OPERATION AND MAINTENANCE MANUAL - Skybrokers · O&M FOR MT3000 TWT AMPLIFIER REV H MCL, INC. 38A1637 6 of 84 LIST OF APPENDICES APPENDIX A - 40A2044 Specification for MT3000 TWT

SYM DESCRIPTION DATE E.E. M.E. Q.A.

A ORIGINAL 3/18/96 TPC BJD JT

B REVISED 9/18/96 TPC BJD JT

C REVISED - MINOR CHANGE 10/2/96 ---- BJD ----

D REVISED 6/10/97 TPC BJD JT

E REVISED 11/12/97 TPC BJD JT

F REVISED - FORMAT CHANGE 4/27/99 ---- BJD ----

G REVISED - FIGURE CHANGE 9/20/99 ---- BJD ----

H REVISED - FIGURE CHANGE 12/29/99 ---- BJD ----

DRAWN DATE

Timothy P. Cornish 3/18/96

501 South Woodcreek RoadBolingbrook, Illinois 60440-4999

CHECKED DATE

PROJECT ENGINEER DATE

MANAGER, MECHANICAL ENGINEERING DATE

Bart Dring 3/20/96 OPERATION AND MAINTENANCE MANUALFOR MT3000 TWT AMPLIFIERMANAGER, ELECTRICAL ENGINEERING DATE

Timothy P. Cornish 3/18/96Q.A. DATE

James F. Teska 3/20/9638A1637

PRODUCTION DATE

John W. Harrington 3/20/961 of 84

O&M FOR MT3000 TWT AMPLIFIER REV H

MCL, INC. 38A16372 of 84

Cautionary Notice

While the Manufacturer has attempted to detail in this manual all areas of possible danger topersonnel in connection with the use of this equipment, personnel should use caution wheninstalling, checking out, operating and servicing this equipment, especially when power is on. Like all electronic equipment, care should be taken to avoid electrical shock in all circuits wheresubstantial currents or voltages may be present, either through design or short circuit. Cautionshould be observed also in lifting and hoisting equipment especially regarding large structuresduring installation. Be sure to keep hands, loose clothing and hair clear of blowers duringoperation and service.

The Manufacturer is specifically not liable for any damage or injury arising out of a worker’sfailure to follow the instructions contained in this manual, or his failure to exercise due care andcaution in the installation, operation check-out and service of this equipment.


MCL, INC. 38A16373 of 84

TABLE OF CONTENTS

SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

DEFINITIONS OF WARNINGS, CAUTIONS, AND NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

LIST OF HAZARDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

1.0 SYSTEM DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151.1 Local Meters, Controls, & Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.1.1 LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151.1.2 Main Power Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151.1.3 Switch Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

1.2 Serial Remote Panel Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181.3 Remote Computer Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181.4 1:1 Switchover Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2.0 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192.1 Unpacking the TWTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192.2 Repacking the TWTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192.3 Returning Damaged Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202.4 Typically Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202.5 Installation of TWTA Drawer into a Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222.6 Computer Interface Set-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

2.6.1 Network Identification Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222.6.2 BAUD Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 232.6.3 Protocol Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 242.6.4 Hardware Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

2.7 Connection to the “User” Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262.8 Connection to the “Switchover” Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 262.9 Installation of Primary Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.9.1 Standard Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282.9.2 Frequency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282.9.3 KVA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282.9.4 Power Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282.9.5 Connector Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

2.10 Cooling Duct Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292.11 Clean-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29


MCL, INC. 38A16374 of 84

TABLE OF CONTENTS (Continued)

3.0 SYSTEM OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303.1 Operator Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

3.1.1 Main AC Power Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303.1.2 Membrane Switch Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 303.1.3 Additional Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323.1.4 LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

3.2 Turn-On Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463.2.1 Initial Turn-On Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 463.2.2 Power-Up Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 473.2.3 Delay & Standby Analog Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493.2.4 Transmit Analog Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49

3.3 Shut-Down Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 493.4 Operating Caution List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 503.5 Prevention of Excessive RF Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3.5.1 The Exciter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 513.5.2 How to Limit RF Input Drive to the TWTA . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

3.6 Tube Degassing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523.7 Setting the Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 523.8 Optional Linearizer Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52

4.0 THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534.1 Power Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53

4.1.1 Unregulated 450V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534.1.2 Control & Logic Module +5V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 534.1.3 +15V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534.1.4 Blower +48V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 534.1.5 Filament Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564.1.6 “Ready” Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

4.2 DC/DC (High Voltage) Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 564.3 Control & Logic Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574.4 RF Chain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

4.4.1 SSA Pre-Amplifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 574.4.2 TWT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 584.4.3 RF Output Waveguide Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

4.5 Gain and RF Power Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60


MCL, INC. 38A16375 of 84

TABLE OF CONTENTS (Continued)

5.0 PREVENTIVE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625.1 Panel Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625.2 Blower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625.3 Switches/Interlocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 625.4 Cabinet Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635.5 Internal Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635.6 Extending Tube Life . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 635.7 Removal/Disassembly/Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

6.0 TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 686.1 Equipment List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 686.2 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 686.3 Potentiometer Location & Function . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746.4 Event Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746.5 Test Fixtures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 746.6 MCL Customer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

7.0 SCHEMATIC AND ASSEMBLY LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76


MCL, INC. 38A16376 of 84

LIST OF APPENDICES

APPENDIX A - 40A2044 Specification for MT3000 TWT Amplifier

APPENDIX B - 34A2531 Acceptance Test Procedure for MT3000 TWT Amplifier

APPENDIX C - 40A1527 HPA and Support Equipment Warranty Information

APPENDIX D - 40A1845 Customer Service Information

APPENDIX E - 46A0009 Extending Tube Life Information

APPENDIX F - 38A1578 Operation and Maintenance Manual for MT3000 Type Control & Logic Module


MCL, INC. 38A16377 of 84

LIST OF FIGURES

Tube Warning Tag . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Figure 1 MT3000 Outline Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Figure 2 Reference Designator Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Figure 3 Cooling Interface Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Figure 4 RS449/485 Interface Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25Figure 5 MT3000 Front View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Figure 6 CLM Screen Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Figure 7 Main Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36Figure 8 Power Level Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Figure 9 Analog Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Figure 10 Fault Status Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Figure 11 Set-Up and Security Code Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41Figure 12 MT3000 General Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Figure 13 Power Distribution Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Figure 14 MT3000 Simplified RF Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Figure 15 RF Output & Gain vs RF Input Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61


MCL, INC. 38A16378 of 84

LIST OF TABLES

Table 1 BAUD Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Table 2 User Interface Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Table 3 Switchover Interface Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Table 4 Single Phase J1 Pinout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28Table 5 Common Soft Key Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33Table 6 Field Modifiable Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 - 45Table 7 Analog Status Nominal Readings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Table 8 Operating Cautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50Table 9 EPROM Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Table 10 Field Modifiable Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Table 11 Recommended Test Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Table 12 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Table 13 Control PCB Potentiometer Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75


MCL, INC. 38A16379 of 84

SAFETY SUMMARY

The following are general safety precautions and instructions that personnel must understand andapply during many phases of operation and maintenance to ensure personnel safety and health andthe protection of property. Portions of this information may be repeated in certain chapters of thispublication for emphasis.

WARNING AND CAUTION STATEMENTS

WARNING AND CAUTION statements have been strategically placed in the text to emphasizecertain steps or procedures for the protection of personnel (WARNING) or equipment(CAUTION). A WARNING or CAUTION once provided will apply each time the related step isrepeated, regardless of the number of times the WARNING or CAUTION is repeated throughoutthe text. Prior to starting any task, THE WARNINGS or CAUTIONS included in the text forthat task should be reviewed and understood.

KEEP AWAY FROM LIVE CIRCUITS

Operating personnel must at all times observe safety regulations. Do not replace components ormake adjustments inside the equipment with the voltage supply turned on. Under certainconditions, dangerous potentials may exist when the power control is in the off position, due tocharges retained by capacitors. To avoid injuries, always remove power from, discharge, andground a circuit before touching it. Adhere to all lock out/tag out requirements.

DO NOT SERVICE OR ADJUST ALONE

Do not attempt internal service or adjustment unless another person capable of rendering aid andresuscitation is present.

RESUSCITATION

Personnel working with or near dangerous voltage shall be trained in modern methods ofresuscitation.

COMPRESSED AIR

Use of compressed air for cleaning can create an environment of propelled foreign particles. Airpressure shall be reduced to less than 30 psi and used with effective chip guarding and personnelprotective equipment.


MCL, INC. 38A163710 of 84

WARNING

CAUTION

DEFINITIONS OF WARNINGS, CAUTIONS, AND NOTES ARE DESCRIBED BELOW:

An operating or maintenance procedure, practice, condition, statement, etc., which if notstrictly observed, could result in injury to or death of personnel.

An operating or maintenance procedure, practice, condition, statement, etc., which if not strictlyobserved, could result in damage to or destruction of equipment, or loss of mission effectiveness.

NOTE

An essential operating or maintenance procedure, condition, or statement which must behighlighted.


MCL, INC. 38A163711 of 84

WARNING

WARNING

WARNING

WARNING

LIST OF HAZARDS

The operation of this amplifier may involve some of the following hazards, any of them couldresult in serious harm to personnel if proper safety precautions are not taken.

HIGH VOLTAGE

Lethal Voltages up to 15,000 Volts are present in this amplifier when it is operating. USE EXTREME CAUTION when inside the unit. When testing, always ground thedrawer chassis.

RF RADIATION

Exposure to RF radiation may cause serious bodily injury possibly resulting inblindness and death. Cardiac pacemakers may be affected. Always terminateboth the RF input and RF output, even during tests which involve no RF drive,to avoid the RF hazard should the TWTA oscillate.

BERYLLIUM OXIDE

The dust or fumes from Beryllium Oxide (BeO) ceramics used in microwavetubes are highly toxic and can cause serious injury or death.

IMPLOSION HAZARD

Ceramic windows from microwave tubes can shatter on impact or crack in useresulting in injury from Beryllium Oxide dust or fumes.


MCL, INC. 38A163712 of 84

WARNING

WARNING

CAUTION

LIST OF HAZARDS (Continued)

X-RAY RADIATION

High voltage tubes can produce dangerous, possibly fatal X-Rays.

HOT SURFACES

Surface temperature of tubes and other air cooled ports can reach severalhundred degrees centigrade.

RF OVERDRIVE

The unit may be damaged by drive levels as low as -24.3 dbm depending upon thesettings of the system attenuator. Please apply RF with caution. Alwaysterminate RF input and output ports properly when AC power is supplied to theTWTA.


MCL, INC. 38A163713 of 84

Tube Warning Tag


MCL, INC. 38A163714 of 84

INTRODUCTION

This manual contains information to allow the system operator to operate and maintain the MCLMT3000 TWT Amplifier. This manual assumes a familiarity and working experience with highpower microwave RF amplifiers.

The MCL MT3000 is designed for long and reliable life under a variety of environmentalconditions. All components utilized in this system are conservatively rated and selected for highreliability and maximum use of existing designs. Mechanical and electrical safeguards are utilizedthroughout the system to insure safety of operating personnel.


MCL, INC. 38A163715 of 84

1.0 SYSTEM DESCRIPTION

This TWT amplifier contains a high power Traveling Wave Tube, solid state amplifier IPA,various RF components, Primary Power Converter Module, High Voltage Power Supplyassembly, and a Control & Logic Module which controls the entire system. These assemblies arehoused in a 19-inch rack-mount drawer which has rear panel air outlet and side air intake forcooling. The standard system is designed for 90 to 264 VAC, 50/60 Hertz, single phase, two wireplus safety ground AC input power.

Figure 1 details the physical outline of the amplifier system. Also available for the system is theoptional MXR remote panel.

Figure 2 is the reference designator chart showing the various sub-assembly components of anMT3000 TWTA system.

1.1 Local Meters, Controls, & Indicators

1.1.1 LCD Display

The display is an LCD-STN graphics display module. The dot configuration is 240 × 128. Thedisplay and keyboard are used as the main interface between the operator and the TWTA. Theuser can select from many different screens which one will be displayed on the LCD.

1.1.2 Main Power Circuit Breaker

The circuit breaker used has a power switch for main AC power into the MT3000. The circuitbreaker is located on the TWTA front panel.

1.1.3 Switch Functions

All control panel switches are part of the CLM membrane panel assembly. The membrane panelassembly consists of metal dome membrane switches. The following switches are present on thecontrol panel:

Number pad [0-9] Enter ClearTransmit Standby Fault ResetLocal Remote ComputerBack Light - Turns On Six display select (soft) keys


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Figure 1 - MT3000 Outline Drawing


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Figure 2 - Reference Designator Chart


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1.1.4 LED Functions

The following LEDs are present on the CLM Front Panel.

Transmit (Green) Standby (Yellow) Fault Reset (Red)Local (Green) Remote (Yellow) Computer (Yellow)Com Tx (Green) Com Rx (Yellow) RF Inhibit (Yellow)+5V (Green) +15V (Green) !15V (Green)

1.2 Serial Remote Panel Control

This interface is designed in such a way to supply to the remote panel status from, and control tothe MT3000. When the MT3000 is in the Remote mode controls from the Local panel & RemoteComputer will be locked out. The MXR remote panel is designed to operate on this interface.

1.3 Remote Computer Control

This interface is designed in such a way to supply to the remote computer status from, and controlto, the MT3000. The communications protocol is CSP [standard] or SA 7670 compatible[optional]. The user can switch between RS232 or RS449/485, but not both at the same time. When the TWTA is in the Computer mode controls from the Local panel & Remote Panel will belocked out.

1.4 1:1 Switchover Network

For this option additional circuits will be added to the TWTA. The additional circuitry is definedin 40A2106 – Specification For 1:1 Redundant System MT3011. This will allow control of an RFswitch through the front panel of either MT3000 series TWTAs.


MCL, INC. 38A163719 of 84

CAUTION

CAUTION

2.0 INSTALLATION

The MT3000 system is shipped in a fully assembled condition. This section details the installationprocedure of the MT3000 system. Several steps in the installation procedure will require heavylifting and more than one person will be required. The installation personnel should have aworking knowledge of electronic and SatCom equipment.

It is recommended that a professional HVAC engineer consult on thedesign of the air intake and exhaust ducts.

The prime power must comply with the specifications in Paragraph 2.9.

2.1 Unpacking the TWTA

Prior to unpacking, inspect the exterior of the packing containers for damage received duringshipment. If damage is present, contact the carrier that delivered the system and submit a damagereport. Failure to do this could complicate or invalidate a claim. Carefully unpack and remove allitems from their shipping containers and inspect the items further for signs of damage.

Be careful not to damage components with pry bars when openingshipping crates. Do not use pry bars to extract components from crates.

Save all packing materials until inspections are complete. Verify that all items listed on thepacking slip have been received.

2.2 Repacking the TWTA

Use original packing containers if possible. Place unit in an clean, open work area. Cover anyopen RF waveguide flanges with a plastic cap designed for this purpose (adhesive tape is notrecommended as it quickly deteriorates, leaving a residue on the flanges). Wrap the unit in heavypaper or plastic. Use a suitable shipping container. Surround the unit in shock absorbing materialto provide a firm cushion and prevent movement inside the container. Do not allow any packingmaterials to enter any drawers, enclosures or waveguide. Seal the container and mark exterior“FRAGILE Electronic equipment.” Further packaging information is available from MCL(request MCL packaging specification 34A2249).


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2.3 Returning Damaged Equipment

If the system must be returned, call the factory for an RMA number (Returned MaterialsAuthorization). See Appendix D, 40A1845 – Customer Service Information for moreinformation.

2.4 Typically Required Tools

• Allen wrench, 5/32• Screwdriver, #1 Phillips • Screwdriver, Standard 3/16• Screwdriver, Standard 1/8 • Screwdriver, 3/8 Blade 8" Long• 5/16" torque sensing open end wrench is recommended• 5/16" blade screwdriver standard• Socket wrench set• 5/16" wrench• 3/8" wrench


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Figure 3 - Cooling Interface Drawing


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CAUTION

CAUTION

2.5 Installation of TWTA Drawer into a Cabinet

The following steps should be taken to insure that the MT3000 is properly installed.

Be sure that the cabinet is firmly supported during installation ofthe MT3000.

1. Position the MT3000 in close proximity to final installation rack (MCL supplied or other). This will eliminate any unnecessary moving of the system.

2. Locate slides in rack to allow the MT3000 to be installed.

3. Make all RF input & output connections.

Be certain that all RF connections are secure and that there is aload, or an antenna, connected to the RF output waveguide. Failure to secure these connections will pose a hazard to operatingpersonnel and could result in malfunction of the equipment.

2.6 Computer Interface Set-Up

Before powering-up the system for the first time, find the set of rotary switches on the back leftcorner of the CLM box. Remove the lid of the MT3000. The back panel of the CLM will now beexposed. The communications configuration of the MT3000 must be set-up to match therequirements of the master device.

2.6.1 Network Identification Switches

Two of the switches are labeled “Low Address” and “High Address.” This address is userdefinable and must be made unique to only one (1) device (MK9000, exciter, 13099, 20087...) pernetwork. When the MT3000 is turned on you will check this address setting on the Main/Morescreen.


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Table 1 - BAUD Rate

2.6.2 BAUD Rate

This switch is used to determine the MT3000’s Computer interface BAUD rate. Table 1 lists the possible BAUD rate settings available for serial communications.

ROTARY SWITCH POSITION BAUD RATE

0 75

1 110

2 134

3 150

4 300

5 600

6 1200

7 1800

8 2000

9 2400

A 3600

B 4800

C 7200

D 9600

E Reserved

F Reserved

To set any of the above BAUD rates, rotate the arrow on the rotary switch to point thecorresponding number in the preceding table. Please remember to select the same BAUD rateused by the “master” device. When the MT3000 is turned on you will check the Baud rate settingon the Main/More screen.


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2.6.3 Protocol Selection

The fourth switch on the back of the CLM is used to determine which Protocol is used. Position“0” selects CSP and position “1” selects SA 7670 compatible.

2.6.4 Hardware Interface

The computer interface for the MT3000 can be set for either RS232 or RS449/485 but not bothat the same time. The MT3000 will be factory set to either RS232 or RS449/485 based on thecustomer specified requirement on the PO.

If the wrong configuration was ordered the following steps will be used to change theconfiguration.

1. Remove the CLM from the MT3000.

2. On the connector which mates with D16765-J7 (baseboard) has a jumper on it (lower leftcorner of D16765 as you are looking at the component side with the front of the CLMfacing you). Change the jumper as follows:

• Pin 3 to pin 4 for RS449/485• Pin 4 to pin 5 for RS232

3. Reinstall the CLM but connect W5 (to J5 of the back panel) as follows:

• To J2 for RS449/485• To J3 for RS232


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Figure 4 - RS449/485 Interface Wiring


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Table 2 - User Interface Wiring

2.7 Connection to the “User” Interface

The User Interface (J6) has been supplied to provide the user a way to connect the MT3000 toother overall system equipment. This interface is a 9 position ‘D’ connector located on the backof the MT3000. The signals available are listed in Table 2.

J6CONTACT SIGNAL NAME SIGNAL FUNCTIONNUMBER

1 RF Inhibit Loop Input Open to Inhibit, Close to Enable

2

3 External Interlock Fault Input Open for a Fault, Close to Clear

4

5 Not Used

6

7 N.O. Summary Fault Energized is no FaultOutput De-energized is a Fault

8 Com.

9 N.C.

2.8 Connection to the “Switchover” Interface

The Switchover Interface (J7) has been supplied to provide the user a way to connect theMT3000 to a Model D13188 switchover interface (or some other user supplied switchover). Thisinterface is a 25 position ‘D’ connector located on the back of the MT3000. The signals availableare listed in Table 3.


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Table 3 - Switchover Interface Wiring

J7CONTACT SIGNAL NAME SIGNAL FUNCTIONNUMBER

1 RF Inhibit Loop Input Open to Inhibit, Close to Enable

14

2 This TWTA to the Antenna Input +15V when on Antenna

3 This TWTA to the Dummy Load Input +15V when on Dummy Load

4 This TWTA to the Antenna Output Pulsed to 15V return for 500 ms

5 This TWTA to the Dummy Load Output Pulsed to 15V return for 500 ms

6 Not Used

7 N.O. Summary Fault Output Energized is no FaultDe-energized is a Fault

8 Com.

9 N.C.

10 Second MT3000 Sum Fault Input +15V when switchover should occur(during a fault)

11 Auto Switching Input +15V for Auto Switching On

12 Auto Switching Output 15V return for Auto Switching On

13 Not Used

15, 16, 25 +15V DC Output

17, 18, 23, & 15V Return24

19 Not Used

20 N.O. RF Low Alarm Output Energized is no AlarmDe-energized is an Alarm

21 Com.

22 N.C.


MCL, INC. 38A163728 of 84

Table 4 - Single Phase J1 Pinout

2.9 Installation of Primary Power

Connect the prime power source of the proper voltage and frequency to the mating AC connectorsupplied with the MT3000. The AC input connector (J1) is located on the MT3000 back panel. In cases of multiple amplifier installations, each amplifier shall be provided with a separatebreaker.

PIN NUMBER FUNCTION

A Line A (Hot)

B Line B (Neutral)

C Not Used

D Safety Ground

A stud on the back panel has been supplied to connect system to a good permanent earth ground. This stud supplies Safety ground to the whole TWTA internal system. A 1/2' thick braidedground strap is recommended between the MT3000’s #10-32 ground stud and earth ground.

NOTE

Prime power requirements are as follows:

2.9.1 Standard Voltage 90 to 264 VAC single phase, two wire plus safety ground

2.9.2 Frequency 47-63 Hz

2.9.3 KVA 1.5 maximum

2.9.4 Power Factor (min in Transmit) 0.95

2.9.5 Connector Type 4 pin male MS circular, mate supplied


MCL, INC. 38A163729 of 84

CAUTION

2.10 Cooling Duct Installation

See Figure 3 for interface locations.

Ducting of the exhaust air from the MT3000 is achieved by attaching a 5.0" Inside Diameter(I.D.) flexible hose (McMaster-Carr P/N 5266K29) no longer than 12 feet in length and with nomore than six 90 degree bends. Any additional flow resistance (pressure head) from the blowerflange through the final exhaust port cannot exceed a value of 0.12 in H O.2

The air supplied to the unit must be maintained between 0°C and 50°C. The maximum must bederated at 1.9°C per 1,000ft of altitude (i.e. max temperature @ 3,000 ft is 44.3°C). Operationoutside these limits will permanently damage the TWT. Check with local weather service to see ifheating or cooling of intake air will be required at any time.

In areas of high humidity, a danger of condensation buildup exists when unconditioned air fromoutside the shelter is delivered to the MT3000 when the MT3000 is “cold.” The MT3000 shouldnot be operated when a temperature difference of greater than 10EF (5.5°C) exists between theinput cooling air and the MT3000 ambient temperatures. Under these conditions, a condensationcheck should be made before attempting a cold-start operation on the MT3000.

Make sure the top cover of the MT3000 is attached. The cover ispart of the cooling circuit.

2.11 Clean-Up

Make certain that all connectors are attached and tight. Remove all tools, packing materials andreference materials.


MCL, INC. 38A163730 of 84

3.0 SYSTEM OPERATION

3.1 Operator Controls and Indicators

3.1.1 Main AC Power Circuit Breaker

Located on the CLM panel is the main power on/off switch. This switch turns AC power to theMT3000 on/off.

3.1.2 Membrane Switch Functions

The following paragraphs give a brief description of the switch functions on an MT3000 LocalPanel. For a more detailed description see Appendix F, 38A1578 – Operation & MaintenanceManual for MT3000 Type CLM.

These control panel switches are part of the CLM membrane panel assembly. The membranepanel assembly consist of metal dome membrane switches. The following switches are present onthe control panel:

1. Standby By depressing and releasing this button the Transmit SelectedMode (TWTA goes into Transmit after delay) is canceled or theMT3000 will go from Transmit to Standby. When the LEDwindow is illuminated the MT3000 is in Standby.

2. Transmit By depressing and releasing this button the MT3000 will go fromStandby to Transmit. When the LED window is illuminated theMT3000 is in Transmit (HV On). When the LED is flashing theCLM is in the XMT SELD mode (Transmit mode is imminent).

3. Fault Reset When the LED window is illuminated a fault has occur which hastaken the MT3000 to the HV off state. By depressing and releasingthis button the faults are cleared and the lamp is extinguished.

4. Local By depressing and releasing this button the operator at the MT3000Local panel will be allowed to control the MT3000. When theLED window is illuminated the Local has control.

5. Remote By depressing and releasing this button the operator at the MXRRemote panel will be allowed to control the MT3000. When theLED window is illuminated the Remote panel has control but Localstatus is still enabled.


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Figure 5 - MT3000 Front View


MCL, INC. 38A163732 of 84

6. Computer By depressing and releasing this button the Remote Mastercontroller will be allowed to control the MT3000. When the LEDwindow is illuminated the Computer has control but, Local &Remote status is still enabled.

7. Back Light After the LCD display back light has gone out, depressing andreleasing this button will illuminate the back light again.

8. Soft Keys The function of these keys will be redefined by the MT3000firmware for each screen configuration displayed on the MT3000.

9. Keypad The keypad (0-9, Enter, & Clear) is used by the operator to inputvarious types of parameters which the MT3000 uses duringoperation.

3.1.3 Additional Status Indicators

In addition to the LEDs embedded in the above function switches there is a column of statusLEDs on the right side of the CLM panel. The following LEDs are present on in that column.

1. Com Tx (Green) When illuminated this LED indicates the MT3000 is Transmitting amessage on the Computer Interface.

2. Com Rx (Yellow) When illuminated this LED indicates the MT3000 is receiving amessage on the Computer Interface.

3. RF Inhibit (Yellow) When illuminated this LED indicates the MT3000 PIN diode switchis turned on shutting off the RF flow out of the MT3000.

4. +5V (Green) When illuminated this LED indicates the MT3000 +5V powersupply is within acceptable limits.

5. +15V (Green) When illuminated this LED indicates the MT3000 +15V powersupply is within acceptable limits.

6. !15V (Green) When illuminated this LED indicates the MT3000 !15V powersupply is within acceptable limits.


MCL, INC. 38A163733 of 84

Table 5 - Common Soft Key Functions

3.1.4 LCD Display

The MT3000 display provides a series of menu driven screens (see Figure 6). This sectiondescribes each of these screens and its operational buttons or “soft keys.”

On each side of the LCD display are three membrane buttons. They are referred to as “softkeys” because they are not directly “wired” to a particular function (like the transmit, fault reset,etc. keys found on the right side of the front panel). These six (6) buttons are used for multiplepurposes. The function the button will perform (for the current screen selected) is displayednext to the button (on the LCD). Each display may have its own a set of “soft” buttons andthey define the functionality of that particular screen. The following sections explain eachscreen’s purpose and how to use the corresponding buttons. It should be noted that certain softkeys are only displayed if the unit is in Local mode.

NOTE

After roughly 2 minutes of inactivity, in any screen, the CLM willautomatically deactivate the back lighting.

The following paragraphs give a brief description of the screens display on an MT3000 display. For a more detailed description see Appendix F, 38A1578 – Operation & Maintenance Manualfor MT3000 Type CLM.

3.1.4.1 Common Soft Key Functions

On all screens where they are used, the soft key functions are listed in Table 5.

LABEL FUNCTION

MAIN Exit current screen & return to the Main screen

BACK Exit current screen & return to the previous screen

SEL Used on menus to select the next screen and on Editscreens used to select the parameter to edit

GOTO Used on menus to display the next screen

EDIT Used to change system parameters

INC Used on Edit screens increase the parameter by 1

DEC Used on Edit screens decrease the parameter by 1

HELP Displays information on the current screen


MCL, INC. 38A163734 of 84

3.1.4.2 The “Main” Screen

The “Main” screen is the first and primary display (see Figure 7). From the Main screen, allmajor functions can be accessed like:

• PWR LVL, RF Power Level Control• ANLG STAT, Analog Status displays• FLT, Digital and CLM generated Fault log• SET UP, Calibration and system parameter Set-up screens

From this screen the operator can control the PIN diode switch, the optional switchover, andthe optional channel changer.

3.1.4.3 The “Pwr Lvl” Screen

The “Pwr Lvl” screen is displayed when the “Pwr Lvl” button is depressed on the Main screen. Figure 8 illustrates the Power Level screen presented to the operator. From this screen theoperator can control the attenuator manually (Gain Inc & Gain Dec) or automatically (SelAuto Pwr).

3.1.4.4 The “Anlg Stat” Menu Screen

The “Analog Status” menu (see Figure 9) is invoked by depressing the “Anlg Stat” button onthe “Main” screen. From this menu the operator selects which group of MT3000 parameters todisplay. When “Goto” is pressed the screen containing the selected parameters will bedisplayed.

3.1.4.5 The “Fault Status” Screen

When the “Flts” soft key is pressed the “Fault Status” screen (see Figure 10) will be displayed. If there are faults present in the MT3000 this screen is used to display the first six (6) faultsdetected in the system in the center of the screen. From this screen the following functions canbe performed:

• EVENT LOG, displays event log (first eight entries)• CLEAR LOG, erases all event log entries• PHONE HELP, displays MCL service center phone numbers


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Figure 6 - CLM Screen Structure


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Figure 7 - Main Screen


MCL, INC. 38A163737 of 84

3.1.4.6 The “Set Up” Menu Screen

When the “Set up” soft key is pressed from the Main screen a security code screen (see Figure 11) will be displayed. The user must enter the correct security code to be allowedaccess to all system parameters. If no security code or the wrong security code is entered theoperator will have access to noncritical (see the System Critical column of Table 6) parametersONLY.

NOTE

The default security code is 777, this is the code which will beinstalled when the MT3000 leaves the factory.

The “Set up” menu is invoked by depressing the “Cont” button on the security code screen. From this menu the operator selects which group of MT3000 parameters to display. When“Goto” is pressed the screen containing the selected parameters will be displayed. Each “Setup” screen is used for setting various field modifiable parameters like the trip levels for thefaults in the system. From these screens parameters such as date, time of day, fault levels andtime delays can be adjusted to the user’s specifications. See Table 6 for a detailed list of fieldmodifiable parameters as they are set from the factory for a typical MT3000 in this frequencyband. Consult the factory before changing “System Critical” parameters as the MT3000calibration may be changed or a wrong setting could damage the TWTA.


MCL, INC. 38A163738 of 84

Figure 8 - Power Level Screen


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Figure 9 - Analog Status Screen


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Figure 10 - Fault Status Screen


MCL, INC. 38A163741 of 84

Figure 11 - Set-Up and Security Code Screen


MCL, INC. 38A163742 of 84

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MCL, INC. 38A163743 of 84

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witc

h be

twee

n St

andb

y&

Tra

nsm

it).

FP17

Hig

h V

olta

ge F

ault

Ena

ble

Del

ayY

mill

i-se

cond

s03

000

1-10

0Pa

rt o

f T

rans

mit/

Stan

dby

timin

g.

FP19

Cla

ss I

V F

ault

Ena

ble

Del

ayY

mill

i-se

cond

s02

500

1-10

0D

elay

tim

e be

twee

n th

e H

V tu

rn o

n (H

DO

02)

ortu

rn o

ff a

nd C

lass

IV

fau

lt en

able

(H

DO

05).

FP21

RF

Hig

h A

larm

Inh

ibit

RF?

NN

/AN

oY

es/N

oY

if a

n R

F H

igh

alar

m s

houl

d ge

nera

te a

n in

tern

alR

F in

hibi

t (H

DO

01).

N if

not

. A

n R

F H

igh

alar

m w

ill a

lway

s be

gen

erat

ed.

FP22

RF

Low

Ala

rm I

nhib

it R

F?N

N/A

No

Yes

/No

Y if

and

RF

Low

ala

rm s

houl

d ge

nera

te a

nin

tern

al R

F in

hibi

t (H

DO

01).

N if

not

. A

n R

FL

ow a

larm

will

alw

ays

be g

ener

ated

.

FP23

RF

Low

Ala

rm T

rip

Lev

elN

Wat

ts00

0000

00-9

999

Whe

n th

e R

F fo

rwar

d po

wer

[A

I01]

fal

ls b

elow

this

leve

l an

RF

low

ala

rm w

ill o

ccur

.

FP24

RF

Hig

h A

larm

Tri

p L

evel

NW

atts

0750

0002

-999

9W

hen

the

RF

forw

ard

pow

er [

AI0

1] r

ises

ove

rth

is le

vel a

n R

F hi

gh a

larm

will

occ

ur.

Tab

le 6

- F

ield

Mod

ifia

ble

Para

met

ers

(con

tinue

d)


MCL, INC. 38A163744 of 84

RE

FN

OP

AR

AM

ET

ER

NA

ME

SYST

EM

CR

ITIC

AL

UN

ITS

DE

FA

UL

TL

IMIT

SF

UN

CT

ION

AL

DE

SCR

IPT

ION

FP25

Tub

e O

ver

Dri

ve F

ault

Lev

elY

mill

i-w

atts

015

002-

999

Whe

n th

e tu

be R

F dr

ive

pow

er [

AI0

0]ri

ses

abov

e th

is le

vel a

Tub

e O

verd

rive

faul

t and

Sum

Fau

lt w

ill o

ccur

.

FP26

RF

Ref

lect

ed P

ower

Tri

p L

evel

YW

atts

0075

0010

-20

00W

hen

the

RF

Ref

lect

ed p

ower

[A

I02]

ris

esab

ove

this

leve

l an

RF

Ref

lect

ed f

ault

and

Sum

Fau

lt w

ill o

ccur

.

FP31

Inve

rt S

cree

n V

ideo

NN

/AN

oY

es/N

oY

es is

whi

te b

ackg

roun

d w

ith b

lue

char

acte

rs.

No

is b

lue

back

grou

nd w

ith w

hite

char

acte

rs.

FP32

Secu

rity

Cod

eY

N/A

777

000-

999

Thr

ee d

igit

num

ber

whi

ch m

ust b

e en

tere

dto

allo

w (

unlo

ck)

adju

stm

ents

of

syst

emcr

itica

l par

amet

ers

(col

umn

thre

e of

this

tabl

e).

FP33

Tub

e R

F D

rive

Pow

er [

AI0

0] F

ull

Scal

e V

alue

Ym

W25

002

0-99

9T

he v

alue

use

d by

sof

twar

e to

cal

cula

te th

ecu

rren

t val

ue o

f A

I00

stat

us.

FP34

RF

Forw

ard

Pow

er [

AI0

1] F

ull

Scal

e V

alue

YW

1000

0100

-99

99T

he v

alue

use

d by

sof

twar

e to

cal

cula

te th

ecu

rren

t val

ue o

f A

I01

stat

us.

FP35

RF

Ref

lect

ed P

ower

[A

I02]

Ful

lSc

ale

Val

ueY

W01

0000

10-

2000

The

val

ue u

sed

by s

oftw

are

to c

alcu

late

the

curr

ent v

alue

of

AI0

2 st

atus

.

FP38

Fila

men

t Cur

rent

[A

I05]

Ful

l Sca

leV

alue

YA

05.0

005

.00-

25.0

0T

he v

alue

use

d by

sof

twar

e to

cal

cula

te th

ecu

rren

t val

ue o

f A

I05

stat

us.

FP41

Hel

ix C

urre

nt [

AI0

8] F

ull S

cale

Val

ueY

mA

050

010-

999

The

val

ue u

sed

by s

oftw

are

to c

alcu

late

the

curr

ent v

alue

of

AI0

8 st

atus

.

FP42

Hel

ix R

un C

urre

nt T

rip

Lev

el[A

I09]

Ful

l Sca

le V

alue

Ym

A05

001

0-99

9T

he v

alue

use

d by

sof

twar

e to

cal

cula

te th

ecu

rren

t val

ue o

f A

I09

stat

us.

FP43

Hel

ix S

urge

Cur

rent

Tri

p L

evel

[AI1

0] F

ull S

cale

Val

ueY

mA

100

010-

999

The

val

ue u

sed

by s

oftw

are

to c

alcu

late

the

curr

ent v

alue

of

AI1

0 st

atus

.

Tab

le 6

- F

ield

Mod

ifia

ble

Para

met

ers

(con

tinue

d)


MCL, INC. 38A163745 of 84

RE

FN

OP

AR

AM

ET

ER

NA

ME

SYST

EM

CR

ITIC

AL

UN

ITS

DE

FA

UL

TL

IMIT

SF

UN

CT

ION

AL

DE

SCR

IPT

ION

FP44

Cat

hode

Vol

tage

[A

I11]

Ful

l Sca

leV

alue

YV

1470

006

000-

2000

0T

he v

alue

use

d by

sof

twar

e to

calc

ulat

e th

e cu

rren

t val

ue o

fA

I11

stat

us.

FP45

Cat

hode

Vol

tage

Set

Poi

nt [

AI1

2] F

ull

Scal

e V

alue

YV

1470

006

000-

2000

0T

he v

alue

use

d by

sof

twar

e to

calc

ulat

e th

e cu

rren

t val

ue o

fA

I12

stat

us.

FP46

Hig

h V

olta

ge U

nder

Vol

t Tri

p L

evel

[AI1

3] F

ull S

cale

Val

ueY

V14

700

0600

0-20

000

The

val

ue u

sed

by s

oftw

are

toca

lcul

ate

the

curr

ent v

alue

of

AI1

3 st

atus

.

FP47

Hig

h V

olta

ge O

ver

Vol

t Tri

p L

evel

[AI1

4] F

ull S

cale

Val

ueY

V14

700

0600

0-20

000

The

val

ue u

sed

by s

oftw

are

toca

lcul

ate

the

curr

ent v

alue

of

AI1

4 st

atus

.

FP49

Aut

o Sw

itchi

ng O

n?N

N/A

No

Yes

/No

Det

erm

ines

if H

DO

00 is

on.

U

sed

for

3005

7 on

ly.

FP55

Zer

o O

ffse

t for

[A

I13]

Hig

h V

olta

geU

nder

Vol

t Tri

p L

evel

NV

0000

000

000-

3200

0FP

55 is

sub

trac

ted

from

AI1

3’s

curr

ent v

alue

.

FP56

Zer

o O

ffse

t for

[A

I11]

Cat

hode

Vol

tage

NV

0000

000

000-

3200

0FP

56 is

sub

trac

ted

from

AI1

1’s

curr

ent v

alue

.

FP57

Zer

o O

ffse

t for

[A

I14]

Hig

h V

olta

geO

ver

Vol

t Tri

p L

evel

NV

0000

000

000-

3200

0FP

57 is

sub

trac

ted

from

AI1

4’s

curr

ent v

alue

.

FP58

Zer

o O

ffse

t for

[A

I12]

Cat

hode

Vol

tage

Set P

oint

NV

0000

000

000-

3200

0FP

58 is

sub

trac

ted

from

AI1

2’s

curr

ent v

alue

.

FP59

Zer

o of

fset

for

[A

I10]

Hel

ix S

urge

Cur

rent

Tri

p L

evel

N

mA

0000

000

.000

-32

.000

FP59

is s

ubtr

acte

d fr

om A

I10’

scu

rren

t val

ue.

FP60

Zer

o O

ffse

t for

[A

I09]

Hel

ix R

unC

urre

nt T

rip

Lev

elN

mA

0000

000

.000

-32

.000

FP60

is s

ubtr

acte

d fr

om A

I09’

scu

rren

t val

ue.

FP61

Zer

o O

ffse

t for

[A

I08]

Hel

ix C

urre

ntN

mA

0000

000

.000

-32

.000

FP61

is s

ubtr

acte

d fr

om A

I08’

scu

rren

t val

ue.

Tab

le 6

- F

ield

Mod

ifia

ble

Para

met

ers

(con

tinue

d)


MCL, INC. 38A163746 of 84

CAUTION

3.2 Turn-On Procedure

3.2.1 Initial Turn-On Check List

All MCL TWT amplifier systems are ready to be activated when the following check list hasbeen complied with:

1. The MT3000 is properly mounted in the cabinet and the cabinet is firmly bolted in place.

Make sure the top cover of the MT3000 is attached. The cover ispart of the cooling circuit.

2. Ground strap (earth) attached to safety ground tie point in cabinet (lower rear).

3. Appropriate AC input voltage and frequency source has been connected to the MT3000. Check AC system voltages by measuring the voltage on the mate for J1.

4. All waveguide flanges securely fastened together and input RF coaxial cable firmlyattached.

5. All electrical connections double checked mechanically and electrically. The main ACpower connector should be properly connected to J1 on the MT3000.

6. Air intake and exhaust properly installed. Make certain that the installation does not allowair to recirculate between the input and output.

7. The Main Power circuit breaker should be in the off position.

8. The input RF drive source should be properly connected with its output set to minimumand off (mute).

9. If the User Interface (J5) and Switchover Interface (J7) are not used, the supplied cheaterplugs should be installed on the rear panel.

10. Connect the Remote Panel & Computer Interface cables to the rear panel.

11. Check that the exciter output is adjusted to minimum.


MCL, INC. 38A163747 of 84

CAUTION

3.2.2 Power-Up Procedure

When the above check list has been completed, the system is ready for activation. To activatethe system, the following steps should be followed:

1. Activated the Main Power circuit breaker, then check the voltage LEDs on the front panelto be sure the logic power supplies are operational. Press the Local & Standby buttons toverify that Xmt Delay is canceled. Check for the Delay indicator on the Main screen (theStandby & Transmit LED will be off).

2. Set the RF Inhb/Enbl control to the Inhb position.

3. Hold the Gain Dec button down for until the attenuation level is 32.0 dB.

4. Check for illumination of the Standby LED at the end of the warm-up cycle. This will befive minutes when set according to Table 6. Remaining Filament delay can be displayedby selecting the Filament Power Supply Analog Status screen.

Never activate transmit unless an RF load is connected to theRF output.

Avoid operating the system in standby for more than 60 minutes.See Appendix E – 46A0009 Extending Tube Life Information formore information.

5. Insure that the RF input to this system is the desired frequency and that it matches theTWTA tube center frequency.

6. Depress the Transmit switch (HV On) to activate the high voltage. The “Transmit” switchwill illuminate.

7. Check the readings on the Analog Status screens against those which were recorded at thefactory and supplied with the MT3000 test data. A discrepancy of 1 or 2 percent isnormal due to factors such as ambient temperature and AC line voltage variation.

8. From the “Main” screen “Enbl” RF.

9. Set the exciter output to RF On.

10. Go to the “Pwr Lvl” screen and press “Gain Inc” slowly and very carefully increase thesystem RF input drive until rated RF Forward Power (Consult the MT3000 test data forthe rated output power to be expected) is obtained from the amplifier system while stayingwithin the TWTA tube current and voltage limitations. Monitor the output reflected RFpower to insure that the transmission line is reflecting less than 10% of the output forwardpower.


MCL, INC. 38A163748 of 84

CAUTION

11. If the system reaches rated output before reaching maximum gain, it will benecessary to further reduce the RF output of the exciter.

12. If the system reaches maximum gain before reaching rated output power, slowlyincrease the exciter output until the system reaches rated output power.

Under no circumstances should the TWTA be driven to an output ofgreater than the system’s rated output. This will result indegradation to or possible immediate permanent damage to theTWT.

13. Once that the exciter output has been set so that the system reaches full rated outputwith the MT3000 gain control set to maximum gain, the exciter output should belocked in place by mechanical means or by way of a tamper proof seal. The MT3000gain control should then be used in the future to make adjustments to the systemoutput power.

14. Allow the system to thoroughly stabilize for no less than 5 hours.

15. Check all meter readings to insure that parameters are within operational tolerances.

16. On the “Fault Status” screen press the “Clear Log” button.

17. If it is desired to have the system recycle into Transmit after transient tube faults, or if thesystem is to be left in unattended operation, see the Fault Counter Operation paragraphof 38A1578.

At all times during various activation phases, spurious faults may occur and can be immediatelycleared by depressing the “Fault Reset” switch momentarily and then releasing.

This completes the procedure necessary to bring the MT3000 TWT amplifier system into fulland complete system operation. The MT3000 TWTA transmitter system is now fullyoperational and will stay functional until either operator shutdown or a fault condition isdetected.

If problems occur during the execution of this procedure, refer to Section 6.0 Troubleshootingfor diagnostic information, and/or Appendix D 40A1845 – Customer Service Information.


MCL, INC. 38A163749 of 84

Table 7 - Analog Status Nominal Readings

3.2.3 Delay & Standby Analog Status

The analog status displays will read as follows during Delay & Standby:

Meter Readings (Warm-Up and Standby Conditions):

1. TWTA Filament Current 2.5 A nominal2. Tube Drive Power (while RF Enabled) 10 mW maximum *

* depends on attenuator setting

All other meters should not be indicating at this time (due to the high resolution A to D circuitryused a small amount of fluctuation may be present on various analog displays).

3.2.4 Transmit Analog Status

Upon activation of the Transmit mode of operation, the analog status displays will read asreferenced in Table 7.

ANALOG STATUS NOMINALREADING

Filament Current 2.0 A

Helix Current 2 mA

Cathode Voltage 11100 V

Tube Drive Power 10 mW

RF Forward Power (rated) 630 W

Upon application of RF drive, the RF Forward Power, the Tube Drive Power, and the HelixCurrent analog statuses should deflect according to the amount of RF drive applied to thesystem and the amount of Attenuation adjusted into the MT3000.

3.3 Shut-Down Procedure

To discontinue operation of an MT3000 TWT amplifier system, the following procedure isrecommended for system shutdown:

1. Remove the input RF drive to the amplifier system.

2. Depress Standby switch until illuminated.


MCL, INC. 38A163750 of 84

Table 8 - Operating Cautions

3. Let TWTA cool down for 5 minutes.

4. Turn off the Main AC Power switch.

Under extreme emergencies, the operator may totally remove AC input power from the systemby simply switching the Main AC Power circuit breaker to the Off position. This shutdownprocedure is only for emergencies and should not be used under normal circumstances. Ifproblems occur during the shutdown procedure, refer to the Section 6.0 Troubleshooting fordiagnostic assistance.

3.4 Operating Caution List

Table 8 is a list of improper operating conditions. These conditions are to be avoided. Theseare conditions which could damage the TWT amplifier system, and their probable sources.

SYMPTOM ORIGIN

High or Low System AC Input Power or AC Line a) Customer Power Source.Unbalance b) Continuous system operation with circuit breakers

bypassed (“cheated”).

High or Low TWTA Filament Voltage or Current a) TWTA Tube Filament Supply D16800 Assembly.b) Continuous system operation with circuit breakers

bypassed (“cheated”).

Excessive Tube Drive Power Overdrive on RF System Input or TWTA GainAdjustment Set Incorrectly.

Airflow Fault System operation with blocked air intake and exhaustports.

Tube Temperature a) System operation outside the specifiedenvironmental range.

b) Continuous system operation with circuit breakersbypassed (“cheated”).

Excessive Output Reflected Power Meter Indication a) System Output Transmission Line Connection andCustomer Waveguide/Load Incompatibility.

b) Operating TWTA with unterminated RF input oroutput ports.

Non-Indication of Fault Parameter a) D16763 TWTA Interface CCA located in theCLM.

b) “Forced” operation by defeating the faultprotection circuitry or control system (do notdefeat fault circuitry unless specificallyrecommended by MCL).


MCL, INC. 38A163751 of 84

CAUTION

Any of these conditions indicate that a critical system parameter is either out of adjustment orthe fault conditions are no longer recognizable. If these conditions should exist, no furtherattempt should be made to use the amplifier system until the defective circuitry or adjustment iscorrected. Of most concern to the operator is potential damage to the TWTA tube because ofits cost and the down time required for repair and/or replacement. Therefore, any parameterrelating to the TWTA tube should be analyzed immediately to prevent damage.

Failure to avoid above conditions will void warranties!!

3.5 Prevention of Excessive RF Input Power

As is well known, drive of all TWTA tube past saturation will damage the tube. Saturation isthe point where further input results in no further increase in power out.

It is requested that the user immediately investigate the possibility of overdrive in hisinstallation. Unfortunately, after a TWTA tube breaks it is difficult to get any one to admit toan error of this type. If this possibility exists, the following is suggested:

3.5.1 The Exciter

The exciter output must be limited to less than or equal to 3 dB greater than the level requiredto drive the system to rated output power. This level can be found on a warning tag attached tothe front of each unit as well as in the system test data.

3.5.2 How to Limit RF Input Drive to the TWTA

3.5.2.1 Rate Power no Attenuation

With attenuation at minimum, measure the amount of power required to drive the MT3000system to rated power (this is also shown on the data sheet sent with the equipments. Allattenuators in the TWTA and TWTA system should be at minimum.

3.5.2.2 Exciter Adjustment

Set the exciter at this level and lock all exciter output adjustments permanently. Use devicesthat must be removed to readjust output. Alternately, set exciter at maximum and insertattenuation in the line to limit power available at the TWTA.

3.5.2.3 Exciter Label

If the exciter has an output meter, place label over this meter showing maximum outputpermitted.


MCL, INC. 38A163752 of 84

3.5.2.4 MT3000 Trip Levels

Go to the “RF Parameters” set-up screen and set “RF H Alm Trip Lvl” to rated power out (Donot use saturated power out for this adjustment). Obviously, if you are using the TWTA at alower power out, continue to do so. If you do not exceed rated power out, you cannot over-drive the tube. For the RF High alarm to occur and prevent overdrive, you must Enable thefunction. Go to the “RF Parameters” set-up screen and set “RF H Alm Rf Inhb” to “Yes.” Thiswill actuate the ability of the pin diode switch to remove the RF drive. User adjustable RF highand RF low alarm trip points are included on the “RF Parameters” set-up screen. The RF lowset-point must be set above 1/100th of full scale for reliable operation.

3.6 Tube Degassing

See Section 5.0 Preventive Maintenance for procedures to prevent excessive cathodeemissions.

If spare tubes are going to remain in storage for long amounts of time it is recommended that anMCL degassing station is purchased and used before installation.

3.7 Setting the Clock

To set the clock to local time from the “Main” screen press “Set Up,” then “Cont,” then “Sel”until “System Timing,” then “Goto,” then “More.” The time set up screen (“System TimingSet Up”) should be on the display. Notice the “Set” button. When the “Set” button is pressedthe clock will be set to the date & time currently displayed in the Edit window. Edit the hours,minutes, and seconds to match local time (set the seconds/minutes ahead at least 30 seconds toallow you time to get ready to press the “Set” button). If required Edit the date also. Press the“Set” button, about one second later you will see the clock change. Press “Main” to return.

3.8 Optional Linearizer Adjustment

If the TWTA was supplied with the optional linearizer, it may be necessary or desirable to fineadjust the linearizer for the specific application. The linearizer is preset at the factory to yield a6 to 10 dB improvement in intermodulation distortion at an output power backoff of 4 dB fortwo carriers spaced 10 MHz apart at mid-band.

If operating with more than two carriers, near the band edges, or at an output power backoffother than 4 dB, a slight increase in performance may be obtainable with a slight adjustment ofthe Phase control behind the accessory panel. The Phase Voltage test points may be used as areference during the adjustment. The factory preset Phase Voltage can be found in the MT3000test data which was supplied with the unit.

The linearizer Mag control is set for the specific TWT characteristics and should not be movedfrom the factory preset position unless the TWT is replaced. MT3000 Acceptance TestProcedure 34A2458 should be used if it becomes necessary to perform a “from scratch”linearizer set-up.


MCL, INC. 38A163753 of 84

4.0 THEORY OF OPERATION

This section deals with the technical aspect of operating the MT3000 TWT amplifier system.

The unit consists of the subassemblies shown in Figure 12.

4.1 Power Distribution

The primary power enters the system through the J1 & CB1 and is supplied directly to PrimePower Converter Module (D13191). The Prime Power Converter Module provides powerfactor correction and AC to DC conversion for the MT3000. The following paragraphsdescribe each of these outputs. Also see Figure 13 for an overview of Prime Power ConverterModule outputs.

4.1.1 Unregulated 450V Power Supply

This power supply is produced on C16839 Capacitor Bank CCA from the rectified & filteredline voltage, then is used internal to the Prime Power Converter Module to produce all the otherMT3000 lower voltage power supplies. The Unregulated 450V is also supplied to the HV(DC/DC) power supply from which it produces the TWT electrode voltages.

4.1.2 Control & Logic Module +5V Power Supply

The +5V for the Control & Logic Module is supplied by the D13191 PPC (see 32D3407). Theoutput and sense lines are routed through the MT3000 harness to the CLM. The sense linesprovide remote sensing for at U7 of D16765 CLM baseboard (32D3200) and the MT3000harness to the CLM.

4.1.3 +15V Power Supply

The SSA, CLM, Linearizer, HV (DC/DC) power supply, & J7 switchover interface are allsupplied +15V power from the D13191 PPC (see 32D3407).

4.1.4 Blower +48V Power Supply

The +48V for the MT3000 blowers is produced in the D13191 PPC, (see 32D3407) andsupplied through the MT3000 harness to the blowers (B1 and B2 on 32E3406).


MCL, INC. 38A163754 of 84

Figure 12 - MT3000 General Layout


MCL, INC. 38A163755 of 84

Figure 13 - Power Distribution Block Diagram


MCL, INC. 38A163756 of 84

WARNING

4.1.5 Filament Power Supply

The Filament power supply AC input voltage is produced in the D13191 Prime PowerConverter (See 32D3407) and routed through the MT3000 harness to the D13192 HighVoltage DC/DC Converter (See 32D3389).

The filament circuit is “floating” at the high voltage level, and extremecaution should be used when servicing this assembly.

4.1.6 “Ready” Status

This signal is sent to the CLM and HV (DC/DC) Power Supply to indicate that the PrimePower Converter Module is ready and DC power is available. This signal is generated onD16842 Prime Power Converter Control CCA. When the output is energized the Prime PowerConverter Module is ready and when it is not energized there is a problem. When the output isdeenergized the CLM will report a “PPM Fault.”

4.2 DC/DC (High Voltage) Power Supply

The DC/DC HV Power Supply (D13192) converts the 450V unregulated input voltage to theCathode & Collector electrode voltages require by the TWT. The electrodes of the TWT aredirectly connected to the DC/DC HV Power Supply (see 32E3406).

The DC/DC HV Power Supply (D13192) is controlled & monitored by the CLM. Thefollowing digital fault inputs and analog trip level inputs are supplied to the CLM to bedisplayed and processed there.

• Helix Surge Current• Helix Run Current• High Voltage Under Volt• High Voltage Over Volt

The following analog status signals which indicate the current level of the electrode outputs aresent to the CLM:

• Helix Current • Cathode Voltage• Cathode Voltage Set To Level


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WARNING

The CLM sends the following control lines to the DC/DC HV Power Supply (D13182-100):

• Transmit (HV On)• Fault Reset• Helix Run Current Fault Enable• High Voltage Fault Enable

Voltages hazardous to life are present in this drawer when power isapplied. Use extreme caution when servicing drawer interior.

4.3 Control & Logic Module

For the Theroy of Operation of the CLM see appendix F (Vol II), 38A1578 Operation &Maintenance Manual for MT3000 Control & Logic Module.

4.4 RF Chain

The RF Chain (see Figure 14 and 32E3406) consist of an SSA module, the TWT, and theoutput waveguide assembly. The RF chain takes input power levels as low as !24 dBm andamplifies them to output levels of approximately 55 – 56 dBm.

4.4.1 SSA Pre-Amplifier

The Solid State Pre-amplifier (SSA) is located on the right hand cabinet side wall near theTWTA tube input. This SSA supplies an RF level of up to +22 dBm with a gain ofapproximately 33 dB to the TWT.

The SSA has a built in PIN diode switch and attenuator which are controlled by the CLM. ThePIN diode switch when activated reduces the RF drive to the TWTA tube by 30 dB minimum. The attenuator can be adjusted to as much as 30 dB of TWT input power attenuation. Whenthe attenuator drive voltage is 10V the attenuator will have 0 dB of attenuation, and 0V willcorrespond to full attenuation.

The SSA has an output power monitor which sends a voltage sample to CLM analog inputAI00. This sample is then calibrate at the CLM (by R1 and FP33, appendix F) to correspond toTWT drive.


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4.4.2 TWT

For information on the tube check the manufacturers information enclosed in the tube shippingcontainer.

4.4.3 RF Output Waveguide Assembly

The output waveguide assembly consist of a high power circulator (HY2) which protects theTWT by controlling the load VSWR into the TWT output port.

The next component is an band-pass filter (FL1).

The last component in the waveguide assembly is a three port directional coupler (DC1). Port#1 has a 39 dB reflected nominal coupling factor and through CR2 drives the Reflected Powerinput (AI02) of the CLM. The sample is calibrate at the CLM (R3 & FP35, appendix F) tocorrespond to the RF reflected output power at the MT3000 output flange. Port #2 has anominal 49 dB forward coupling factor and through CR1 drives the Forward Power input(AI01) of the CLM. The sample is calibrate at the CLM (R2 & FP34, appendix F) tocorrespond to the RF forward output power at the MT3000 output flange. Port #3 has a 52 dBforward nominal factor and is connected to the output monitor port on the MT3000 back panel. The sample port is factory calibrated before shipment.


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Figure 14 - MT3000 Simplified RF Block Diagram

Gain (Sat ., dB ) ' P (out , dBm ) ! P (in, dBm ) (1)

Gain (SSG , dB ) ' P (out , SSG , dBm ) ! P (in, SSG , dBm ) (2)


MCL, INC. 38A163760 of 84

4.5 Gain and RF Power Output

When gain is considered, it is necessary to differentiate between gain experienced when the tube(or TWTA) is in the linear region and gain when it is operating in the saturated output powermode. These two values of gain are called the “Small Signal Gain” and the “Saturated Gain”respectively. A curve of RF Power Output versus RF Power Input for a typical TWTA isshown in Figure 15 the saturated power output is the peak value of the curve. Rated poweroutput is defined as the guaranteed maximum power output and is usually slightly less (<0.5 dB)than saturated power output.

The saturated gain is defined as the saturated RF power output divided by the RF power inputrequired to produce the saturated power output:

The difference between TWTAs and solid state amplifiers is that solid state amplifiers aretypically specified in terms of their RF power output at 1 dB gain compression. As shown inFigure 15, the RF power output at 1 dB gain compression is less than the RF power output atsaturation. For most TWTAs, the saturated gain is 5 to 6 dB less than the small signal gain.

Small signal gain is typically specified as the gain when the RF power output is 10 dB or morebelow the saturated RF power output. The small signal gain is then defined as:

Maximum gain for the TWTA or TWTA system is, of course, when all variable attenuation is ata minimum.

NOTE

The exciter output must be limited to less than or equal to 3 dBgreater than the level required to drive the system to rated outputpower. This level can be found on a warning tag attached to thefront of each unit as well as in the system test data.


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Figure 15 - RF Output & Gain vs RF Input Power


MCL, INC. 38A163762 of 84

CAUTION

5.0 PREVENTIVE MAINTENANCE

The MT3000 TWT amplifier system should be inspected on a three month basis for dust anddirt accumulation. This is especially important in any area operating at high voltage. Allevidence of dust and/or dirt should be removed during the inspection process.

When the system has been shut off for any length of time, an inspection for moistureaccumulation and water buildup in the interior of the cabinet should be performed before anyattempt is made to activate the system.

Do not operate this system when excessive moisture is present in theinterior.

The following guides are offered to aid in the event trouble-shooting becomes necessary, andfor routine preventive maintenance.

5.1 Panel Lamps

The panel lamps are all solid state LED lamps and should never need replacement throughoutoperational life of the TWTA. In the event of LED failure, remove all power from the systemand remove the front panel LED PCB from the CLM. Unsolder the LED and replace,observing LED polarity. Reinstall the PCB, reapply power.

5.2 Blower

The blower in the MT3000 system are permanently lubricated bearing types and should neverrequire oiling or greasing. It is recommended that, on a six month schedule maximum, theblower is inspected at both the intake and exhaust for any potential obstruction build-up. Pressurized air can be used to free the blower of any dirt accumulation.

5.3 Switches/Interlocks

All switches, interlocks, and mechanical relays should be inspected on a six month basis foroperational integrity. Obvious switch and relay failures will be apparent from the normalday-to-day operations, however, the interlocks, relays, and switches should be regularly testedfor electrical function. Testing can consist of simply opening a drawer to activate an interlockswitch in question to test its function.


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5.4 Cabinet Cleaning

Completely shut off all power at the system circuit breaker before cleaning. The externalsurfaces are coated with a baked-on enamel finish to protect them against day-to-day abuse. The finish will protect them against mild cleaning solutions. Use a mild soapy water solution, ora diluted alcohol solution on a damp cloth to clean the panel. Avoid using an excessive amountof cleaning solution as this could migrate into unwanted areas.

5.5 Internal Cleaning

With prolonged use, there could be an accumulation of airborne residue within the MT3000. Shut off the system power. Dust off the MT3000 top cover. Remove the lid and use a streamof compressed air to dislodge and remove any residue.

5.6 Extending Tube Life

It is not recommended that the MT3000 TWT Amplifier remain in cold standby (MT3000Standby mode) for more than 1 hour. Prolonged operation in this state may cause permanentdamage to the TWT cathode.

It is recommended that if the MT3000 is used in 1:1 systems (or any other type of system)where it will serve as a back-up TWTA carrying no traffic, that the MT3000 be left in hotstandby (MT3000 Transmit mode with the RF drive turned off).

See Appendix E 46A0009 – Extending Tube Life Information for more information.

5.7 Removal/Disassembly/Replacement

5.7.1 TWT Replacement

The TWT manufacturer rates the tube life of the C-Band TWTA tube at a minimum of25,000 hours. A more typical value seems to be 55,000 hours, which implies that tubereplacement would be required on a maintenance basis approximately every 3.0 years operationin a given continuous mode. In order to remove the TWT, the following steps should be takenin the order given:

1. Remove RF input drive and place unit in Standby. Allow to cool for 5 minutes.

2. Switch off the Main AC power switch.

3. Remove AC input power to the amplifier system.

4. Remove MT3000 lid.

5. Remove HVPS D13192.


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CAUTION

Table 9 - EPROM Locations

6. Remove PPC D13191.

7. Remove waveguide assembly.

8. Remove blower assembly.

9. Remove tube.

10. Remove air flange gasket and bracket from tube for re-use on new tube.

Nicks and tool marks on High Voltage wiring may damageinsulation and be a cause of unwanted corona. Due to the weight ofthis tube, assistance may be required.

This completes the removal procedure for the TWT. Again, it is extremely helpful to mark anywires removed, noting any additional information to allow for more rapid reassembly. Also, useextreme caution when working with the high voltage wiring as the solder points tend to becomebrittle after extended usage.

5.7.2 EPROM Replacement Procedure

There are four EPROMS located in a CLM, one or all of them may need to be changed. TheEPROMS will be marked with MCL part numbers which determine which CCA they must beinstalled in. Some steps of this procedure are skipped depending on which EPROMS you mustchange.

EPROM NUMBER LOCATION

45A0032 U5 of D16763, TWTA Interface CCA

45A0030 U1 of D16762, Local Interface CCA

45A0018 U8 of D16765, Baseboard CCA

45A0031 U3 of D16762, Local Interface CCA


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WARNING

CAUTION

During this procedure you will have to lay the CLM front-panel face-down on a protectivesurface that will not scratch it.

1. Put the MT3000 into Standby and let it cool-down while you record all Field ModifiableParameters in Table 10. Also record the communications address & baud rate from theMain/More screen.

2. Turn off the MT3000 Main power switch then turn all AC power off to the MT3000 atthe wall breaker.

The AC supply to the MT3000 must be turned off at this time, asthe main AC on circuit is always live on one side!

3. Remove the MT3000 top cover.

4. Disconnect the wires to the Main AC Power switch (first be sure they are marked as towhere they connect).

5. Disconnect all harness connectors from the back of the CLM (first be sure they aremarked as to where they connect).

6. Remove the six screws (two each on the left, right, & bottom) which hold the front panelto the chassis.

7. Gently tip the front panel forward until you can get at the three ‘D’ connectors on theback of the CLM, then disconnect them. Place the CLM on a bench face down.

Be careful not to scratch the LCD lenses in the membrane panel.

8. Remove the CLM lid then the six nuts which hold the CLM chassis to the front panel. SeeE30080, to aid in disassembly of the CLM. Separate the chassis from the front panel(without putting stress on the interconnecting cables), lay the front panel face-down on aprotective surface so that it does not get scratched. Disconnect the four interconnectingcables between the front panel and the D16762 Local Interface CCA.

9. If you are only changing EPROMs on the Local Interface CCA skip to step 11. Removethe D16762 Local Interface CCA.


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Table 10 - Field Modifiable Parameters

10. If you are not changing 45A0018 on the Baseboard CCA skip to step 11. Remove theD16763 TWTA Interface CCA from the CLM chassis but do not disconnect the threeribbon cables from the chassis back-wall.

11. Remove the old EPROMs (being careful not to mix them up) and install the new versions. See assembly prints D16762, D16763, & D16765 included in the back of Appendix F,O&M Manual for MT3000 type CLM, to aid in finding the EPROM locations.

12. Set the address switches (two switches closest to the corner) on the back of the CLM tothe “0” position. Reassemble the CLM and reinstall it into the MT3000 by performingsteps 10 through 3 in reverse order.

13. Reconnect AC power to the MT3000. For about 1 second turn-on the MT3000 MainAC power switch, then turn it back off.

14. Reset the CLM address back to it’s original setting. Turn-on the MT3000 MainAC power switch. Now reset the Field Modifiable Parameters to the values recorded inTable 10.

REF # PARAMETER NAME SCREENCURRENTSETTING

FP00 Automatic Fault Counter Window Auto Fault Counter Set-Up

FP01 Enable Fault Counter and Automatic Auto Fault Counter Set-UpFault Reset

FP02 Auto Fault Reset Retry Count Auto Fault Counter Set-Up

FP03 Fault Counter Fault Reset Wait Time Auto Fault Counter Set-Up

FP04 Auto Power Set to Level Auto PWR & Chng Flag Set-Up

FP05 Auto Power % Regulation Auto PWR & Chng Flag Set-Up

FP06 Auto Power Min Regulation & Chng Auto PWR & Chng Flag Set-UpFlag Delta Min

FP09 Change Flag Delta % Auto PWR & Chng Flag Set-Up

FP16 Filament Delay System Timing Set-Up

FP17 HV Fault Enable Delay System Timing Set-Up

FP19 Class IV Fault Enable Delay System Timing Set-Up

FP21 RF High Alarm Inhibit RF? RF Parameter Set-Up

FP22 RF Low Alarm Inhibit RF? RF Parameter Set-Up

FP23 RF Low Alarm Trip Level RF Parameter Set-Up

FP24 RF High Alarm Trip Level RF Parameter Set-Up


REF # PARAMETER NAME SCREENCURRENTSETTING

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FP25 Tube Over Drive Fault Level RF Parameter Set-Up

FP26 RF Reflected Power Trip Level RF Parameter Set-Up

FP27 Attenuation Level Power Level

FP32 Security Code System Timing Set-Up

FP33 Tube Drive Power Full Scale Value Analog Scale Set-Up

FP34 RF Forward Power Full Scale Value Analog Scale Set-Up

FP35 RF Reflected Power Full Scale Value Analog Scale Set-Up

FP38 Filament Current Full Scale Value Analog Scale Set-Up

FP41 Helix Current Full Scale Value Analog Scale Set-Up

FP42 Helix Run Cur Trip Lvl Full Scale Analog Scale Set-UpValue

FP43 Helix Surge Cur Trip Lvl Full Scale Analog Scale Set-UpValue

FP44 Cathode Voltage Full Scale Value Analog Scale Set-Up

FP45 Cath Volt Set Point Full Scale Value Analog Scale Set-Up

FP46 High Voltage Under Volt Full Scale Analog Scale Set-UpValue

FP47 High Voltage Over Volt Full Scale Analog Scale Set-UpValue

FP49 Auto Switching On? Switchover Set-Up

FP55 Zero Offset for HV Under Volt Trip HVPS Analog OffsetLevel

FP56 Zero Offset for Cath Voltage HVPS Analog Offset

FP57 Zero Offset for HV Over Volt Trip HVPS Analog OffsetLevel

FP58 Zero Offset for Cath Volt Set Point HVPS Analog Offset

FP59 Zero Offset for Helix Surge Current HVPS Analog OffsetTrip Level

FP60 Zero Offset for Helix Run Current HVPS Analog OffsetTrip Level

FP61 Zero Offset for Helix Current HVPS Analog Offset


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WARNING

6.0 TROUBLESHOOTING

During the course of the service life of the MT3000 TWT amplifier, problems may arise andfailure modes may occur. This section will give the user information which will be useful whilefinding and solving problems.

It is important when troubleshooting this equipment that theutmost caution is utilized since extremely lethal voltages exist in allareas of this amplifier system.

6.1 Equipment List

Table 11 is the recommended equipment for use while troubleshooting an MCL MT3000 TWTAmplifier.

6.2 Troubleshooting Guide

For general trouble-shooting purposes, Table 12 will allow the operator to isolate the problemarea to the appropriate assembly with a high degree of confidence. As each problem area isidentified, the most likely cause of the problem, the appropriate sub-assembly schematic andassembly drawing is referenced for further diagnostic information. These schematics andassembly drawings are located at the end of this manual. Recommend test equipment is listed inTable 11.

The MT3000 has built in fault diagnostic information which will point the operator to a list ofpotential problem areas for each fault. This fault diagnostic information where applicableclosely parallels Table 12. This fault diagnostic information can be accessed by selecting (bypressing the “Sel” button) an event on the “Event Log” screen then pressing the “Goto” button.

The following procedures assume some knowledge of power supply and logic controloperation. A review of the Theory of Operation presented in Section 4.0 might be advisablebefore attempting to service the MT3000. It is especially important to go a step beyond simplyreplacing failed components to find and correct the underlying cause. The time spent inperforming a few simple tests before attempting a full power turn-on will be well justified.


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WARNING

Table 11 - Recommended Test Equipment

High voltages are present in a fully operational MT3000. The cathodeand filament voltages are over ten-thousand volts. Since these voltagescould occur at locations and under conditions which are unexpected,particularly if the unit is malfunctioning, extreme caution is advised. Always make sure that the chassis is earth grounded (see installationcaution). Use caution in connecting scope probe grounds.

ITEM MANUFACTURER &NO MODEL NUMBER

QTY DESCRIPTION

1 1 Fluke DVM Fluke 25

2 1 Precision Divider Fluke 80E

3 1 Power Supply 10 VDC @ 2A Adjustment

4 1 Resistor 1 ohm 5W Precision

5 1 HV (collector) Load 8k ohm @ 800W

6 1 Parallel Interface Test Fixture MCL TD30200-707

7 1 Network Analyzer HP 8722A

8 1 Power Meter HP438A w/8481A

9 1 Calibrated Directional Coupler

10 1 Dummy Load, W/G

11 2 Coaxial Isolator

12 1 Think-Jet Printer HP 2225A

13 1 Coaxial Directional Coupler

14 1 10 dB PAD Wheinchel 210-10

15 1 20 dB PAD Wheinchel 210-20

16 1 Clamp-on Current Meter Bell #GC-100D


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Table 12 - Troubleshooting Guide

FAULT INDICATION REFERENCE DIAGNOSTIC AREAPRESENT SCHEMATIC

POTENTIALPROBLEM

AREA

1. No indication of 32E3406 Primary Power Converter 1. No primary power being delivered.primary power. Module (PPCM) 2. Circuit Breaker (System Power) is open.

3. Connection at J1 not secure.

2. Indication of primary 32E3406 Open CLM power con 1. Check P2/3 & P6 of the harnesspower but no power 32C3241 (32E3406).supply LEDs illuminateon the CLM.

3. No standby indication. 32E3406 Control & Logic Module 1. Check for presence of faults.32B3254 2. Check for failed LED.

4. Logic failed to go into 32E3406 Control & Logic Module 1. Check for presence of system faults.Transmit. 32C3241 Presence of Fault 2. Be sure MT3000 is in Local.

30D2554 3. Check Membrane panel.32D3197 4. Check operation of U13 & U14 on

D16762.

5. Transmit activated but 32E3256 DC/DC Power Supply 1. Ensure that 450 V is present at DC/DC.no voltage. PPCM

6. Transmit activated. 32E3406 DC/DC Power Supply 1. No high voltage to the tube, open wire?High voltage higher 32D3291 TWT 2. Check for normal filament current.than normal. 32C3289 Filament Power Supply

32C3298 Analog scale (FP44)3. Check FP44 value, see Table 6.



POTENTIALPROBLEM

AREA

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7. Transmit On. Normal 32E3406 TWT Tube 1. Check attenuator setting & operation.Beam current 32C3241 Solid State Amplifiers 2. See if Driver is producing RF output.indication but no RF 32D3198 DC/DC Power Supply 3. See if the SSA is receiving RF inputout. PPCM signal.

RF Inhibited 4. Check +15V to the SSA.Control & Logic Module 5. Check RF plumbing from MT3000 input

to tube input.6. DC/DC Power Supply outputs.7. Check for RF Inhb on front panel.8. Check RF Inhibit from User input.9. Check RF Inhibit from Switchover input.10. If FP21=Yes, check for RF High fault and

the Event log for an RF High alarm.11. If FP22=Yes, check for RF Low fault and

the Event log for an RF Low alarm.12. Check RF Inhibit drive circuity on

D16763.

8. Won’t go from 30D2554 Standby Switch failed 1. Put MT3000 in Local.Transmit to Standby 32D3197 D16762 CCA failed 2. Check membrane panel.(Transmit LED off, HV MT3000 not in Local 3. Check operation of U13 & U14 onoff, & Standby LED D16762.on).

9. Check TWTA Board- 32C3241 Control & Logic Module 1. Check connections between CLM CCAs.CLM Sum Flt. 32D3198 2. Check U2, U4, &U21 of D16765 for

32D3200 proper operation.3. Check U29 & U30 of D16763 for proper

operation.

10. Check Base Board- 32C3241 Control & Logic Module 1. Check connections between CLM CCAs.CLM Sum Flt. 32D3197 2. Check D16765 for proper operation.

32D3200

11. Check Local Board- 32C3241 Control & Logic Module 1. Check connections between CLM CCAs.CLM Sum Flt. 32D3197 2. Check U2, U4, & U21 of D16765 for

32D3200 proper operation.3. Check U17 & U20 of D16762 for proper

operation.



POTENTIALPROBLEM

AREA

MCL, INC. 38A163772 of 84

12. Erratic operation. 32E3406 Control Logic 1. Ensure connectors are firmly attached to32C3241 Interconnect their mating connectors in the CLM.30D2554 DC/DC Power Supply 2. Verify presence of logic power.

Control & Logic Module 3. Check for broken wires in inter-connectFailed membrane panel harness cable assembly.

4. High voltage arc or corona is presentduring XMT.

5. Check membrane panel.

13. Helix Current trip level 32E3406 DC/DC Power Supply 1. Check RF Drive level.exceeded. 32C3241 Helix Supply Arc 2. Check electrode voltages.

32D3198 Tube Arc 3. Check for HV arcs.Analog Scale (FP43)Control Logic Module

4. Check trip level, FP08 of Table 6.5. Check scale, FP43 of Table 6.6. Check AI10 operation on D16763.7. Disconnect the tube and run into resistor

load.

14. RF Reflected power 32E3406 RF Load 1. Check VSWR of RF Load.trip level exceeded. 32C3241 Waveguide Assembly 2. Check RF connections.

32D3198 RF Sensor 3. Check RF sensor for excessive output.Analog Scale (FP35)Control Logic Module

4. Check trip level, FP26 of Table 6.5. Check AI02 operation on D16763.6. Check scale, FP35 of Table 6.

15. Tube temperature fault. 32E3406 Blower 1. Blower or 450V P/S has failed.32C3241 Tube 2. Check RF Drive level.32D3198 Temperature Switch 3. Check tube temp switch.

DC/DC Power Supply 4. Check electrode voltages.RF drive 5. Check operation on D16763.Control Logic Module 6. Check wiring between CLM & tube.Interconnect harness

16. Interlock fault. 32E3406 Open switch or wire 1. Check for loose top cover.32C3241 Control Logic Module 2. Check switch and wiring.32D3198 Interconnect harness 3. Check operation on D16763.

4. Check for open filament P/S connector.

17. Airflow fault. 32E3406 Open switch or wire 1. Check switch and wiring.32C3241 Control Logic Module 2. Check operation on D16763.32D3198 Interconnect harness

18. Tube Overdrive fault 32E3406 Solid State Amplifier 1. Check MT3000 RF drive input.32C3241 Analog scale32D3198 Control & Logic Module

2. Check trip level, FP25 of Table 6.3. Check scale setting, FP33 of Table 6.4. Check attenuator setting & operation.5. Check the SSA RF output.6. Check AI00 circuitry on D16763.



POTENTIALPROBLEM

AREA

MCL, INC. 38A163773 of 84

19. RF Low Alarm. 32E3406 TWTA Tube 32C3241 Solid State Amplifiers32D3198 DC/DC power supply

PPCMRF InhibitedRF FWD PWR scaleControl & Logic Module

1. Check RF Low trip level, FP23 of Table6.

2. RF FWD PWR scale setting, FP34 ofTable 6.

3. Check attenuator setting & operation.4. See if the SSA is producing RF output.5. See if the SSA is receiving RF input

signal.6. Check +15V to SSA.7. Check RF plumbing from MT3000 input

to tube input.8. Check electrode voltages.9. Check for RF Inhb on front panel.10. Check RF Inhibit drive circuity and AI01

circuitry on D16763.

20. RF High Alarm. 32E3406 Solid State Amplifier 1. Check MT3000 RF drive input.32C3241 RF FWD PWR scale32D3198 Control & Logic Module

2. Check RF High trip level, FP24 of Table6.

3. RF FWD PWR scale setting, FP34 ofTable 6.

4. Check attenuator setting & operation.5. Check SSA RF output.6. Check AI01 circuitry on D16763.

21. Normal power out 32E3406 Solid State Amplifier 1. Defective monitor port on SSA.indication but no IPApower out registered.


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6.3 Potentiometer Location & Function

Table 13 lists potentiometer located in the MT3000 system and their functions.

6.4 Event Log

The CLM will store all faults and alarms it receives or generates in an event log. The log willcontain the Event name, the day of the month, month, time of day, and year the event wasreceived or generated by the CLM. The Event log can be displayed on the front panel.

Stored in the log will be all TWTA faults, waveguide switch position change, Switchover modechange, Transmit on, Standby on, and AC Power on events. The time resolution of the log willbe to the nearest second (±1 second). When the event log is entered the most recent eightevents are displayed. The most recent event will be on top of the display and the oldest on thebottom. By pressing “More” button eight events which preceded (older) the first eight will bedisplayed.

When troubleshooting the event log can be used to determine generally what order eventsoccurred in (to the nearest second). Once the failure has been identified in the log use the “Sel”button until the cursor is pointing to the failure then press “Goto.” Information will bedisplayed to help find the source of the problem.

6.5 Test Fixtures

The following test fixtures are available for purchase from MCL.

TD20107-199 TWTA simulator for 20107 Control & Logic Modules – Used totroubleshoot problems with the CLM’s TWTA interface CCA. This can also be used to troubleshoot the MT3000 controllingsoftware (Earth station controlling software) when used with astand-alone CLM.

TD20107-499 Front Panel simulator for 20107 Control & Logic Modules – Usedto troubleshoot problems with the CLM’s Local Interface CCA.

TD30200-707 MT3000 Parallel Interface Test Fixture – Used to verify operationof the User & Switchover interface of the MT3000.


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Table 13 - Control PCB Potentiometer FunctionsPOT LOCATION FUNCTION

R31 D16832 Helix Run Current Trip Level

R44 D16832 Helix Surge Current Trip Level

R5 D16832 Cathode Voltage Level Adjustment

R1 D16763 Tube Drive Power (AI00) Analog Status Gain

R2 D16763 RF Forward Power (AI01) Analog Status Gain

R3 D16763 RF Reflected Power (AI02) Analog Status Gain

R4 D16763 AI03 Analog Status gGin

R7 D16763 Attenuator Drive (AO00) Analog Output Offset

R8 D16763 AO01 Analog Output Offset

R1 CLM back panel LCD Contrast

6.6 MCL Customer Service

MCL provides complete technical support on all MCL equipment, 24 hours a day, 7 days aweek. MCL can be contacted by telephone, as follows:

Direct Technical Phone Support

8:00 a.m. to 4:30 p.m. Monday through FridayCentral Standard Time/U.S.A. 1-630-759-9500

After Hours Emergency Assistance

1-800-743-4MCL Domestic1-312-461-4536 International

For further information on MCL customer support see Appendix D 40A1845 – MCL CustomerService Information.


MCL, INC. 38A163776 of 84

7.0 SCHEMATIC AND ASSEMBLY LIST

43D1343 MT3000 TWT Amplifier Interface Drawing . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

32E3406 MT3000 TWT Amplifier Interconnect Schematic . . . . . . . . . . . . . . . . . . . . . . . . 78E30080 MT3000 TWT Amplifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

32D3389 HV (DC/DC) Power Supply Module Schematic . . . . . . . . . . . . . . . . . . . . . . . . . 80D13192-037-TAB Transformer Rectifier Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

D16832 Regulation CCA Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

32D3407 Single Phase Prime Power Converter Module Schematic . . . . . . . . . . . . . . . . . . 83D13191-050 PPC LRU Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84


MCL, INC. 38A163777 of 84

43D1343

MT3000 TWT Amplifier Interface Drawing


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32E3406

MT3000 TWT Amplifier Interconnect Schematic


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E30080

MT3000 TWT Amplifier Assembly


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32D3389

HV (DC/DC) Power Supply Module Schematic


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D13192-037-TAB

Transformer Rectifier Assembly


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D16832

Regulation CCA Assembly


MCL, INC. 38A163783 of 84

32D3407

Single Phase Prime Power Converter Module Schematic


MCL, INC. 38A163784 of 84

D13191-050

PPC LRU Assembly


MCL, INC. 38A1637A

APPENDIX A - 40A2044

Specification for MT3000 TWT Amplifier


MCL, INC. 38A1637B

APPENDIX B - 34A2531

Acceptance Test Procedure for MT3000 TWT Amplifier


MCL, INC. 38A1637C

APPENDIX C - 40A1527

HPA and Support Equipment Warranty Information


MCL, INC. 38A1637D

APPENDIX D - 40A1845

Customer Service Information


MCL, INC. 38A1637E

APPENDIX E - 46A0009

Extending Tube Life Information


MCL, INC. 38A1637F

APPENDIX F - 38A1578

Operation and Maintenance Manual for MT3000 Type Control & Logic Module

Documents

OPERATION AND MAINTENANCE MANUAL - Skybrokers · O&M FOR MT3000 TWT AMPLIFIER REV H MCL, INC. 38A1637 6 of 84 LIST OF APPENDICES APPENDIX A - 40A2044 Specification for MT3000 TWT