Attachment 3 - FPMU Specification Information.pdf

Handbook No. 1391-9 November 2011

Page (i)

THALES Defence Security C4I Systems and Air Operations (DSC&AO) Manor Royal, Crawley, West Sussex, RH10 9HA, England.

TEL: +44 (0)1293 580000

FAX: +44 (0)1293 581523

USER'S MANUAL

FOR

COMMON AERIAL WORKING

CA6400 SERIES

(604442-00)

1391-9

Page (ii) Nov 11

THALES UK DSC&AO equipment is subject to continuous development and improvement and, in consequence, may incorporate minor detail changes from the information contained in this handbook.

© 2011 THALES UK DSC&AO

NO PART OF THIS HANDBOOK MAY BE COPIED, REPRODUCED, TRANSMITTED

OR UTILISED IN ANY FORM OR BY ANY MEANS WITHOUT THE PRIOR WRITTEN

PERMISSION OF THALES UK LIMITED.

Nov 11 Page (iii)

AMENDMENT RECORD

When an Amendment is inserted in this handbook, the brief details below should be filled in. The method of incorporating the amended material will be described on the accompanying Amendment Instruction Sheet.

Amdt.

No.

Amendment incorporated by

Date of insertion

Amdt.

No.

Amendment incorporated by

Date of insertion

1 CN41108 Mar 10 21

2 TAP5799 Mar 10 22

3 CN41820 Jun 11 23

4 CN42664 Nov 11 24

5 25

6 26

7 27

8 28

9 29

10 30

11 31

12 32

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14 34

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INTENTIONALLY BLANK

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QUALITY ASSURANCE

Quality is recognised as the cornerstone of the company’s success, and all THALES UK DSC&AO activity is governed by the stringent standards laid down in BS EN ISO 9001, TickIT and other European quality standards.

PRODUCT SUPPORT

The company’s policy is to provide a wide range of ancillary services geared to the customer’s needs.

This involvement ranges from the initial feasibility study, through installation and commissioning, to the provision of training courses for both operators and maintainers. Comprehensive handbooks are provided with all equipments and systems. These may be written either to our standard commercial specification, based on BS4884, or to meet specific customer requirements. All products are backed by our service and repair facility, with associated spares back-up and post design service. Additional product support can be offered as required.

DSC & AO

Page (vi) Nov 11

NOTES TO MAINTAINERS

FEEDBACK

Every effort is made to ensure that THALES UK DSC&AO handbooks provide information that is as complete and accurate as possible. If by practical experience maintainers identify areas where changes or additions to the information may be beneficial, the company would welcome such suggestions.

Correspondence should be addressed to:

THALES UK DSC&AO,

Customer Support and Services Department, Manor Royal, Crawley, West Sussex, RH10 9HA, England.

From UK: From abroad:

Telephone: 01293 580000 +44 1293 580000

HANDBOOK NUMBERING

The handbook number appears within the header of each page. The suffixed number after the hyphen indicates the issue status of the handbook, e.g. 1391-9 indicates that the handbook is at Issue 9. In general when referring to handbooks the issue status will not be included.

Numbers in brackets, after the issue status, e.g. 1391-9(4), indicates the category and will only appear in the handbook header.

All drawings, unless otherwise indicated, are shown from the viewpoint of a person standing in front of the installed equipment.

CUSTOMER SUPPORT

In the event of any problems being experienced with the product THALES UK DSC&AO Customer Support Department may be contacted by telephone (see above) or by FAX on:

From UK: From abroad:

FAX (Customer Support): 01293 581523 +44 1293 581523

Or e-mail to: tclsupporteng@uk.thalesgroup.com

Nov 11 Page (vii)

SAFETY FIRST

GENERAL

The operation of electronic equipment involves the use of voltages that may present a hazard to the maintainer. A hazardous voltage is any voltage exceeding 42.4V peak (AC) or 60V DC.

Although every reasonable practicable safety precaution has been incorporated in this equipment, the following rules should be observed.

The power should be disconnected and any high voltage capacitors tested to ensure discharge is complete before handling the interior of equipment units.

If it is necessary to make measurements on equipment with power applied it is essential that two persons are present, both fully conversant with the equipment, and capable of rendering first aid. A means of isolating the equipment from the mains must be within easy reach.

If, for special purposes, safety devices such as interlocks, gate switches or protective covers are made inoperative, the person authorising this act thereby assumes responsibility for ensuring that suitable alternative safety precautions are taken to safeguard personnel and for the restoration to normal operating conditions.

The equipment should never be operated without being connected to earth and to the supply in the approved manner outlined in the installation chapter of the handbook.

MECHANICAL SAFETY

To ensure safe handling every effort is made to eliminate sharp edges, burrs and protrusions from equipment on both external and internal faces.

Racks and cabinets, when properly installed, are designed to be stable and safe from toppling when any unit is extended on runners, and also upon removal of a lower heavy unit.

When removing units from a rack or cabinet, cables must be disconnected and a flat surface large enough to support the entire unit placed as close as possible, with suitable protection for any projecting items.

Careful note should be made of limits of extraction or stops when starting withdrawal and the marked lifting points or handles used.

No attempt should be made to transfer equipment weighing more than 13kg (28lb) to a supporting surface without an assistant, since even comparatively light units are frequently too large for a safe two hand grasp.

CHEMICAL SAFETY

Where the use of potentially toxic material is unavoidable dangerous material is clearly marked.

Warnings are published in local Safety Instructions and Regulations and manufacturers data sheets specifying the precautions to be taken in handling such material, and remedial action to be taken in the event of accidental contact with the material.

DISPOSAL OF HAZARDOUS MATERIAL

The disposal of hazardous material is to be carried out in accordance with the latest local Safety Orders and Regulations.

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Nov 11 Page (ix)

WARNINGS

HAZARDOUS SUBSTANCES

Before using or handling any hazardous substance or material, the user must be conversant with the safety precautions and first aid instructions:

1. On the label of the container it was supplied in.

2. On the material Safety Data sheet.

3. In local Safety Orders and Regulations.

WARNINGS

1. BERYLLIUM. THIS EQUIPMENT CONTAINS COMPONENTS MANUFACTURED FROM

BERYLLIUM. TAKE ALL PRECAUTIONS IN ACCORDANCE WITH LOCAL SAFETY

ORDERS AND REGULATIONS.

2. LETHAL VOLTAGES. DANGEROUS VOLTAGES EXIST IN THIS EQUIPMENT. REFER

TO LOCAL SAFETY ORDERS AND REGULATIONS.

3. RF EMISSIONS. HIGH POWER RF IS TRANSMITTED BY THIS EQUIPMENT. BEFORE

WORK IS CARRIED OUT ON THE EQUIPMENT OR ASSOCIATED AERIAL SYSTEMS,

MAN ALOFT PROCEDURES, ARE TO BE COMPLETED IN ACCORDANCE WITH

LOCAL SAFETY ORDERS AND REGULATIONS.

4. RELEASE OF TOXIC SUBSTANCES. AS THE RESULT OF A FIRE, SOME MATERIALS

IN THE EQUIPMENT CAN RELEASE TOXIC FUMES OR LEAVE A TOXIC RESIDUE.

REFER TO LOCAL SAFETY ORDERS AND REGULATIONS.

5. CARBON DIOXIDE. WHEN CO2 HAS BEEN RELEASED, THE COMPARTMENT IS TO

BE FULLY VENTILATED FOR 10 MINUTES TO RETURN THE AIR TO NORMAL.

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Nov 11 Page (xi)

CAUTIONS

1. SWITCH CLEANING FLUID. Propriety brands of switch cleaning fluid may contain solvents capable of dissolving plastic used in certain types of switch and is only to be used as directed by the manufacture.

2. ELECTROSTATIC SENSITIVE DEVICE. All necessary precautions, in accordance with good work practice, are to be observed when handling these devices.

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FOREWORD

This User’s Manual (Handbook No.1391) is supplied with each Common Aerial Working outfit in the CA6400 series, and contains all the information necessary for personnel to install, operate and maintain the equipment in the field in safety and with maximum efficiency.

The CA6400 series represents a range of equipments within the THALES UK DSC&AO Series 6000, the various digits having the following meanings:

CA 6 x x x Series 6000 family of products

Number of transmitter inputs:

4 to 16

Flexible Power Management:

0 - Not fitted 4 - 4-way matrix

Diplexer cross-over frequency:

0 - Not fitted 1 - 8 MHz 2 - 9 MHz 3 - 6 MHz

NOTE

THALES UK DSC&AO equipment is subject to continuous development and improvement and, in consequence, may incorporate minor detail changes from the information contained in this handbook.

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Nov 11 Page (xv)

ASSOCIATED HANDBOOKS

1. Engineering Manual for Series 5000/6000 System Control (Handbook 1435) contains protocol information necessary for a System engineering organisation to adapt their Communications Management System (CMS) to control and monitor a Series 5000 or Series 6000 HF radio sub-system.

Handbook 1503 Technical Manual for CU6000 Control Unit.

For Control Unit Category 2 (Operating Information) necessary for personnel to operate specific series 6000 radios reference should be made to the following handbooks:

Handbook 1441 Operating Information for CU 6000 Control Unit when used with Receivers Type

TMR6100/6110S/D

Handbook 1446 Operating Information for CU 6000 Control Unit when used with Transmitters

TMR6309/6319S/D

Handbook 1447 Operating Information for CU 6000 Control Unit when used with Transceivers Type TMR6209/6219S/D

Handbook 1449 Operating Information for CU 6000 Control Unit when used with Multicoupler -

MCU 6412

For information on specific equipment reference should be made to the following handbook(s):

Handbook 1341 User's Manual for Aerial Coupling Unit Type AEA-177 (ACU50)

Handbook 1382 User's Manual for single 500W Transmitter T6501S and single 1kW Transmitter T6102S with single Exciter E6000S.

Handbook 1384 User's Manual for dual 1kW Transmitter T6102D & dual 500W Transmitter T6501D with two Drive Units type DU600.

Handbook 1386 User's Manual for Receiver Multicoupler Type MCU6412

Handbook 1392 User's Manual for Common Aerial Working CA6500 Series

Handbook 1393 User's Manual for Common Aerial Working CA6840 Series

Handbook 1402 User's Manual for Single and Dual HF Transmitters and Transceivers

TMR6305/TMR6315 TMR6205/6215

Handbook 1428 User's Manual for 6000 Series Single/Dual Receiver and Exciters Half and Full Duplex.

Handbook 1430 User Manual for Series 6000 Standard Receiver Cabinet.

Handbook 1431 User's Manual for 6000 Series Frequency Reference Assembly

Handbook 1433 User’s Manual for Single and Dual HF Transmitters and Transceivers

TMR6309/TMR6319 TMR6209/6219

Handbook 1435 Engineering Manual for Series 5000/6000 System Control

Handbook 1439 User's Manual for Transmitter Loop Antenna Type AS6001

Handbook 1501 User Manual for 125W Transceivers Type TMR6201 and TMR6211

Handbook HB634797-00 User Manual for PA8105H 500W HF Power Amplifier

Handbook HB608690-00 User Manual for PA8109H 1kW HF Power Amplifier

Page (xvi) Nov 11

LIST OF ABBREVIATIONS

ACH Anti-Condensation Heater O/H Overheat

BCD Binary Coded Decimal PA Power Amplifier BITE Built-In Test Equipment PAL Programmable Array Logic PEC Panel, Electronic Circuit CAW Common Aerial Working pep Peak Envelope Power CMOS Complementary Metal Oxide Silicon PMU Power Monitor Unit CO2 Carbon Dioxide PMU6400 Power Management Unit

(as developed for Series 6000 CAW)

CU

Control Unit (in transmitter cabinet) PSU Power Supply Unit

PTT Press To Talk DU Drive Unit (in transmitter cabinet) PWR Power

FWD Forward R/C Resistor/Capacitor (filter network) FPMU REM Remote

Flexible Power Management Unit (Type PMU6400) REV Reverse

RF Radio Frequency HAT Harbour Acceptance Trial RN Royal Navy HF High Frequency Rx Receiver

IC Integrated Circuit SS Ship’s Staff IDC Insulated Displacement Connector TDR Tune Drive Ready

(signal in transmitter) LED Light Emitting Diode L/R Local/Remote TI Tune Initiate (signal in transmitter) TPR Tune Power Request

(signal in transmitter) MCB Miniature Circuit Breaker MF Medium Frequency TTL Transistor-Transistor Logic M/S Master/Slave Tx Transmitter; consists of Exciter

(Signal Control/Source) and PA.

NSN Nato Stock Number VSWR Voltage Standing Wave Ratio

Nov 11 Page (xvii)

CONTENTS

Preliminary pages:

Title/Copyright Amendment Record Safety Information Warnings Cautions Foreword/List of Abbreviations Contents (this page)

CATEGORY 1 PURPOSE AND PLANNING INFORMATION

CATEGORY 2 OPERATING INFORMATION

CATEGORY 3 TECHNICAL DESCRIPTIONS

CATEGORY 4 INSTALLATION AND SETTING TO WORK

CATEGORY 5 MAINTENANCE INFORMATION

CATEGORY 6 MAINTENANCE SCHEDULE

CATEGORY 7 PARTS LISTS

APPENDIX A CIRCUIT DIAGRAMS

APPENDIX B HEAT EXCHANGER

APPENDIX C ERROR CODES

APPENDIX D ONE-LINE RF LOAD BALANCING UNIT

Page (xviii) Nov 11

1391-9(1)

Nov 11 Page i

CATEGORY 1

PURPOSE AND PLANNING INFORMATION

Chapter 1 Introduction to Common Aerial Working

Chapter 2 Brief Description

Chapter 3 Specification

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Nov 11 Page 1-1

CHAPTER 1

INTRODUCTION TO COMMON AERIAL WORKING

Paragraph Page

Introduction ......................................................................................................................................... 1-3 Hybrid Power Combiner Technique.................................................................................................... 1-3 Series 6000 Common Aerial Working................................................................................................. 1-4

Diplexer ........................................................................................................................................... 1-5 Frequency Flexibility........................................................................................................................ 1-5 Effect of VSWR ............................................................................................................................... 1-5

Alternative Configurations................................................................................................................... 1-6 Number of Lines .............................................................................................................................. 1-6 Power Efficiency.............................................................................................................................. 1-6 Physical Size ................................................................................................................................... 1-6 Inter-Transmitter Intermodulation Products..................................................................................... 1-6

Broadband Aerials .............................................................................................................................. 1-7

Figure Page

Figure 1 - Non Related Signals .............................................................................................................. 1-3 Figure 2 - Equal Amplitude Phase Coherent Signals............................................................................. 1-4 Figure 3 - Typical CAW System ............................................................................................................. 1-4 Figure 4 - Inter-TX IPs, No Filters........................................................................................................... 1-6 Figure 5 - Inter-TX IPs, Low-Pass Filters ............................................................................................... 1-6 Figure 6 - Inter-TX IPs, Band-Pass Filters - 1 ........................................................................................ 1-7 Figure 7 - Inter-TX IPs, Band-Pass Filters - 2 ........................................................................................ 1-7

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INTRODUCTION

1. The tactical and strategic communications needs of a modern fighting vessel dictate the need for a considerable number of discrete lines of HF communications. The number of these lines can give rise to a proliferation of aerials on the upper deck which in addition to creating mutual interference problems, limits the use of the upper deck as a weapon platform. The solution is to provide a system which enables one aerial to service several lines, I.E. a Common Aerial Working System.

HYBRID POWER COMBINER TECHNIQUE

2. We can state the primary objectives of the Common Aerial Working System as being:

• To provide a clean transmit frequency spectrum with minimum intermodulation products thereby avoiding blocking of receive channels.

• The ability to operate each line independently with no constraints on the use of the other lines.

3. The Thales Hybrid Power Combiner Technique achieves these objectives by amplifying the channels in individual amplifiers. The power outputs of each of the amplifiers are then combined in an array of hybrid combiners which provide isolation of one amplifier to another and by being passive are inherently linear.

4. The system makes use of the inherent characteristics of hybrid combiners which are:

• Application of two unrelated signals, one to each input port of the hybrid, results in half of each signal being delivered to the output port and half to the balancing loads (see Figure 1).

• Application of two equal amplitude and in phase signals; one to each input port of the hybrid, results in summing of the two signals at the output port with only unbalance signals (ideally zero), being delivered to the balancing loads (see Figure 2).

• The inherent isolation provided across the ports thereby buffering the outputs of the driving sources one from the other.

Hybrid Combiner

Balancing Loads

P1, F1

P2, F2

P1x0.5, F1 P2x0.5, F2

P1x0.5, F1 P2x0.5, F2

FIGURE 1 - NON RELATED SIGNALS

Page 1-4 Nov 11

Hybrid Combiner

Balancing Loads

P1, F1

P1, F1

P = 0

P1x2, F1

FIGURE 2 - EQUAL AMPLITUDE PHASE COHERENT SIGNALS

SERIES 6000 COMMON AERIAL WORKING

5. The CA6400 series provides 4 lines of common aerial working with a transmitted power of 250 W per line, using the combiner configuration shown in Figure 3.

2 - 8 MHz

8 - 30 MHz

BPF

BPF

BPF

BPF

Power Management Matrix - PMU6400

1 kW

1 kW

1 kW

1 kW

500 W x 2 (or 2 kW x 1)

H1

H2

H3 Diplexer

Exc

Exc

Exc

Exc

FIGURE 3 - TYPICAL CAW SYSTEM

6. Flexible power management is provided, through the use of the PMU6400, whereby the available aerial power can be optimised in respect of the actual number of lines required for any specific operational scenario.

7. In the case where the full four lines are required, Exciters 1 to 4 operate in independent mode, and each hybrid in the transmission path reduces the available power by 3 dB, resulting in each transmitter line delivering 250 W to the aerial.

8. Where only 3 lines are required then PAs 1 and 2 can be driven together (via the PMU6400) by one Exciter. In this case the available power at H1 output is the sum of the two amplifier outputs, i.e.

2000 W, to be reduced by 3 dB by H3 resulting in 1000 W at the Diplexer. The 2 lines of 250 W from PA’s 3 and 4 remain unchanged.

9. Alternatively, PAs 3 and 4 can be driven together (via the PMU6400) by one Exciter. In this case the available power at H2 output is the sum of the two amplifier outputs, i.e. 2000 W, to be reduced by 3 dB by H3 resulting in 1000 W at the Diplexer. The 2 lines of 250 W from PA’s 1 and 2 remain unchanged.

Nov 11 Page 1-5

10. Similarly should only 2 lines be required then both PA’s 1 and 2 and PA’s 3 and 4 can be likewise switched, providing 1000 W from PA’s 1 and 2 and 1000 W from PA’s 3 1nd 4 at the Diplexer.

11. If only one line is required then PA’s 1, 2, 3 and 4 can be driven from 1 Exciter, resulting in 2 kW at the outputs of both H1 and H2. These levels are summed in H3 to give 4000 W at the Diplexer.

12. This implementation therefore provides line combinations as follows:

• 4 lines at 250 W, or

• 2 lines at 250 W plus 1 at 1 kW, (PA’s 1 and 2 combined or PA’s 3 and 4 combined) or

• 2 lines at 1 kW, (PA’s 1 and 2 combined, PA’s 3 and 4 combined) or

• 1 line at 4 kW (PA’s 1, 2, 3 and 4 combined)(see Note at paragraph 15).

Diplexer

13. The combined signals at the output of H3 are divided into the two outputs, dependent upon frequency, for direct feed to the two sections of the broadband aerial. This is achieved using a Diplexer

- a purely passive filter which routes frequencies above 8 MHz out of one port and frequencies below 8 MHz out of the other. Alternative Diplexer cross-over frequencies are available and may be specified to order.

Frequency Flexibility

14. It can be seen that there is inherently no frequency separation constraint in this system; the four transmitters can for example be set on four adjacent channels or scattered anywhere between 1.5 and 30 MHz. This includes the Diplexer crossover frequency where there is no limitation in use, or degradation in performance.

Effect of VSWR

15. HF broadband aerials tend to have a fairly poor VSWR on board ship which can severely degrade transmission performance particularly in respect of intermodulation product generation. The high level combining, however, overcomes these difficulties. The power losses in the combiners provide buffering from the aerial, ensuring that the transmitters always see a good VSWR.

Consequently the VSWR does not significantly degrade the intermodulation products.

NOTE

Using the PMU6400 to drive multiple PAs from one Exciter reduces the combiner losses and therefore increases the aerial's VSWR as seen by the PAs. Using one Exciter to drive two PAs leaves the output combiner to provide buffering from the aerial's VSWR, which is sufficient. Configuring the PMU6400 to use one Exciter to drive all four PAs, provides no aerial VSWR buffering and should only be used if:

• The aerial’s VSWR is <2:1 at the operational frequency, and

• The power rating of the aerial is sufficient to support 4 kW mean power.

Page 1-6 Nov 11

ALTERNATIVE CONFIGURATIONS

Number of Lines

16. The Hybrid Combiner CAW system is not limited to the 4 lines of the CA6400 series. Thales have also supplied 5 line and 8 line systems, and can supply systems combining any quantity of transmitters from 4 to 16; larger quantities tend to become inefficient and smaller quantities provide insufficient buffering from a poor aerial VSWR.

Power Efficiency

17. The overall efficiency is high since the use of discrete class AB amplifiers with their inherently high efficiency more than compensates for the RF power lost in the combining process.

Physical Size

18. The Hybrid Combiner arrangement for a 4 x 250 W combiner system requires 2 Dual 1 kW Transmitter cabinets (2 cabinets) + a CA6400 combining system (1 cabinet) = 3 cabinets in total.

Inter-Transmitter Intermodulation Products

19. Inter-Transmitter IPs (or back-door IPs as they are sometimes called) result from one transmitter coupling to another. The fundamental frequency of one transmitter mixes, at the output of the PA of a second transmitter, with the fundamental frequency and its harmonics. This results in the usual series of IPs given by nf1 ± mf2. This effect can be seen with transmitters using whip aerials as well as those in CAW systems.

PA

PA

F1 = 2 MHz

F2 = 10 MHz

Output: F1 & F2 eg 2nd order: 8 & 12 MHz 3rd order 6, 14, 18 & 22 MHz etc.

Tx 1

Tx 2

Unwanted Outputs: nF1+/- mF2

FIGURE 4 - INTER-TX IPS, NO FILTERS

20. With Low Pass Filters fitted, which is normal practice for harmonic filtering, the third and higher order IPs are suppressed below the level of “top-side” noise. This is because F2 sees the stop-band of the LPF on Tx1 and is therefore prevented from mixing with F1 harmonics in PA1; F1 does mix with harmonics of F2 in PA2 to generate products around 2F2, 3F2 etc., which fall within the filter stop-band of Tx2. Accordingly they are suppressed by the filter and do not get radiated:

PA

PA

F1 = 2 MHz

F2 = 10 MHz

Output: F1 & F2 Unwanted Outputs: nF1 +/- mF2 eg 2nd order: 8 & 12 MHz

3rd order: None Higher orders: None

LPF

LPF

Tx 1

FIGURE 5 - INTER-TX IPS, LOW-PASS FILTERS

Nov 11 Page 1-7

21. On a large system even the second order IPs can add up and so in Series 6000 transmitters High-pass filters are fitted in series with the Low-pass to produce Band-pass filters. This results in no unwanted products being generated in the example used. This is because F1 sees the high-pass filter stop-band of Tx2 and F2 sees the low-pass filter stop-band of Tx1.

PA

PA

F1 = 2 MHz

F2 = 10 MHz

Output: F1 & F2 Unwanted Outputs: nF1 +/- mF2 eg 2nd order: None

3rd order: None Higher orders: None

BPF

BPF

FIGURE 6 - INTER-TX IPS, BAND-PASS FILTERS - 1

22. When the two frequencies fall in the same operational filter band then two of the four third order IPs are radiated, at approximately -50 dB wrt carrier, as these also fall within the same band:

PA

PA

F1 = 9 MHz

F2 = 10 MHz

Output: F1 & F2 Unwanted Outputs: nF1 +/- mF2 eg 2nd order: None

3rd order: 8 & 11 MHz Higher orders: None

BPF

BPF

FIGURE 7 - INTER-TX IPS, BAND-PASS FILTERS - 2

BROADBAND AERIALS

23. Since an element of modelling is required to predict the aerial performance the aerial selection is invariably determined by the customer’s own preference, experience on previous vessels and the top-side design of the vessel concerned.

24. The Series 6000 CAW systems are well suited for operation into all known naval broadband aerials.

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Nov 11 Page 2-1

CHAPTER 2

BRIEF DESCRIPTION

Introduction............................................................................................................................................. 2-3 Major Units.............................................................................................................................................. 2-6 Input/Output Data ................................................................................................................................... 2-6 Physical Data.......................................................................................................................................... 2-6

Figure 1 - Common Aerial Working Cabinet CA6441 ............................................................................ 2-2 Figure 2 - CA6400 Type Numbering System ......................................................................................... 2-3 Figure 3 - CA6441 - Layout of Units....................................................................................................... 2-4 Figure 4 - CA6443 - Layout of Units....................................................................................................... 2-5

Page 2-2 Nov 11

FIGURE 1 - COMMON AERIAL WORKING CABINET CA6441

Nov 11 Page 2-3

INTRODUCTION

1. The CA6400 series of Common Aerial Working systems combine the RF outputs of four 1 kW transmitters enabling simultaneous transmission from a single broadband aerial. The CAW system uses a passive hybrid combiner array to achieve an extremely linear combination of the transmitter lines.

This gives excellent spectral purity which ensures that the receive system can operate effectively.

2. The CAW system is designed to be used with Series 6000, 1 kW transmitters and transceivers, to provide 4 lines of 250 W (nominal) into a single broadband aerial or may be used with 500 W transmitters/transceivers to provide 4 lines of 125 W (nominal). Permutations of 1 kW and 500 W transmitters may also be used.

3. The CA6441 CAW system comprises a Combiner Array, a Diplexer with 8 MHz cross-over frequency and a Flexible Power Management Unit type PMU6400. The PMU6400 allows one exciter to drive up to four PAs resulting in phase coherent addition of signals within the combiner network, thus achieving greater output power per line at the aerial. The PMU6400 provides 4-way RF multiplexing and the switching of control lines. It uses 4-way hybrid splitter networks in conjunction with very linear amplifiers in each of the 4 inputs to achieve a 4-way power output matrix with zero nominal insertion loss. The PMU6400 contains non-volatile memory, enabling it to revert to the previous setting after a loss of or an interruption in power to the unit.

4. The PMU6400 has no front panel controls but operates from a remote control system via an RS485 serial data bus, or via an optional RS232 serial data interface. The Combiner Array provides status information to the remote control system via an RS485 serial data bus.

5. The CA6400 series is housed in a single 34U, 19” cabinet and is of rugged construction, suitable for use on a naval platform.

6. Details of variants and options available in the CA6400 series are shown in Figure 2.

CA 6 4 x x Series 6000 family of products

Number of transmitter inputs:

Flexible Power Management:

0 - Not fitted 4 - 4-way matrix

Diplexer cross-over frequency:

0 - Not fitted 1 - 8 MHz 2 - 9 MHz 3 - 6 MHz

FIGURE 2 - CA6400 TYPE NUMBERING SYSTEM

NOTE: Except where stated, this handbook covers all variants of the CA6400 series CAW systems.

Page 2-4 Nov 11

5409B

FRONT PANEL

INTAKE ASSY.

STATUS UNIT

DIPLEXER

FRONT PANEL

EXHAUST ASSY.

BLANK PANEL

(6U)

BLANK PANEL

(6U)

POWER MANAGEMENT

UNIT

FIGURE 3 - CA6441 - LAYOUT OF UNITS

Nov 11 Page 2-5

5409B

FRONT PANEL

INTAKE ASSY.

STATUS UNIT

DIPLEXER

FRONT PANEL

EXHAUST ASSY.

BLANK PANEL

(5U)

BLANK PANEL

(6U)

POWER MANAGEMENT

FIGURE 4 - CA6443 - LAYOUT OF UNITS

Page 2-6 Nov 11

MAJOR UNITS

7. Major units in the CA6441 cabinet are as follows:

• Status Unit - provides power distribution, cabinet indications and control (via an integral serial interface to the control system).

• Diplexer Unit - splits the RF output between the two output ports to the broadband aerial, depending on selected frequency.

• Flexible Power Management Unit (FPMU, type PMU6400) - enables up to four exciters to exclusively control up to four PAs simultaneously.

• Power Monitor Unit (PMU) - monitors the forward and reverse power output to the broadband aerial and provides an indication of VSWR.

• Hybrid Combiner Units and associated terminating loads - enable four transmitters to work into a common aerial.

• Dummy Load - enables combined output to be terminated internally for test purposes.

INPUT/OUTPUT DATA

8. Principal input/output data is given below:

Power supply, main: 115/230 V AC, 50 Hz, 300 W (maximum) anti-condensation: 115/230 V AC, 50 Hz, 110 W (nominal)

Wild heat output: 300 W, basic

3.3 kW, Inc Tx combining losses

Transmitter power: 500 or 1000 W pep/mean (1.2 kW max)

Nominal frequency range, HF: 1.5 - 30 MHz

Input to PMU6400: 100 mW (max) into 50 ohm load, 50mW (nominal)

PMU6400 output: 50 mW (nominal) into 50 ohm load

Maximum available output to common aerial: 4 kW pep/mean into 50 ohm load.

PHYSICAL DATA

9. Physical data for the CA6441 Cabinet is given below (nominal, excluding resilient mounts and heat exchanger):

Cabinet dimensions: Depth 800 mm Width 600 mm

Height1690 mm

Weight, fully equipped: 230 kg nominal.

10. The CA6443 has the same overall dimensions and weight; the only physical difference is the Diplexer (6 MHz) which is 4U high compared with 3U for the higher frequency devices. As a result the PMU6400 and air-intake panel have been lowered and the upper blank panel reduced from 6U to 5U.

Later versions of the CA6441 maintain the units in their lowered positions and a 1U blank is fitted below the Diplexer.

Nov 11 Page 3-1

CHAPTER 3

SPECIFICATION

Hazards............................................................................................................................................... 3-3 Interfacing ........................................................................................................................................... 3-3

Aerials.............................................................................................................................................. 3-3 Remote Control ............................................................................................................................... 3-3 Control Functions ............................................................................................................................ 3-4 Status Information ........................................................................................................................... 3-4

CAW Combiner Unit............................................................................................................................ 3-4 CAW Load Unit ................................................................................................................................... 3-5 Power Monitor Unit ............................................................................................................................. 3-5 Aerial VSWR ....................................................................................................................................... 3-6 Diplexer (Optional) .............................................................................................................................. 3-6 Power Management Unit (Optional) ................................................................................................... 3-6 Power Supply Requirement ................................................................................................................ 3-6 Environmental Limitations................................................................................................................... 3-7 Physical Characteristics...................................................................................................................... 3-7

Weight ............................................................................................................................................. 3-7 Dimensions...................................................................................................................................... 3-7 Installation ....................................................................................................................................... 3-7

Figure 1 - Combiner Unit Block Diagram................................................................................................ 3-5

Page 3-2 Nov 11

Nov 11 Page 3-3

HAZARDS

1. A general Safety First instruction page appears at the front of this handbook. Hazards and consequent handling precautions relate to the following CA6441 assemblies or units:

High Voltages - Status Unit

- CAW Combiner Loads (fans only)

- Anti-Condensation Heaters

Heavy Units - Status Unit

- CAW Combiners

- CAW Combiner Loads

- Dummy Load

Beryllium Oxide - CAW Combiner Loads (resistors) Components

2. Further hazards, which may be encountered during maintenance activities, are listed below; full details appear at the front of the Maintenance instructions, Category 5A.

Metal Surfaces Carrying - CAW Combiner Loads RF Power

Hot Surfaces - CAW Combiner Loads

- Anti-Condensation Heaters

- Dummy Load

Electrostatic Sensitive - Status Unit Devices - Power Monitor Unit

- Flexible Power Management Unit

Coolant Spillage - Dummy Load

INTERFACING

Aerials

3. The CA6000 series has been designed to operate with a variety of broadband aerials, which may comprise a single element covering 2 - 30 MHz, or two parts covering, say, 2 - 8 MHz and 8 - 30 MHz.

4. The Diplexer is designed to route the combined output of the four transmitters to the high and low frequency parts of a two-part broadband aerial. The cross-over frequency of the Diplexer is set during manufacture to the required frequency and, currently, may be set to 6, 8 or 9 MHz. The most commonly used frequency is 8 MHz, so for ease of reading, this frequency is assumed throughout this handbook.

Remote Control

5. The Serial Interface board in the Status Unit provides remote indication of the Combiner Array status to the remote Control system via an RS485 serial data global bus. An RS232 serial data interface is provided as optional.

6. The Control board in the PMU6400 provides an RS485 serial data interface for unit control and status indication. RS232 serial data interface is provided for diagnostics purposes.

Page 3-4 Nov 11

Control Functions

7. Combiner Array:

Switching of combined output power to internal dummy load.

8. FPMU:

RF input/output switching (exciter/PA) configuration

Status Information

9. Combiner Array:

Combiner Load(s) Over-temperature Dummy Load Over-temperature Fault Bad VSWR Fwd Power Rev Power Manaloft Dummy Load selected

PSU FAULT

10. FPMU:

Exciter/PA RF routing configuration Fault

CAW COMBINER UNIT

11. The Combiner Unit comprises three combiners type P46369, each able to handle two 2 kW inputs, which are configured as shown in Figure 1.

12. The frequency range is 1.5 - 30 MHz. The lower end frequency range is normally restricted by the characteristics of the broadband aerial to > 2 MHz (to 30 MHz).

13. Maximum RF Input Power: 4 lines, each of 1 kW nom, 1.2 kW max.

14. The maximum insertion loss is 7.25 dB, with the outputs and all other inputs terminated in 50 ohm loads.

15. Over the frequency range 1.5 - 30 MHz, the input VSWR is typically ≤ 1.2:1 at any input port, with all other input and output ports terminated in 50 ohm loads.

16. Hybrid combiner input port to port isolation is > 25 dB with other input and output ports terminated in 50 ohm loads.

17. Intermodulation Products (IPs) generated by the combiner array are better than -70 dB with respect to 250 W, when measured with two equal level input signals each of 1 kW. The actual radiated level of IPs is consequently determined by the transmitters' characteristics.

Nov 11 Page 3-5

FIGURE 1 - COMBINER UNIT BLOCK DIAGRAM

CAW LOAD UNIT

18. The Load Unit consists of eight loads arranged in 2 trays of four loads, each load having a separate fan. Each load is capable of dissipating up to 500 W continuously. A thermostat (140 ºC) is mounted on each load to check for over-dissipation or fan failure. In the event of over-temperature on one or more of the loads the transmitters feeding those loads are placed in standby (by the Tx Tripl lines).

19. A loopback facility is provided to the Status Unit to indicate that the fan cables are connected. If this is not present all transmitters associated with the CA6441 are placed in standby by the Tx Trip and Inhbit lines, causing a fault indication to be displayed.

POWER MONITOR UNIT

20. The Power Monitor Unit (PMU) uses a directional coupler in conjunction with diode detectors to measure the forward and reverse power output to the broadband aerial and provides a logic indication for aerial VSWR > 4.5:1, for forward power ≥ 600 W and reverse power > 250 W for forward power < 600 W it enables the combined power output to be routed to internal dummy load for test purposes.

21. When terminated in 50 ohm load the input VSWR of the PMU is < 1.15:1 and insertion loss is < 0.2 dB.

22. When dummy load is selected the aerial is grounded and leakage from any RF input to aerial is < -80 dB. A Sample Output of -60 dB nominal (± 3 dB ripple) is provided for test and monitoring purposes, including Tx/Rx off-air check.

23. A loopback facility is provided to the Status Unit to indicate that the PMU is connected. If this is not present all transmitters associated with the CA6541 are placed in standby by the Tx Trip and Inhibit lines, causing a fault indication to be displayed.

4 x 250W POWER

MONITOR

4 x 250W

2 x 500W

DUMMY

LOAD

DIPLEXER

1kW Tx

1kW Tx

1kW Tx

1kW Tx

SAMPLE

OUTPUT

-60 dB

2 x 500W H2

H1

H3

(HF2)

(HF1)

(HF3)

(HF4)

Page 3-6 Nov 11

AERIAL VSWR

24. The CA6441 output can withstand a broadband aerial VSWR of 4.5:1 with all four transmitter inputs at full power. This VSWR is measured at the output of the combining network, using the Power Monitor Unit and is the sum of the HF lines working into the broadband aerial. If the VSWR exceeds 4.5:1, for forward power ≥.600W or the reverse power exceeds 250 W forward power <.600 W, interlock control signals are sent to the four transmitters to reduce the power.

DIPLEXER (OPTIONAL)

25. The Diplexer is a passive filter, which routes frequencies below 8 MHz to one half of the broadband aerial, and frequencies above 8 MHz to other half. At the crossover frequency half power is routed to each part of the aerial.

26. When terminated in two 50 ohm loads the insertion loss of the Diplexer is < 0.2 dB and the input VSWR is < 1.2:1.

27. The low pass filter in the 8 MHz Diplexer has an attenuation of >9 dB at 9 MHz and the high pass section has attenuation > 9 dB at 7 MHz.

28. Similar, proportionally scaled, figures apply for Diplexers with other cross-over frequencies.

POWER MANAGEMENT UNIT (OPTIONAL)

29. The Power Management Unit (PMU6400) enables any one of the four exciters to drive and control up to four power amplifiers simultaneously, resulting in phase coherent addition of signals within the combiner network, and thereby achieving greater output power at the aerial. It uses four way hybrid splitter networks in conjunction with very linear amplifiers in each of the four RF inputs to achieve a four way output matrix with zero nominal insertion loss. The PMU6400 is configured via remote control received across the global bus. The unit contains non-volatile memory, enabling it to revert to the previous setting after a loss of or an interruption in power to the unit.

30. The Insertion loss over the frequency range 1.5 - 30 MHz is 0 dB ±2 dB.

31. The input VSWR is < 1.5:1 with other input and output ports terminated in 50 ohm loads.

32. The isolation between any input port to unwanted output port is 36 dB with other input and output ports terminated in 50 ohm loads.

33. Third order Intermodulation products generated by the PMU6400 are better than -55 dB with respect to two equal level output signals each of 14 dBm.

POWER SUPPLY REQUIREMENT

34. The CA6400 series will function normally over the following mains supply input ranges:

Supply voltage, 115 V working : 100 - 125 V rms 230 V working : 200 - 250 V rms

Supply frequency : 47 - 63 Hz.

35. The CA6400 series will not be damaged by a 100% over-voltage surge for up to 1 ms.

Nov 11 Page 3-7

ENVIRONMENTAL LIMITATIONS

36. The CA6400 series is designed to operate within the following environmental constraint

Maximum shock, cabinet resiliently mounted, horizontal : 30 g vertical : 30 g

Maximum ambient temperature, operation : +49 °C storage : +70 °C

Minimum ambient temperature, operation : 0 °C storage : -30 °C

PHYSICAL CHARACTERISTICS

Weight

37. Nominal weight, including PMU6400 and Diplexer, excluding heat exchanger and shock mounts:

CA6441: 230 kg

Dimensions

38. Cabinet nominal dimensions including Mains Filter Unit, excluding heat exchanger and shock mounts:

Height: 1690 mm (34U) Width: 600 mm (19") Depth: 800 mm

Installation

39. The CA6000 Series is designed to be free standing, on shock mounts supplied. Alternatively, the unit can form part of a suite of equipment with the Thales TMR6000 transmitters or transceivers, mounted together on a single shock-mounted raft in order to reduce the occupied space.

40. All cabling is top entry.

Page 3-8 Nov 11

1391-9(2)

Nov 11 Page 2-1

CATEGORY 2

OPERATING INFORMATION

Brief Description.................................................................................................................................. 2-4 Functions of the CA6441 Cabinet ................................................................................................... 2-4 Units Within the CA6441 Cabinet.................................................................................................... 2-4

Switch On Procedure .......................................................................................................................... 2-7 Normal Operation................................................................................................................................ 2-7 CAW systems without FPMU fitted..................................................................................................... 2-8 CAW systems with FPMU fitted.......................................................................................................... 2-8

Power Selection .............................................................................................................................. 2-9 Power Monitoring .......................................................................................................................... 2-10 Faults............................................................................................................................................. 2-10

Switch Off Procedure ........................................................................................................................ 2-10

Table Page

Table 1 - Status Unit - Controls and Displays ........................................................................................ 2-6 Table 2 - Flexible Power Mangement Unit - Displays ............................................................................ 2-7 Table 3 - Output Power Combinations ................................................................................................. 2-10

Figure 1 – CAW Cabinet CA6441 .......................................................................................................... 2-3 Figure 2 – Status Unit Front Panel ......................................................................................................... 2-5 Figure 3 – Flexible Power Management Unit Front Panel ..................................................................... 2-5 Figure 4 - System Block Diagram - Combiner Array ............................................................................ 2-11 Figure 5 - System Block Diagram - Flexible Power Mangement Unit .................................................. 2-12

Page 2-2 Nov 11

Nov 11 Page 2-3

FIGURE 1 – CAW CABINET CA6441

Page 2-4 Nov 11

BRIEF DESCRIPTION

Functions of the CA6441 Cabinet

1. The Common Aerial Working equipment consists of one cabinet (see Figure 1), with a primary function of combining the outputs of four transmitters for direct connection to a single-part broadband aerial or via a Diplexer to a two-part broadband aerial. The CA6400 allows the transmitters to operate on adjacent channels or spread across the HF band without restriction. The CA6441 variant, fitted with a Flexible Power Management unit and a Diplexer, enables the overall communication system to operate in a phase coherent mode, thus delivering greater power, and, into a two-part broadband aerial.

2. During normal operation the CA6400 combiner array requires no control by the user; it is a fixed passive hybrid combiner network. Forward and reverse power into the aerial may be monitored and for test purposes, and the combined output can be routed to an internal dummy load.

3. The inherent high reliability of the CAW systems requires that the BITE circuitry is kept simple.

Monitors within the CA6400 cabinets check the combiner loads and system integrity, whilst further checks are provided at system level in conjunction with forward and reverse power data from the transmitters.

4. Each output connector to the aerial is fitted with a surge arrestor for lightning protection.

5. The use of active-low open-collector lines ensures failsafe operation in the event of power loss or open circuit wiring.

6. Subsidiary functions of the CA6441 cabinet are as follows:

• Aerial isolation (3 position Man-Aloft key-switch). This key-switch has three positions Test, Isolated and In Service. The locally-selected AERIAL ISOLATE facility enforces Tx TRIP and INHIBIT modes on all transmitters. Isolation allows safe access to the aerial outfit for maintenance purposes. The key must be removed to achieve full safety.

NOTE

The Anti-Condensation Heaters (ACH) must be switched OFF externally to the cabinet.

• Test. The local switching or remote selection of TEST facility enables the combined output power of the combiner array to be diverted to the internal dummy load for test purposes.

Local or remote selection of TEST enforces the Tx INHIBIT mode on all transmitters for an interval of about 50 ms to allow RF relays within the power monitor unit to switch without damage.

• Cabinet status. Local indication is provided for normal operation of the internally-derived dual DC supplies. Local and remote indication is provided for loss of either of the supplies.

The temperature of load units associated with the CAW combiners and internal dummy load is monitored to provide local and remote indications in the event of an overheat condition occurring and switch off the associated transmitters.

• Power monitoring. The forward and reverse power at the output can be monitored at any time on the local power meter or via the serial interface. Internally, forward and reverse powers are continuously monitored so that power reduction at the transmitters is enforced by the Power Reduction lines if the VSWR becomes unacceptable; the amber VSWR LED provides a local warning.

Units Within the CA6441 Cabinet

7. At the top of the cabinet are the RF input/output connectors and the control-cable entry glands.

Control cables are connected to 8 terminal blocks (sockets) which mate with 4 headers on the Status Unit Distribution board and 4 on the FPMU Distribution Board, at top rear of the cabinet.

Nov 11 Page 2-5

8. The Status Unit at the top of the cabinet houses the Man-aloft key-switch, the main supervisory controls and displays and the serial interface to the control system for the combiner array.

9. Below the Status Unit is a blank panel, and/or an optional Diplexer for connection to a 2-part broadband aerial.

10. Below the blank panel or optional diplexer is a 2U blank panel or an optional Flexible Power Management Unit. This unit houses the RF Switching matrix , local supervisory controls and displays, and the serial interface to the control system for flexible power management.

11. Behind the large vent panels are three hybrid combiner units, each of which adds two inputs to give a single output. The three units are configured in the manner indicated by the OVERTEMP display layout on the Status Unit. Four transmitter inputs combine together to give a single output for direct connection to a single-part broadband aerial or via a Diplexer to a two-part broadband aerial. Each hybrid requires two 50 ohm loads for balancing purposes; three load trays beneath the hybrids are fitted with the necessary resistor combinations.

12. The Power Monitor Unit is at the back…