alb180 - series c-band bucs - installation and operational manual

IM02960153 REV A

ALB180 - Series High Power C-band BUC

Installation and Operation Manual

IM02960153 REV A

ST Electronics (Satcom & Sensor Systems) Pte Ltd No. 29 New Industrial Road ST Electronics Paya Lebar Building Singapore 536213 Tel: +65 65217954 / + 65 65217959 Fax: +65 65217333 (Regn No.: 199103901W)

ST Electronics (Satcom & Sensor Systems) Pte Ltd

IM02960153 REV A

Revision Revision Descriptions Date

A New Release Dec 2010

© 2009 ST Electronics (Satcom & Sensor Systems) Pte Ltd All Rights Reserved.

All Information contained in this Manual are the property of ST Electronics (Satcom & Sensor Systems) Pte Ltd. The Manual in whole or in part, may not be duplicated or reproduced without the written permission of ST Electronics (Satcom & Sensor Systems) Pte Ltd. The Manual is intended to be used as a guide only and may be revised, modified or altered at any time by ST Electronics (Satcom & Sensor Systems) Pte. Ltd. ST Electronics (Satcom & Sensors Systems) Pte Ltd shall not be liable to users of the Manual nor to any other person, firm, company or other body for any loss, direct, indirect or consequential, in contract or in tort or for any negligent mis-statement or omission contained herein, by reason of, arising from or in relation to any such user, other person, company or body relying or acting upon or purporting to rely or act upon any matter contained in this Manual. If you have any enquiry or require any technical assistance or training, please contact our Customer Service Centre via:

ST Electronics (Satcom & Sensor Systems) Pte. Ltd. No. 29 New Industrial Road, ST Electronics Paya Lebar Building Singapore 536213 Hotline : +65 65217954 / + 65 65217959 Fax : +65 65217333 E-mail : [email protected] Website: www.stee.stengg.com


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TABLE OF CONTENTS

CHAPTER 1

INTRODUCTION 1-1 1.1 General Descriptions 1-1 1.2 Frequency Band Options 1-2 1.3 Supply Voltage Options 1-2 1.4 Power Rating Options 1-2

CHAPTER 2

SPECIFICATIONS 2-1 2.1 Specifications of C-band Block Up-Converter 2-1 2.1.1 Electrical 2-1 2.1.2 Power Supply 2-2 2.1.3 Mechanical 2-2 2.1.4 Environmental 2-3 2.2 Outline Drawings 2-4 2.3 Connection Ports 2-5 2.4 Wire Connection 2-6

CHAPTER 3

INSTALLATION 3-1 3.1 General 3-1 3.2 Transportation 3-1 3.3 Unpacking 3-1 3.4 Packing List 3-1 3.5 Repacking 3-2 3.6 Preparation 3-2 3.7 Pre-Installation Test 3-3 3.7.1 Uplink Test Procedure 3-3 3.8 Site Considerations 3-4 3.9 Mounting 3-5 3.10 Power Requirements 3-5


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3.11 Sealing 3-6

CHAPTER 4

MAINTENANCE 4-1 4.1 General 4-1 4.2 Maintenance Procedure 4-1 4.2.1 Gain Testing 4-1 4.2.2 Water Leakage Protection 4-2 4.3 Final Check 4-2

CHAPTER 5

WARRANTY 5-1 5.1 Limited Warranty 5-1 5.2 RMA 5-1 5.3 Other Repairs 5-1


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CHAPTER 1 INTRODUCTION 1.1 General Description

The VSAT ALB180 -series C-band BLOCK UP CONVERTER (C-BUC) is a high performance, cost-effective RF transmitter designed for satellite communication with high speed transmission capability suitable for both telephony and high speed data communication. The C-band BUC can be operated with different modulation formats like BPSK, QPSK and FM. It is suitable for Single Carrier Per Channel (SCPC), Multi-Carrier Per Channel (MCPC), Demand Assigned Multiple Access (DAMA) and Time Division Multiple Access (TDMA) applications.

Baseband signals are modulated onto L-band frequency and multiplexed with 10 MHz reference on the centre conductor of the IF cable.It is then up converted and amplified in the ALB180-series C-BUC for transmission to the satellite via an antenna dish. The DC power supply is on a separate connector on the BUC.

The ALB180-series C-BUC is an outdoor unit mounted directly onto the orthogonal mount transceiver (OMT) of the antenna.

The C-band Block Up Converter (C-BUC) serves to up convert the L-band transmit signal to the C-band transmit frequency range and amplifies it by an integrated SSPA.

It is designed with low DC power consumption, well suited for systems and applications where power is of prime concern. With low pulse mode phase perturbation, it is extremely useful for systems that require burst mode applications.

For mounting, it has one M8 × 10 mm screw hole for support mounted frames. It can also be mounted directly onto the waveguide orthogonal mount transducer by means of four screws.

The transmit output waveguide is WR137 with groove and O-ring is provided. A yellow transparent tape is laminated onto the waveguide; together with the O-ring and proper installation, this prevents water ingress through the waveguide.

Note: DO NOT remove the yellow transparent tape; it is meant to be

permanently laminated at the waveguide transmit output.


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1.2 Frequency Band Options

The VSAT ALB180 transmits with the following frequencies options:

INTELSAT C-band Output transmit: 5.850 to 6.425 GHz Local oscillator: 4.900 GHz Input transmit: 950 to 1525 MHz INSAT C-band Output transmit: 6.725 to 7.025 GHz Local oscillator: 5.625 GHz Input transmit: 1100 to 1400 MHz PALAPA-C / ST-1 C-band Output transmit: 6.425 to 6.725 GHz Local oscillator: 5.275 GHz Input transmit: 1150 to 1450 MHz FULL C -band Output transmit: 5.850 to 6.725 GHz Local oscillator: 4.900 GHz Input transmit: 950 to 1825 MHz

1.3 Supply Voltage Options

The VSAT ALB180-K derives its voltage supply through the separate DC connector.

DC Input: Voltage range is 40 to 60 VDC

1.4 Power Rating Options

The ALB180-Series of 40W and 60W BUCs are packaged as a single feed mount unit.. This manual is intended to provide the system operator or system integrator a guideline to set up the ODU system with the rest of the VSAT system. Chapter 2 discusses the specifications of the C-BUC. This allows the users to gain a basic understanding of the ODU working principles. Chapter 3 details the installation procedures of the ODU system. Chapter 4 describes the system maintenance guide.


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CHAPTER 2 SPECIFICATIONS

2.1 Specifications of C-band Block Up Converter

The C-BUC is a single stage up conversion from L-band to C-band frequencies using a 10 MHz external referenced phase locked oscillator. The spectrum is non-inverted with phase noise surpassing Intelsat standards and low DC power consumption. The BUC consists of the following functional blocks, L-Band de-multiplexer and amplifiers, RF up-converter, Power Amplifier, M&C and Power-supply. The unit can be monitored and controlled using RS485/232 cable using the Agilis Monitoring and Control software. The output power, temperature and alarms can be monitored using the software. A user settable 15 dB attenuation control is also available. Refer to AMC manual for details.

2.1.1 Electrical

Parameter Unit Min Typ Max

Input Frequency

Option A – Intelsat MHz 950 1525

Option B – Insat MHz 1100 1400

Option C – ST-1 / Palapa-C MHz 1150 1450

Option D – FULL-C MHz 950 1825

Input VSWR 2.0 : 1

Input Impedance Ω 50 or 75

Output Frequency

Option A – Intelsat GHz 5.850 6.425

Option B – Insat GHz 6.725 7.025

Option C – ST-1 / Palapa-C GHz 6.425 6.725

Option D – FULL-C GHz 5.850 6.725

Output VSWR 2.0 : 1

Local Oscillator Frequency w/o freq inversion

Option A – Intelsat GHz 4.900

Option B – Insat GHz 5.625

Option C – ST-1 / Palapa-C GHz 5.275

Option D – FULL-C GHz 4.900

External Reference


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Frequency MHz 10

Power Level dBm -5 +5

Phase Noise at frequency offset

10 Hz dBc/Hz -120

100 Hz dBc/Hz -140

1 kHz dBc/Hz -150

10 kHz dBc/Hz -155

100 kHz dBc/Hz -160

P1dB Compression Point (P1dB)

40W dBm 46

60W dBm 47.8

Conversion Gain

40W dB 69 77

60W dB 70 78

36MHz Gain Flatness dB 2

Gain Flatness Over Full Bandwidth dB 4

Gain Stability Over Operating

Temperature (-40°C to 60°C)

dB ± 2

Intermodulation Distortion

2 carriers 1 MHz apart, @ 6dB Back off from Prated (Single Carrier)

dBc -25

Spurious – In-band @ Prated dBc -55

Phase Noise at frequency offset

100 Hz dBc/Hz -63

1 kHz dBc/Hz -73

10 kHz dBc/Hz -83

100 kHz dBc/Hz -93

Attenuation Adjustment Range dB 15

Attenuation Adjustment Resolution dB 1

Attenuation Adjustment Accuracy dB ± 1

Output Power Detect Range dBm Prated-20 to Prated

Output Power Detect Accuracy over Frequency

dB ± 2


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2.1.2 Power Supply


C-BUC Power Supply

Supply Voltage VDC 40 48 60

DC Power Consumption

40W W 300

60W W 350

2.1.3 Mechanical


Input Interface N-type or F-type female

Output Interface WR-137G with O-ring

External Dimension

40W/60W mm 235 (L) × 175(W) × 90(H)

Weight

40W/60W kg 5

Finish Creamy white, matt surface

Mounting Holes

At opposite side

2.1.4 Environmental


Operating Temperature °C -40 60

Storage Temperature °C -55 85

Relative Humidity, Condensing % 0 100

Altitude Up to 15,000 ft

Solar 360 BTU/sq. ft/hr @ 50°C

Salt No corrosion, salt as found in coastal areas

Operating Shock 30gn to 50 gn, 11 msec, each axis

Operating Drop 4 inch, bottom face

Operating Vibration Random vibration, 5 – 500 Hz, 10 min/axis, 4.74 GRMS


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Survival Vibration, Unpackaged Random vibration

10 min/axis,

5-350Hz 0.05G2/Hz 350-500Hz –6dB/octave

500Hz 0.0245G2/Hz

Resonant search

5 – 500 Hz, swept sine, 1 octave/min sweep rate, 1G peak

Resonant dwell

1G peak, 10 min each resonance, 4 resonances per axis

2.2 Outline Drawings


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2.3 Connection Ports

Front View

RF IN connector is an N-type connector which is used to feed the L-Band and 10 MHz signal to

the unit

Side View

The DC IN connector is used to feed the 48V DC input to the BUC. The FAN DC connector provides a DC voltage for the DC fans used for cooling. Care must be taken to keep the fan cable connected as long as the unit is powered ON.


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Side View

The M&C IN connector is used to communicate with the unit using RS 485 serial mode of communication. The AMC manual describes the use of AMC software to monitor and control the unit.

2.4 Wire Connection

The tables below describe the pin and wire connection for the DC and M&C connectors that are located at the side wall of the High Power C-BUC.

DC Pin Out

Pin # Function Wire Colour

A Positive Red

B Negative Blue

C Not Connected N/A


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M&CIN Pin Out

Pin # Function

Pin A N/A

Pin B Ground

Pin C 3.3V

Pin D Tx link status (Normally close of Tx Form “C” Relay)

Pin E Tx232

Pin F Rx232

Pin G Data

Pin H Clk


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CHAPTER 3 INSTALLATION 3.1 General

This chapter provides all the necessary information and step-by-step instructions for the successful installation of the ALB180 C-BUC VSAT Outdoor Unit.

Always handle the ODU with care. Do not let the ODU drop or knock against things as excessive shock may cause damage to the units. ST Electronics (Satcom & Sensor Systems) Pte Ltd will not warranty any defects due to excessive shock or vibration.

3.2 Transportation When transporting the ODU, surround the unit with shock absorbing material to provide a firm cushion and prevent movement inside the container. This is to prevent excessive shock to the unit as it may cause damage.

3.3 Unpacking Prior to unpacking, inspect the exterior of the container for any damage suffered during shipment. If any damage is present, contact the carrier that delivered the system and submit a damage report. Failure to do so could complicate or invalidate a claim. Carefully unpack and remove all items from the shipping container, and inspect the items further for any sign of damage. Be careful not to damage any components when opening the shipping container. Save all packing materials until the inspections are completed. Compare the contents of the shipping container to the packing slip to ensure the items received match those listed. If any loss or damage is discovered, contact STEE-SatComS or the local STEE-SatComS representative before proceeding with the installation.

3.4 Packing List Below is the packing list for the ALB180-series 40W/60W C-BUC

S/N Item P/N Qty

Modules

1 C-BUC ALB180xxxx 1

!WARNING


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Accessories

2 Half gasket for WR137 CPRF-CPRG 1

3 Screw Hex socket head M5 × 16mm 8

4 Washer flat ID5.16 × OD11.28 × H0.5mm 8

5 Washer split lock ID5.1 × OD8.5 × H1.2mm

8

6 Screw Hex socket head M8 × 14mm 1

7 Washer flat ID8.2 × OD20.8 × H1.0mm

2503160038

1

8 DC Connector 5702200003 1

9 M&C cable 2502040699 1

10 M&C cable 6103480008 1

Documents

11 Manual IM02560153 1

Table 3-1: Packing List

3.5 Repacking Use the original packing containers if possible. Place the unit in a clean and open work area. Cover all connectors with a plastic cap designed for this purpose (adhesive tape is not recommended as it quickly deteriorates, leaving a residue on the connector). Wrap the unit in a bubble plastic bag. Surround the unit in a shock absorbing material to provide a firm cushion and prevent movement inside the container. Use a proper shipment container. Seal the container and mark exterior clearly “FRAGILE Electronic equipment.”

3.6 Preparation

It is strongly recommended that sufficient tools be available for the installation. The following Table 5-2 lists some of the typical tools required for the installation.

Description Qty

Complete Set of Socket wrench 1

Screw driver (Philips) 1

Cutter 1

Cable ties (Long and Medium length) 1

Multimeter 1

Table 3-2: Typical Tools Required For Installation


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3.7 Pre-Installation Test

A strong impact during shipment could cause damage to the ODU. Therefore, it is always a good practice to set-up the whole system for testing prior to field installation. This is to ensure that there is no damage inflicted on the unit during shipment. Following are the test procedures for the ODU system. There are two tests that are recommended; namely, the uplink and downlink tests. Before performing any test, ensure that no alarm appears at the C-BUC.

3.7.1 Uplink Test Procedure

To avoid damaging the C-BUC accidentally, connect a 30 dB, > 100W power attenuator to the RF output.

Step 1 Connect the C-BUC as shown in Figure 3-1 and power up the system.

Step 2 Use the modem to input an L-Band pure carrier (by turning on

the transmit carrier and set the pure carrier feature to ON). Adjust the modem output power so that the IF level input to C-BUC is -25 dBm.

Step 3 Measure the RF OUT of the C-BUC by a spectrum analyzer at

C-band. Calculate the transmit gain by subtracting the input power from the output power plus the amount of attenuation included in this link. Compare the gain obtained with the specifications. If there is no signal, check if the channel setting is correct.

Example:

Transmit gain = RF OUT power - IF IN power + Attenuation

= 1 - (-25) + 30 = 56 dB

!WARNING


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Figure 3-1: Uplink Test Set-up

3.8 Site Considerations

The C-BUC is designed for direct installation onto the antenna’s OMT. According to the instructions supplied by the antenna manufacturer, locate and install the antenna in an area that is free from RF interference from motors and electronic equipment. A clear line of sight from the antenna to the satellite is essential. To ensure safety and protection of personnel and equipment, lightning arresters should also be used at the site. Size 3/0 or 4/0 stranded copper wire should be used to bond the C-BUC, PLLNB and Booster to the antenna frame and to the lightning protection ground rod. The

grounding resistance of the antenna should not be more than 10 Ω.


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Restricted Access: This unit is intended for installation in restricted access areas. A restricted access area is where access can only be gained by service personnel through the use of a special tool, lock and key or other means of security, and is controlled by authority responsible for the location.

3.9 Mounting The antenna must have sufficient support to minimize sway in strong winds with the C-BUC mounted. The C-BUC is designed for mounting on both Offset and Prime Focus Antennas.

A set of mounting accessories is provided to mount the C-BUC to the OMT of the antenna.

Figure 3-3 illustrates the mounting position of the C-BUC on the antennas.

Figure 3-3: Mounting the C-BUC and PLLNB on the OMT of antenna

3.10 Power Requirement Refer to Chapter 2 Paragraph 2.1.2 for the power requirement.

!WARNING


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3.11 Sealing

To complete an installation, seal up all the connectors and waveguide joints of the system using self-amalgamating tape. It is recommended that all “sealing job” be done after the system has been verified to be operational. The following points should be taken care of:

1. Make sure that all the connectors are hand-tightened before sealing. 2. The sealing must cover from the housing of the C-BUC until after the

heatshrink sleeve. Refer the Figure 3-4 for the sealing. 3. All the unused connectors must be covered with a cap and sealed.

4. Make sure all waveguide joints are properly sealed with an appropriate

gasket.

Figure 3-4: Sealing the Connectors


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CHAPTER 4 MAINTENANCE 4.1 General

This chapter describes how to perform periodic maintenance on the ALB180-series C-BUC. It is recommended to carry out the maintenance service at least twice a year to ensure the performance of the system. It is recommended to maintain a SET-UP RECORD that contains the modem and C-BUC configurations, power levels of the carriers at various points of the link and the system power level diagram when the system was set up. Make sure that this record is updated every time when any changes are made. Make sure that the system can be interrupted for approximately two hours before starting the maintenance. It is advised to understand the procedure and prepare necessary equipment before starting the service.

4.2 Maintenance Procedure 4.2.1 Gain Testing

The following procedure is to be carried out to check the uplink gain.

At indoor, Step 1 Check if the transmit configuration of the modem and C-BUC

configuration comply with the SET-UP RECORD. Contact the responsible personnel in case of any discrepancies.

Step 2 Turn on the pure carrier of the modem and measure the power level

using a spectrum analyzer.

At outdoor, Step 3 Ensure that all the IF and RF cables are labeled. Step 4 Make sure that all the cables are in good condition using the mega

ohm meter. Ensure that the cables are removed at both ends before the measurements are taken. Check visually if the connectors are not damaged.

Cable connection and disconnection should be done properly to avoid damage to the cables or connectors that may cause intermittent problems in the future.

!CAUTION


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Step 5 Measure the ground resistance of the antenna with a mega ohm

meter. The reading should not be more than 10 Ω. Step 6 Connect back the transmit cable to the modem and measure the

power level of the pure carrier to the C-BUC input. Calculate the transmit IFL loss and check if it is close to that at the SET-UP RECORD.

Power off the C-BUC and connect a power attenuator (30 dB, > 100W) at the RF OUT of the C-BUC.

Step 7 Turn on the C-BUC and connect the IF IN cable to the C-BUC. Record the RF OUT power level and calculate the uplink gain. Check if it complies with the SET-UP RECORD and C-BUC gain setting.

4.2.2 Water Leakage Protection

All the connectors at the outdoor should be properly sealed against water leakage using self-amalgamating tapes. The following is the procedure for the maintenance.

Step 1 Make sure all the connectors are hand-tightened before sealing. Step 2 Check and ensure that all the connectors and waveguide joints of

the system are properly sealed using self-amalgamating tape. Re-do the sealing if the existing sealing is not good

Step 3 The sealing must cover from the housing of the C-BUC until after the

heatshrink sleeve at the cables. Step 4 All the unused connectors must be covered with caps and sealed.

4.3 Final Check

Make sure every thing including the equipment settings is normalized after the maintenance. Make sure that the SET-UP RECORD is updated for any changes made to the configuration.

!CAUTION

!CAUTION


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CHAPTER 5 WARRANTY 5.1 Limited Warranty

Should this product fail due to defects in materials or workmanship, STEE-SatComS will, at its sole option, repair or replace it with new or rebuilt parts, free of charge, for ONE year from the date of its shipment from the STEE-SatComS factory. This warranty does not cover damage which occurs in shipment or failures caused by products not supplied by STEE-SatComS or its authorized contractors or agents, or any failure caused by operation of the product outside of its published electrical or environmental specifications, or any causes other than ordinary use.

5.2 RMA

In order to exercise your rights under the warranty, you must first contact STEE-SatComS to obtain an RMA (Return Material Authorization) number. The RMA tag as shown in Figure 5-1 will have to be filled in and attached to the unit before the unit is shipped to STEE-SatComS. If it is necessary to return the product for repair, you are responsible for paying the cost of shipping it to STEE-SatComS factory. STEE-SatComS will pay the cost of shipping the product to you when the repairs are completed.

5.3 Other Repairs

Non-warranty and out-of-warranty repair service is available from STEE-SatComS for a nominal charge. The repair service can be obtained by contacting STEE-SatComS to request for an RMA number, as described above. You are responsible for paying the cost of shipping the unit both to and from STEE-SatComS factory for these repairs.


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Figure 5-1: RMA Tag