June 2015

The Changing (and Greening) of the Teleport or New High Power

Amplifier Technology Dramatically Reduces Power Consumption
in Satellite Communication Uplinks
By Heidi Thelander, Senior Director of Business Development at Comtech
Xicom Technology, Inc.

For several decades, if satellite communications (satcom) systems operators

wanted to be sure their link would operate and maintain performance over all
conditions, they built some margin into their links and used multi-kilowatt (kW)
Klystron power amplifiers (KPAs) for their uplinks. These Klystron tube-based
amplifiers provided reliable communications for decades, but all the while
consuming lots of rack space and 10s of kWs of prime power no matter how
low the output power was set. The KPAs were relatively narrowband, so each
uplink channel had its own KPA plus one for redundancy until the availability
of a fast channel-tuner allowed multiple KPAs to be backed up by a single one.
These systems required a knowledgeable technician on-site to manage the issues
that arose, especially with the relatively unreliable channel tuners. No one
worried too much about these issues, because there werent a lot of other ways
to achieve the power levels needed for the uplink amplifiers.

Early TWTAs Inside and Out.

Then the advent of higher power traveling wave tube amplifiers (TWTAs)
began to make other options possible. First coupled-cavity TWTAs were
introduced, which were wider band than KPAs, but still hard to tune for good
performance across full satcom uplink bands such as Ku-band (14.0-4.5 GHz,
later 13.75-14.5 GHz, and now 12.75-14.5 GHz) and DBS band (17.3-18.1
GHz, and now also 17.3-18.4 GHz). Finally, 400W and then 750W helix tube-
based TWTAs became available. These helix TWTAs are inherently broadband,
making it possible to put many channels through a single TWTA as long as
enough power per channel is available for the link. These newer TWTAs could
be rack-mounted and located indoors like the KPAs, but they could also be
moved outdoors, closer to the antenna to eliminate much of the RF waveguide
loss between the HPA and the antenna feed, also freeing up massive rackspace
for expansion or reuse for baseband equipment (Figure 1). And they are much
more efficient than the KPAs, allowing a reduction in prime power usage.
However, because the highest output power available was still significantly less
than the KPAs, many teleports which need to accommodate a range of
situations and traffic over the life of the earth station kept the KPAs in place to
maintain the link margin.

Linear Power Advances with Pre-Distortion.

The advent of pre-distortion linearizers made these TWT amplifiers more
useful, as greater linear power could be achieved from the same amplifier
output. Typical back-offs required for TWTAs without pre-distortion in order to
meet standard communication link requirements were 6-7 dB below saturated
output power. With well-matched pre-distortion linearizers, the back-off could
be reduced to 3-4 dB, effectively doubling the useable output power of the
TWTA. Figure 2 shows how a pre-distortion linearizer can offset the effects of
amplifier gain and phase distortion and the typical improvement in noise power
ratio and intermodulation product performance achieved with linearization.
Reaching for Higher Power.
Linearized helix TWTAs were finally reaching power levels that could prove
useful in teleports which had been replying on KPAs for decades. However,
many operators still wanted more linear RF power than a single 400W and later
750W TWTA could provide. Power combining, including hybrid combining
and later variable-phase-combining, became a preferred method for reaching
output power levels comparable to those achieved with the KPAs. Two-way,
four-way, and sometimes even eight-way power-combined systems, with
various redundancy schemes were developed to meet these needs; some
commonly used ones are shown in Figure 3. The complexity, space, and
expense of these systems kept KPAs in place as an alternative for some
operators despite the benefits of fewer total high power amplifiers (HPAs) and
reduced power consumption.
Enter SuperPower TWTA Technology.
In 2015, new TWTA technology has finally been introduced that fully shifts the
balance in the trade between TWTAs and KPAs. With the advent of the new 2
kW Ku-band and 1.5 kW DBS-band SuperPower helix TWTAs, Comtech
Xicom Technology, Inc. has finally provided the definitive solution for the
teleport uplink amplifiers. These new TWTAs use highly efficient advanced
technology developed both for space applications and for millimeter-wave
TWTAs to create an unmatched TWTA capability for satellite communication
uplink systems. These units provide double the capability previously available
yet are packaged in about the same size and draw about the same prime power
as previous 750W units (Figure 4). Compared with the best KPAs available, the
SuperPower TWTAs offer similar RF output power levels for to 1/3 the size,
weight and prime power.

Bringing Space to Earth and mmwave to Microwave.

SuperPower technology was developed adapting the key collector and cathode
designs from existing ones in space and at higher frequency. The five-stage
collector is the first to be used in a standard commercial ground-based uplink
HPA; these amplifiers typically use a three-stage collector. The additional
stages and the nature of the peak power amplifier [see side note on Peak
Power TWTAs] which limits the output power to just above the linear power
level, enable highly optimized collector depression ratios which dramatically
improve efficiency. The 5-stage collector is not entirely new, as it draws its
heritage from frequently used 5-stage collectors in space tubes. This is how the
SuperPower TWTA doubles output power for the same prime power
consumption in a similar package size.
These new products incorporate a combination of established features from
recent and current TWTA designs that make it both high performing and highly
robust. With the latest high-voltage power supply designs adapted from airborne
MIL-qualified and millimeter-wave products, the power supply becomes one of
the most reliable parts of the amplifier. Existing RF chain components,
processor, and low-voltage supplies are used to ensure ease of manufacture and
quality. Existing thermal designs from 750W HPAs were adapted for the
SuperPower TWTAs because the power dissipation is the same or lower with
the new high efficiency tubes. Output waveguide components are designed with
significant thermal margin to support even higher power capability that may
become available in the future. Thermal analysis completed on the new products
show margin throughout.

Extending the Life of the TWTAs.

In addition to the new SuperPower TWT technology, these TWTAs also
incorporate Comtech Xicoms Life Xtension with Constant Current control
mechanism for extending the useful life of the TWTA dramatically with very
low risk while providing the operations team with valuable and accurate
predictive information on end-of-life (EOL) for long-term replacement
planning. The primary factor for end-of-life for TWTAs is the depletion of the
cathode and resulting reduction in cathode current which results in gain and
output power degradation. Drop in output power of 1dB is typically considered
criteria for EOL failure of a TWTA. The Constant Current feature in these
amplifiers uses the available anode voltage control mechanism with a
continuous, low-rate, autonomous feedback loop to maintain a constant cathode
current throughout the life of the TWTA. This results in maintenance of the
beginning-of-life (BOL) gain and output power all the way until near EOL
when the anode voltage reaches its maximum allowed value. A side benefit is
the reduction in maintenance required over the life of the TWTA, since the
linearizer does not need periodic adjustment to maintain pre-distortion
performance as the gain changes.

This Constant Current Life Xtension is the same type of adjustment used in
virtually all space-based TWTAs which have very long lifetime requirements.
This approach has been used for decades in space on thousands of TWTAs, with
no issues. Other types of approaches to extending TWT life by adjusting
cathode temperature carry risks in affecting beam stability and of poisoning the
tube, and do not maintain BOL performance throughout the life of the TWTA
without adjustments. As a result, this Life Xtension approach not only saves on
reduced capital expenditures from extension of TWTA use, but also reduces risk
to the TWT and the uncertainty of replacement timing, allowing capital to be
allocated more efficiently by operators.
Full Featured TWTAs
The XTD-2000KHE 2kW Ku-band TWTA provides the user with over 750W
of linear power in a compact package weighing only 92 lbs and drawing less
than 3200 watts of prime power. The XTD-1500DBSHE 1.5kW DBS-band
TWTA provides the user with over 560 watts of linear power for DTH
applications in the same 92 lb package and draws only 2500 watts of prime
power. The SuperPower TWTAs at both frequency bands are available as
rugged outdoor antenna-mount units that can withstand -40 to +60 C operating
temperatures or as indoor rackmount configurations that incorporate Xicoms
industry-leading TouchScreen front panels for ease of use and access (Figure 5).
Each has built-in predistortion linearizers, output protection circuitry, SNMP-
based ethernet monitor and control interfaces, and built-in redundancy switch
control capability. Options are offered for extended frequency bands, internal
upconversion from L-band, and liquid-cooling for low acoustic noise or
elimination of hub air conditioning. Insertion of these products is
straightforward with all interfaces designed for direct replacement of 750W
TWTAs; the 3 increase in length and maintenance of the exact mounting hole
to waveguide location allows almost any operator to just replace their existing
outdoor Xicom units for a 3-4dB increase in power. The 6RU indoor rackmount
units allow a full 1:1 system in less than of a rack.

The SuperPower Impact.

The resulting impact on the trade for teleports is stunning. For teleports which
use KPAs, transitioning to the new TWTAs can reduce power consumption by
as much as 90% depending on system configurations and channel counts. In
addition to the direct prime power savings, there is dramatic reduction in
required rack space and air conditioning. Indoor, rack-mount SuperPower
TWTAs can reduce rack space requirements by 50-80% depending on the
channel configuration. Use of outdoor antenna hub-mounted SuperPower
TWTAs can free up 100% of HPA indoor rack space and air flow for other
upgrades by moving the whole amplifier function outdoors. Figure 6 shows a
comparison between existing Ku-band KPAs and new SuperPower TWTAs of
the rack space, weight, power consumption, and thermal load for a typical 4-
channel and 8-channel terminal.

The savings on capital investment of adding infrastructure to support necessary

expansion often pays for the cost of the new TWTAs. And the reduction in
power consumption can significantly reduce operating expenses, especially in
areas with high power cost. Large uplink facilities often use multiple
megaWatts of power, with KPAs being one of the largest consumers. The cost
of this will only become worse as requirements for renewable energy usage
grow along with the trading of carbon permits. So a simple way to green your
teleport is to replace those KPAs with the highest efficiency, highest output
power-level TWTAs available SuperPower.

System Architecture Impacts.

These TWTAs can have an even larger impact on system trades for some new
uplinks by changing the antenna size vs. HPA output power level trade. With an
additional 2-4dB available from the amplifier (before power combining), the
system designer could potentially select a smaller antenna size, assuming
receive band requirements can be met, or for asymmetric or transmit only
systems such as direct-to-home (DTH). Figure 7 shows the effect on EIRP of
increasing antenna size vs HPA power output. The cost of installing fixed
antennas goes up dramatically with size for larger than 5m antennas.

Redundancy and phase combining systems can also be used to further extend
the comparison with indoor KPAs or the antenna size trade, enabling multiple
kW inputs to the antenna feed if needed. Some examples of these amplifier
systems with the resulting output power levels are shown in Figure 8, including
Comtech Xicoms Continuous Power System which can provide over 2.75 kW
of linear power output while maintaining over 1.5 kW linear power output
during loss of one TWTA. Shaking Things Up at Teleports.Overall, the
SuperPower technology and resulting product are shaking things up in teleport
and earth station engineering where new things are possible and transformation
is the next step. Going green, cutting expenses, making space for expansion,
increasing data rates or channels any way you look at it, the operator saves
space, prime power consumption, and money by incorporating this new
technology.

Comtech Xicom Technology, Inc.

www.xicomtech.com
Email this article to a friend!