITHOUT THE EXPRESS WRITTEN CONSENT
OF CUBIC DEFENSE APPLICATIONS, INC. NO RIGHT, TITLE, OR INTEREST IS GRANTED, EXPRESSLY
OR BY IMPLICATION, IN OR TO ANY DATA CONTAINED HEREIN BY VIRTUE OF ITS DISCLOSURE
TO OR USE BY THE HOLDER/RECIPIENT. DISCLOSURE MAY NOT BE MADE TO ANY THIRD
PARTY FOR ANY PURPOSE. ALL STATUTORY AND COMMON LAW RIGHTS ARE HEREBY RESERVED.
Cubic Defense Applications, Inc.
9333 Balboa Ave
San Diego, CA. 92123
Telephone: (858) 505-2024
Telefax (858) 505-1593
Manual Part No. 351804-1

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  • Page 1 COM5000-8 HF-SSB 5-kW Linear Power Amplifier THIS DOCUMENT CONTAINS DATA WHICH IS PROPRIETARY TO, OR A TRADE SECRET OF, CUBIC DEFENSE APPLICATIONS, INC. THIS DOCUMENT AND THE DATA CONTAINED THEREIN SHALL NOT BE USED, DUPLICATED, DISCLOSED OR ALTERED WITHOUT THE EXPRESS WRITTEN CONSENT OF CUBIC DEFENSE APPLICATIONS, INC.
  • Page 2 COM5000-8 HF-SSB 5-kW Linear Power Amplifier THIS DOCUMENT CONTAINS DATA WHICH IS PROPRIETARY TO, OR A TRADE SECRET OF, CUBIC DEFENSE APPLICATIONS, INC. THIS DOCUMENT AND THE DATA CONTAINED THEREIN SHALL NOT BE USED, DUPLICATED, DISCLOSED OR ALTERED WITHOUT THE EXPRESS WRITTEN CONSENT OF CUBIC DEFENSE APPLICATIONS, INC.
  • Page 3 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Revisions/Updates Date Description Approval Initial release. E. Wise 1/30/15...

  • Page 4: Table Of Contents

    Transmitter External Control Protocol ................... 17 3.3.4 Continuous Bit Operation ...................... 17 CHAPTER 4 FUNCTIONAL DESCRIPTION ..................... 25 INTRODUCTION ........................25 COM5000-8 SYSTEM ......................25 1.25KW PA MODULE ......................25 COMBINER MODULE......................28 SYSTEM CONTROLLER MODULE ..................28 POWER SUPPLY MODULE ....................30 CHAPTER 5 MAINTENANCE ........................
  • Page 5 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL MODULE AND SUBASSEMBLY MAINTENANCE ............... 31 5.4.1 PA Module Maintenance ....................... 32 5.4.1.1 Harmonic Filter Assembly Maintenance................36 5.4.1.2 350 W Amp Assembly Maintenance ..................37 5.4.1.3 PA Controller PCB Assembly Maintenance ................38 5.4.1.4...
  • Page 6 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL FRONT VIEW OF TRANSMITTER...

  • Page 7: General

    This manual describes the 5 kW Linear Power Amplifier that is part of a 5 kW Transmitter. The 5 kW Transmitter comprises the COM5000-8 power amplifier with the T-4180 Exciter as pictured above. This manual provides a basic description of Transmitter operation. For detailed operation of the Exciter, refer to the T-4180 manual.

  • Page 8: 5-Kw Transmitter Performance Specifications (*)

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 5-kW TRANSMITTER PERFORMANCE SPECIFICATIONS (*) Frequency Range: 2 to 30 MHz Power Output: Nominal 5000 watts average and PEP RF Input Power: + 21 dBm nominal (from T-4180 Exciter) Gain Flatness: +/-0.5dB over 2.0 to 30 MHz (4455 - 5610 watts) with T-4180 Exciter...

  • Page 9: Scope Of Manual

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL SCOPE OF MANUAL This Manual is intended for use by experienced technicians familiar with similar equipment. The information it contains is current as of the printing date. Subsequent engineering changes are described in supplementary Instruction Manual Revisions issued as needed. The applicable schematic diagram is updated and the changes are described in a revision column on the diagram.
  • Page 10 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL In addition, do not operate this equipment near electrical blasting caps or in an explosive atmosphere. All equipment must be properly grounded according to installation instructions for safe operation. Compressed air used for cleaning purposes shall not exceed 30 psi (207 kPa) and then shall be used only when goggles or face shields are used for personnel eye protection.

  • Page 11: Chapter 1 Description

    4-Way Combiner module, a System Controller module and a T-4180 exciter module. The modules are enclosed in a standard 19” rack cabinet. The COM5000-8 is capable of delivering a nominal output power of 5000 watts over the frequency range of 2 to 30 MHz.

  • Page 12: Chapter 2 Installation

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL CHAPTER 2 INSTALLATION GENERAL 2.1.1 Government Regulations Ensure that the use of the 5-kW Transmitter satisfies government regulation. In most countries, radio transmitters may be adjusted only by persons holding a suitable government license or by personnel working under their immediate supervision.

  • Page 13: Rack Cabinet Installation

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 2.1.4 Rack Cabinet Installation Install the Transmitter by first installing the rack cabinet in its intended location. It may be necessary first to remove modules from the rack cabinet in order to reduce cabinet weight or to fasten the cabinet to the floor.

  • Page 14: Rack Cabinet Mounting

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 2.1.4.2 Rack Cabinet Mounting Prior to installation of the rack cabinet, the location must be prepared to accept mounting bolts in the locations shown in figure 2.1.4.2A. All external cables are routed through the large cable entry brush strip opening at the lower rear of the cabinet.
  • Page 15 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 21.9 31.6 Pivot radius = 2.75 Slot size = 1.2 x 0.4 Typical Bolt Hole Pattern Bolt-down brackets can be rotated 360° All dimensions are in inches Figure 2.1.4.2A. Rack Cabinet Mounting Hole Locations...
  • Page 16 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 2.25” (5.7cm) Lifting Eyes (4X) Blank Panel (2U) 4-Way Combiner Module (3U) System Controller Module (3U) T-4180 Exciter Module (3U) 1.25 kW PA Module (6U) 1.25 kW PA Module (6U) 83.1” (211cm) 1.25 kW PA Module (6U) 1.25 kW PA Module...

  • Page 17: Reconnecting Cables To Modules

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 2.1.4.3 Reconnecting Cables To Modules The connections are shown on the Transmitter Interconnect Wiring Diagram in schematic form (see figure 5.1). Cables are secured to cable retractors and are ready to be connected to modules except for the following large coax cables: a.

  • Page 18: System Controller Module Connections

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 2.1.4.3.2 System Controller Module Connections System System Module Module Controller Controller Connected Connector Connector Connector Connector Label Type Label Type RF Output RF INPUT PA module #1 J6-1 RF Output RF INPUT PA module #2...

  • Page 19: Additional Module Connections

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 2.1.4.3.3 Additional Module Connections PA Modules Combiner Combiner PA module PA module Connected Module Module Connector Connector Connector Connector Label Type Label Type RF Output Combiner RF IN PA module #1 RF IN RF Output...

  • Page 20: External Connections To The Transmitter

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 2.1.4.4 External Connections to the Transmitter All connections are routed through the cable entry brush strip located below the rear door. AC LINE Input Connection The External AC Line power cable connects to the terminal block inside a junction box at the bottom inside floor of the cabinet.

  • Page 21: Chapter 3 Operation

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL CHAPTER 3 OPERATION 3.1. INTRODUCTION This section describes the controls and indicators available to the operator. Basic operation of the Power Amplifier is also described. For a description of the exciter controls and display refer to the T-4180 manual.
  • Page 22 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Figure 3.2.1. Power Supply Module Front Panel...

  • Page 23: Pa Module

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 3.2.2 PA Module Figure 3.2.2 shows the PA Module front panel. The indicators are described below: Indicator Function POWER LED, (green) When lit, indicates that bias is enabled in the PA module. FAULT LED, (red) When lit continuously, indicates a fault in the PA module.
  • Page 24 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Figure 3.2.2. PA Module Front Panel...
  • Page 25 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Figure 3.2.3. System Controller Module Front Panel...

  • Page 26: T-4180 Exciter Module

    The COM5000-8 power amplifier can be considered an "extension" of its model T-4180 exciter. Transmitter operation is described in the T-4180 Manual. To a major degree, the COM5000-8 is transparent to the operator of the T-4180 however, the following should be noted: The COM5000-8 power amplifier will continue to operate under most fault conditions providing as much power output as is possible dependent upon the particular condition.

  • Page 27: Transmitter External Control Protocol

    During operation a number of critical functions are monitored to detect performance degradation or faults. The conditions monitored in each of the modules comprising the COM5000-8 and in the rack cabinet system as well as “external” conditions monitored are described in the following.
  • Page 28 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL In addition to the System Controller and PA module LED display, the T-4180 Status display will show operational parameters and specific fault conditions. The first of two T-4180 status screens is evoked as follows: From the T-4180 default screen press [NEXT] ...
  • Page 29 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Fault definition: P X A 0 0 0 350W AMP 350W AMP Bit 0 350W AMP 1A Bit 1 350W AMP 1B 350W AMP 350W AMP Bit 2 350W AMP 2A Bit 3 350W AMP 2B 1.25 kW PA module front view.
  • Page 30 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL PA Module Fault Decoding Tables Left Digit (P) 350W AMP 2B 350W AMP 2A 350W AMP 1B 350W AMP 1A FAULT FAULT FAULT FAULT FAULT FAULT FAULT FAULT FAULT FAULT FAULT FAULT FAULT FAULT...
  • Page 31 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL LED FAULT DISPLAY 1.25kW PA Module: PA Module Temperature Fault: A temperature (TEMP) fault is declared when the 350W AMP heatsink temperature exceeds approximately 100°C. The transmitter response is to disable bias from the affected 350W AMP and reduce system power output as needed to continue operation.
  • Page 32 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL PA Module Harmonic Filter Fault: Filter relay faults are declared whenever the selected filter relay pair current is above or below specific hardware set limit. The loss of RF signal through the filter selected also results in a filter fault.
  • Page 33 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL The LED display will only show that a PA module has faulted. The specific fault condition is indicated on the T-4180 Module Status screen #2. When the fault condition disappears, the fault LED’s will turn OFF on the next key – or in case of a critical fault –...
  • Page 34 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL When the FAN fault condition disappears, the AIR FLOW fault LED will turn OFF on the next key. It takes approximately 10 seconds of transmission for this fault to be cleared. (Note: Momentary flashing of a fault LED does not indicate a fault.

  • Page 35: Chapter 4 Functional Description

    The Combiner output is routed to the antenna. Control and monitoring functions are provided by the System Controller Module. The COM5000-8 is powered by a 3-phase Power Supply Module rated at 15kW DC out (50V @ 300A). 1.25KW PA MODULE A block diagram of the 1.25kW PA Module is shown below in figure 4.3.
  • Page 36 PA module RF #1 RF #2 RF #3 RF #4 PA Control I/O Driver/Splitter/ALC PCB Controller PCB assembly assembly System Controller module Exciter Control I/O Supply monitor/control T-4180 System Control I/O’s Exciter 50VDC Power Supply module Figure 4.2. COM5000-8 Block Diagram...
  • Page 37 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 350W AMP 350W AMP 350W AMP 350W AMP Figure 4.3. 1.25 kW PA module Block Diagram...

  • Page 38: Combiner Module

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL COMBINER MODULE The Combiner module receives signals from the four 1.25kW PA modules and combines the signals, in-phase, to yield the 5kW output signal. The output signal is routed through a VSWR Detector (located inside the combiner module) to provide forward and reflected power information for the System Controller.
  • Page 39 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Combiner Combiner module Control control and monitoring circuitry PA module Front Panel control and Meters monitoring Meter driver circuitry circuitry Microprocessor controlled RF OUT Fault sensing, control and multiplexing Driver/Splitter/ALC circuitry PCB assembly Power Supply...

  • Page 40: Power Supply Module

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL POWER SUPPLY MODULE The Power Supply consists of 3 invertors with the AC inputs and DC outputs connected in parallel. Each invertor is rated for 5 kW (50 VDC at 100 A). Total output power of the Power Supply is 15 kW (50 VDC at 300 A).

  • Page 41: Chapter 5 Maintenance

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL CHAPTER 5 MAINTENANCE INTRODUCTION The maintenance chapter contains a list of recommended test equipment, and instructions for mechanical disassembly, for verifying the performance of the amplifier, for routine adjustments, and for aligning the Transmitter.

  • Page 42: Pa Module Maintenance

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 5.4.1 PA Module Maintenance For 1.25kW PA Module maintenance refer to the PA Module Interconnect wiring diagram shown in figure 5.4.1. The 1.25kW PA Module comprises the following assemblies: 1 ea. PA/Driver/Splitter (heatsink) 351275-1 2 ea.
  • Page 43 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Figure 5.4.1A. 1.25kW PA Module Subassembly Location...
  • Page 44 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 351293-1 351293-1 1.25 kW COMBINER 351285-1 350W Amp #1A 350W Amp # 1B 351280-1 L163209-1 351289-1 FAN INTERFACE CONTROLLER FRONT TOP VIEW Figure 5.4.1B. 1.25kW PA Module...
  • Page 45 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 351280-1 350W Amp #2B 350W Amp #2A 351275-1 DRIVER/SPLITTER Line Flattener FRONT BOTTOM VIEW Figure 5.4.1C. 1.25kW PA Module...

  • Page 46: Harmonic Filter Assembly Maintenance

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 5.4.1.1 Harmonic Filter Assembly Maintenance See figure 5.4.1A To gain access to the Harmonic Filter PCB assembly, loosen the six captive screws that secure the filter assembly cover to remove the cover. CAUTION: RF HAZARD...

  • Page 47: 350 W Amp Assembly Maintenance

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 5.4.1.2 350 W Amp Assembly Maintenance To gain access to the bottom two 350 W Amp's remove the bottom cover. To gain access to the top two 350 W Amp's proceed as follows: Loosen the two "captive" screws that secure the Filter assembly to the 1.25kW PA Module front panel.

  • Page 48: Pa Controller Pcb Assembly Maintenance

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 5.4.1.3 PA Controller PCB Assembly Maintenance To gain access to the PA Controller PCB, proceed as follows: Loosen the two "captive" screws that secure the Filter assembly to the 1.25kW PA Module front panel.
  • Page 49 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Measure from: Verify values: Adjust for: Using potentiometer: 750 – 850 Ohm U2 pin 3 to ground 800 Ohm 800 – 900 Ohm U20 pin 6 - 7 850 Ohm 600 – 900 Ohm...
  • Page 50 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 50 Ohm Load 1.25kW PA Module “T” connector (direct at Wattmeter) RF OUTPUT Wattmeter Connector 50 Ohm Load Starting with a low RF output level from the RF Signal Generator increase the generator level until the forward power reading is 500W.

  • Page 51: Driver/Splitter Maintenance

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 5.4.1.4 Driver/Splitter Maintenance To gain access to the Driver/Splitter, remove the 1.25kW PA Module bottom cover. The location of the Driver/Splitter is shown in figure 5.4.1C. Adjustments: The following adjustments should only be performed when a PCB assembly has been repaired in the field.

  • Page 52: Kw Combiner Maintenance

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Driver Gain adjustment (1.25kW PA Module gain): The DRIVER/ALC gain adjustment, using potentiometer R2, is performed to set the 1.25kW PA Module gain equal to approximately 47 dB at 29.9 MHz. Operate the PA Module as a “stand alone” Amplifier – while still part of the Transmitter - as described in section 5.4.1 above.

  • Page 53: Combiner Module Maintenance

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 5.4.2 Combiner Module Maintenance Adjustments: See System Controller operational adjustment in section 5.4.3.3. 5.4.3 System Controller Module Maintenance For System Controller maintenance, refer to the System Controller Interconnect wiring diagram shown in Figure 5.4.3.

  • Page 54: Driver/Splitter/Alc Pcb Maintenance

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 21000044 1638-2001-1 Driver/Splitter/ System Controller 1638-2000-1 L162087 Power Supply Front Figure 5.4.3A: SYSTEM CONTROLLER TOP VIEW 5.4.3.1 Driver/Splitter/ALC PCB Maintenance To gain access to the Driver/Splitter/ALC PCB proceed as follows: 1. Remove the 4 retaining screws that secure the System Controller module to the rack cabinet. Pull the module slowly out all the way.

  • Page 55: System Controller Pcb Maintenance

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Adjust VR1 for 1.0 VDC measured on U13 pin 8 on the Driver/Splitter/ALC PCB. This sets the normal input drive level to the microprocessor. If more than 22 dBm is applied to the RF input connector of the System Controller, the overdrive protection will engage.
  • Page 56 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Measure resistance between: Verify values: Adjust: 2.2 – 2.4 K ohm U29 pin 3 and GND VR6 for 2300 Ohm 2.2 – 2.4 K ohm U29 pin 5 and GND VR7 for 2300 Ohm 2.6 –...
  • Page 57 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL 5 kW Transmitter T-4180 Exciter Audio (J6) PA Control (J5) Output (J3) Variable Attenuator RF Signal Generator Exciter Interface (J3) RF INPUT (J5) System Controller module Directional 50 Ohm RF OUTPUT Termination Coupler ≤12”coax...
  • Page 58 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Setting System Controller potentiometers, Forward Power Set up per figure 5.4.3.3. Command the Transmitter to operate on a frequency of 15 MHz, CW mode. Set the variable attenuator for maximum attenuation. Key the Transmitter.
  • Page 59 Setting System Controller potentiometers, Reflected Power Connect the T-4180 – through a variable attenuator – to the COM5000-8. The variable attenuator is set for maximum attenuation. The T-4180 is set to operate in CW mode of operation at 100% power at a frequency of 15 MHz.
  • Page 60 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Transmitter ≤ 5 feet coax Directional Coupler Wattmeter 4381 50 Ohm, 4 kW Load/ Attenuator w. Blower 8929-300 50 Ohm Load, 10 kW Bird 8931 Key the system and observe the Wattmeter reading. The forward power should be close to 2000W and the reflected power close to 200W.

  • Page 61: Power Supply Module Maintenance

    351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Observe the forward power reading on the wattmeter. Adjust VR5 clockwise until the power drops to 1750W - or if no power reduction is observed - adjust VR5 fully clockwise. While observing that the power output remains below 2750W, reduce the attenuation on the Variable Attenuator in small increments until the attenuation is zero.
  • Page 62 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL SPARE MODULES AND ASSEMBLIES Spare Modules: Description PART NUMBER COM5000-8 System Controller 1638-1000-12 1.25 kW Power Amplifier 351270-2 Power Supply 351830-2 Output Combiner L163145-1 T-4180 Exciter 1644-1000-4 Spare Assemblies: Description PART NUMBER Part of...
  • Page 63 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Figure 5.1. Transmitter Interconnect Wiring Diagram...
  • Page 64 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Figure 5.4.1. PA Module Interconnect Wiring Diagram...
  • Page 65 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Figure 5.4.3. System Controller Interconnect Wiring Diagram...
  • Page 66 351804-1 Rev. 100 COM5000-8 TECHNICAL MANUAL Figure 5.4.4. Power Supply Interconnect Wiring Diagram...

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