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ALB180 - Series High Power C-band BUC

Installation and Operation Manual

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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)

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ST Electronics (Satcom & Sensor Systems) Pte Ltd

Revision A

Revision Descriptions New Release

Date 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 : balamurugan@stee.stengg.com Website: www.stee.stengg.com

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ST Electronics (Satcom & Sensor Systems) Pte Ltd

TABLE OF CONTENTS
CHAPTER 1
INTRODUCTION
1.1 1.2 1.3 1.4 General Descriptions Frequency Band Options Supply Voltage Options Power Rating Options

1-1
1-1 1-2 1-2 1-2

CHAPTER 2
SPECIFICATIONS
2.1 Specifications of C-band Block Up-Converter 2.1.1 Electrical 2.1.2 Power Supply 2.1.3 Mechanical 2.1.4 Environmental Outline Drawings Connection Ports Wire Connection

2-1
2-1 2-1 2-2 2-2 2-3 2-4 2-5 2-6

2.2 2.3 2.4

CHAPTER 3
INSTALLATION
3.1 3.2 3.3 3.4 3.5 3.6 3.7 General Transportation Unpacking Packing List Repacking Preparation Pre-Installation Test 3.7.1 Uplink Test Procedure Site Considerations Mounting Power Requirements

3-1
3-1 3-1 3-1 3-1 3-2 3-2 3-3 3-3 3-4 3-5 3-5

3.8 3.9 3.10

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3.11

Sealing

3-6

CHAPTER 4
MAINTENANCE
4.1 4.2 General Maintenance Procedure 4.2.1 Gain Testing 4.2.2 Water Leakage Protection Final Check

4-1
4-1 4-1 4-1 4-2 4-2

4.3

CHAPTER 5
WARRANTY
5.1 5.2 5.3 Limited Warranty RMA Other Repairs

5-1
5-1 5-1 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: Local oscillator: Input transmit: Output transmit: Local oscillator: Input transmit: 5.850 to 6.425 GHz 4.900 GHz 950 to 1525 MHz 6.725 to 7.025 GHz 5.625 GHz 1100 to 1400 MHz 6.425 to 6.725 GHz 5.275 GHz 1150 to 1450 MHz 5.850 to 6.725 GHz 4.900 GHz 950 to 1825 MHz

INSAT C-band

PALAPA-C / ST-1 C-band Output transmit: Local oscillator: Input transmit: FULL C -band Output transmit: Local oscillator: Input transmit:

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 noninverted 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 Input Frequency Option A Intelsat Option B Insat Option C ST-1 / Palapa-C Option D FULL-C Input VSWR Input Impedance Output Frequency Option A Intelsat Option B Insat Option C ST-1 / Palapa-C Option D FULL-C Output VSWR Local Oscillator Frequency Option A Intelsat Option B Insat Option C ST-1 / Palapa-C Option D FULL-C External Reference
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Unit MHz MHz MHz MHz GHz GHz GHz GHz

Min 950 1100 1150 950

Typ

Max 1525 1400 1450 1825

2.0 : 1 50 or 75 5.850 6.725 6.425 5.850 2.0 : 1 w/o freq inversion GHz GHz GHz GHz 4.900 5.625 5.275 4.900 6.425 7.025 6.725 6.725

ST Electronics (Satcom & Sensor Systems) Pte Ltd

Parameter Frequency Power Level Phase Noise at frequency offset 10 Hz 100 Hz 1 kHz 10 kHz 100 kHz P1dB Compression Point (P1dB) 40W 60W Conversion Gain 40W 60W 36MHz Gain Flatness Gain Flatness Over Full Bandwidth Gain Stability Over Operating Temperature (-40C to 60C) Intermodulation Distortion 2 carriers 1 MHz apart, @ 6dB Back off from Prated (Single Carrier) Spurious In-band @ Prated Phase Noise at frequency offset 100 Hz 1 kHz 10 kHz 100 kHz Attenuation Adjustment Range Attenuation Adjustment Resolution Attenuation Adjustment Accuracy Output Power Detect Range Output Power Detect Accuracy over Frequency

Unit MHz dBm dBc/Hz dBc/Hz dBc/Hz dBc/Hz dBc/Hz dBm dBm dB dB dB dB dB dBc

Min -5

Typ 10

Max +5 -120 -140 -150 -155 -160

46 47.8 69 70 77 78 2 4 2 -25

dBc dBc/Hz dBc/Hz dBc/Hz dBc/Hz dB dB dB dBm dB 15 1 1

-55 -63 -73 -83 -93

Prated-20 to Prated 2

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2.1.2 Power Supply


Parameter C-BUC Power Supply Supply Voltage DC Power Consumption 40W 60W W W 300 350 VDC 40 48 60 Unit Min Typ Max

2.1.3 Mechanical
Parameter Input Interface Output Interface External Dimension 40W/60W Weight 40W/60W Finish Mounting Holes At opposite side kg 5 Creamy white, matt surface mm 235 (L) 175(W) 90(H) Unit Min Typ Max

N-type or F-type female WR-137G with O-ring

2.1.4 Environmental
Parameter Operating Temperature Storage Temperature Relative Humidity, Condensing Altitude Solar Salt Operating Shock Operating Drop Operating Vibration Unit C C % Min -40 -55 0 Up to 15,000 ft 360 BTU/sq. ft/hr @ 50C No corrosion, salt as found in coastal areas 30gn to 50 gn, 11 msec, each axis 4 inch, bottom face Random vibration, 5 500 Hz, 10 min/axis, 4.74 GRMS
23

Typ

Max 60 85 100

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Parameter Survival Vibration, Unpackaged

Unit

Min

Typ

Max

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 # A B C Function Positive Negative Not Connected Wire Colour Red Blue N/A

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M&CIN Pin Out Pin # Pin A Pin B Pin C Pin D Pin E Pin F Pin G Pin H Function N/A Ground 3.3V Tx link status (Normally close of Tx Form C Relay) Tx232 Rx232 Data 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.

!
WARNING

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 1 Modules C-BUC
31

Item

P/N ALB180xxxx

Qty 1

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Accessories 2 3 4 5 6 7 8 9 10 11 Half gasket for WR137 CPRF-CPRG Screw Hex socket head M5 16mm Washer flat ID5.16 OD11.28 H0.5mm Washer split lock ID5.1 OD8.5 H1.2mm Screw Hex socket head M8 14mm Washer flat ID8.2 OD20.8 H1.0mm DC Connector M&C cable M&C cable Documents Manual Table 3-1: Packing List 5702200003 2502040699 6103480008 IM02560153 2503160038 1 8 8 8 1 1 1 1 1 1

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 Complete Set of Socket wrench Screw driver (Philips) Cutter Cable ties (Long and Medium length) Multimeter Qty 1 1 1 1 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

!
WARNING

To avoid damaging the C-BUC accidentally, connect a 30 dB, > 100W power attenuator to the RF output. Connect the C-BUC as shown in Figure 3-1 and power up the system. 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 CBUC is -25 dBm. 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.

Step 1

Step 2

Step 3

Example: Transmit gain = RF OUT power - IF IN power + Attenuation = 1 - (-25) + 30 = 56 dB

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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 antennas 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 .

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!
WARNING

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.
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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. 2. Make sure that all the connectors are hand-tightened before sealing. The sealing must cover from the housing of the C-BUC until after the heatshrink sleeve. Refer the Figure 3-4 for the sealing. All the unused connectors must be covered with a cap and sealed. Make sure all waveguide joints are properly sealed with an appropriate gasket.

3. 4.

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 ALB180series 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. Turn on the pure carrier of the modem and measure the power level using a spectrum analyzer.

Step 2

At outdoor, Step 3 Step 4 Ensure that all the IF and RF cables are labeled. 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.

!
CAUTION

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

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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 . 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.

Step 6

!
CAUTION

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 Step 2 Make sure all the connectors are hand-tightened before sealing. 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 The sealing must cover from the housing of the C-BUC until after the heatshrink sleeve at the cables. All the unused connectors must be covered with caps and sealed.

Step 3

Step 4

4.3

Final Check

!
CAUTION

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.

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CHAPTER 5 WARRANTY 5.1 Limited Warranty Should this product fail due to defects in materials or workmanship, STEESatComS 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 STEESatComS 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 STEESatComS 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

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5-2