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Full-line supplier of telecommunications subsystems and equipment for satellites and spacecraft.

Facts, Products and Services

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Tesat Spacecom and the world of telecommunications

Tesat-Spacecom GmbH & Co.KG,based in Backnang, Germany,designs and manufactures payloadequipment for communicationssatellites. It has 700 employeesand achieved total sales of 103million EUR in 2001.

The company has participated inmore than 350 space projects.Tesat-Spaecom’s core product isthe travelling-wave tube amplifierwhich is supplied to more than45% of the open world market.Moreover, Tesat-Spacecom isdeveloping laser crosslinks whichoperate at very high bit rates totransmit information betweenmultimedia system satellites.

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All necessary space qualifiedmanufacturing processes includingsilver plating and soldering facilitiesare available at Tesat-Spacecom forthe production of the flighthardware.

All tests are performed in the testarea fully equipped with thermalvacuum and vibration test facilities,high and low power computer-controlled test benches.

Block Diagram of a Communications Payload

EPC

Electr. PowerConditioner

Receiveantenna

Receiver/Converter

Inputmultiplexer

Switchassembly

Demo-dulator

On-boardprocessor(Switchingequipment)

Mo-dulator

Chan-nelampl.

Power ampl.(travellingwave tube/solid stateampl.)

Switchassy

Outputmultipl.

Transmitantenna

Opt.Terminal

OISL

transparent/regenerative regenerative transparent/regenerative

product scope core products

ANT RX RCV/CONV IMUX SWA DEMOD OBP MOD CAMP TWTA/SSPA SWA OMUX ANT TX

EPC

LIN

MPM

Line-arizer

Satellite Communications Systems

Tesat-Spacecom’s space activitiescomprise system design, develop-ment, production, integration andtesting as well as the managementof satellite projects and communi-cations equipment for spacevehicles.

Payloads for communicationssatellites

Complete telecommunicationsequipment for the frequency rangesof 1.7/2.6 (L/S-Band), 4/6 GHz (C-Band), 8 GHz (X-Band) / 11/12/14 GHz (Ku-Band), 20/30 GHz (Ka-Band) and 39/44 GHz (EHF-Band).

Payloads for broadcastingsatellites

Complete telecommunicationsequipment for the frequency rangesof 12/18 GHz.

Earth exploration systems

Communications equipment forweather satellites and other earthobservation satellites for thetransmission of measured data toearth stations and the distributionof evaluated data.

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In the scope of the Artemis project, Tesat-Spacecom wasresponsible for development and manufacturing of the Ka-Bandreturn repeater

Output multiplexer in thermo vacuum chamber

Thermo vacuum chambers for testingspace equipment

Space stations and spacetransport systems

Communications systems forinformation transfer within stationsand information exchange betweenplatforms, scientific satellites, datarelay satellites and with earthstations.

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Projects and References

Tesat-Spacecom has suppliedpayloads or subsystems for thefollowing space programs:

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ECS EutelsatComplete telecommunicationspayloads for five satellites.

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DFS KopernikusSystem leadership, developmentand supply of telecommunicationspayloads for three satellites and thedrives for the solar generators.

TV-SatTelecommunications payloads fortwo satellites.

Telecommunications equipmentfor TDF, Tele-X, Olympus.

ArtemisDevelopment and manufacturing ofthe Ka-Band return repeater.

EuroskywayData transmission subsystem foradvanced multimedia satellites.

The following weather/earthexploration satellites havereceived their payloads or sub-system from Tesat-Spacecom:

MeteosatTelecommunications payloads forfive satellites.

EnvisatTelecommunications equipment

for systems used for earthobservation and scientific

experiments.

MetopComplete datatransmissionsubsystems for highdata rates as well asthe transmit unit forlow data rates.

Helios IIData transmissionsystem for two

satellites.

Rocsat 2Data transmission system

for one satellite.

Since 1971, Tesat-Spacecomhas been involved in the abovesatellite projects

Radarsat 2Data transmission system for one satellite.Cryosat Data transmission system for one satellite.

Sar-LupeData transmission system andpulsed amplifier subsystems for five satellites.

Terra-SarData transmission system andpulsed amplifier subsystem for one satellite.

CosmoData transmission system for one satellite.

Customers

Europe:Alcatel SpaceAstriumAlenia AerospazioESADLROHB

USA/Canada:Space Systems LoralTRWLockheed Martin SpaceEMSBoeing Space Systems

Asia:CASTISRONECMELCO

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Key components for communications satellites are the power amplifiers in the telecommunications payload. More than

30 years of experience enable Tesat-Spacecom to provide Travelling Wave Tube Amplifiers (TWTAs) for space

applications. Today, Tesat-Spacecom has a 45 percent shareof the world market for power amplifiers. In numerous

communications satellites Tesat-Spacecom TWTAs have now accumulated 10 million operating hours in space without failure. TWTA lifetimes of up to 15 years are usual.

Travelling Wave Tube Amplifier

The TWTA is a key element for a satellite transponder. Tesat-Spacecom has provided TWTAswhich satisfied requirements ofNASA, ESA, Intelsat, Inmarsat,European, Asian and US commer-cial programs. Starting fromfrequencies at 1.5 GHz up to 60GHz, Tesat-Spacecom has TWTAson hand with RF output powerranges from 10 W up to 450 W.High efficiency is required in orderto optimize RF output

power and heatdissipation. TheRF performancecharacteristics

such as high gain,gain flatness, low

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phase distortion and high linearityshall be combined with straightforward mechanical design whichresults in low mass and smalldimensions.

The TWTA consists of the TravellingWave Tube (TWT) mainly deter-mining the RF performance and theElectronic Power Conditioner(EPC), designed and manufacturedby Tesat-Spacecom, for powermatching of the DC and businterfaces. The Tesat-SpacecomEPC is designed to be integrated

with any TWT of thedifferent TWT manu-facturers by optimizing thehigh voltages for theindividual approaches. The integration of the TWT

and EPC as well as thetesting of the TWTA areperformed by Tesat-Spacecom.

Based on the technology of thecurrent TWTA programs, Tesat-Spacecom has developed a newline of EPCs. The family nowcovers the RF output power range from 10 W up to 150 W. The EPCsare comprehensively qualificationtested for quite a number ofapplications.

Eurasiasat Ku-Band TWTA

Dual TWTA

The dual EPC is capable to operate two TWTs up to 150 Wsimultaneously. The two TWTs canbe operated as single TWTAsindependently or RF combined inorder to provide 290 W of RFoutput power from radiation cooledor conduction cooled TWTs.

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ATC-EPC with TWT ATC-L EPC

Tesat-Spacecom EPC family

Dual MPM

Dual TWTA

MPM

The Microwave Power Module(MPM) is a compact amplifierconsisting of our advanced techno-logy Electronic Power Conditionerwith integrated Tesat-SpacecomChannel Amplifier (CAMP) andTesat-Spacecom Linearizer (LIN). It provides many advantages assavings in mass, mounting areaand simplification in payloadintegration, as well as better EMCcharacteristics and only one uniqueconnection to the EPC for DC andall TC/TM functions of the MPM.Also available as Dual MPM.

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Tesat-Spacecom has an extensive experience in the field of satellite filters. A multitude of input and output multi-

plexers and filters from L- to Ka-Band have been designed, manufactured and qualified in various programs

in the last 30 years. Individual designs to customer requirements using advanced CAD tools and dedicated

manufacturing facilities.

Filters and Multiplexers

Tesat-Spacecom has excellentinhouse computer programs for thedesign of all kinds of filters such asTchebyscheff, elliptic function,pseudoelliptic function, and linearphase (self equalized) asymetricalcharacteristic, and for the effectivesimulation and optimization ofmultiplexers. All necessary spacequalified manufacturing processesincluding EDM (Electrical DischargeMachining), silver plating andsoldering facilities are available atTesat-Spacecom for the productionof the flight hardware. All tests areperformed in the test area fullyequipped with thermal vacuum andvibration test facilities, high and lowpower computer-controlled testbenches.

Input Multiplexers andMultiplexer Assemblies

The function of an input multi-plexer (IMUX) is to separate theindividual channels out of theincoming broadband signal. Highlydemanding requirements of theelectrical performance have to bemet by the input multiplexers. Alsoavailable as Input MultiplexerAssemblies including switches,low-pass filters, hybrids, circulators,isolators etc.

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The main features of the Tesat-Spacecom Input Multiplexers are:

Applications in L, S, C, X, Ku-, Ka-BandsLarge number of channels per multiplexerSpace-qualified and flight provendesignsSuperior performance Excellent temperature stabilityQuasi-elliptic filter functionsSelfequalized or external equalizationVery low losses due to high practical Q factorLarge variety of useful channel bandwidthPrediction and control of higher modesCompact design

Output Multiplexer andMultiplexer Assemblies

Tesat-Spacecom has excellentfacilities to design and manufacturemicrowave output multiplexers.These multiplexers are alwayscritical components as far as loss,mass and volume are concerned.Their function is to combine thepower signals coming from thepower amplifiers and to feed theantenna network.

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Main features of the Tesat-Spacecom Output Multiplexers are as follows:

Designs available for L, S, C, X, Ku-, and Ka-BandsVariety of filter grade and functions availableContiguous, noncontiguous, and quasi-contiguous filter characteristicsInhouse developed RF simulationand optimisation software tools provide exact full wave modellingincluding influence of tuning screws and accurate prediction of higher order modesNo breadboarding requiredSimulation capability up to 32 channelsRealisation of 14 channel multiplexers in C-Band and 18 channels in Ku-BandFull band multiplexing: 2 GHz in Ku-Band and 800 MHz in C-BandMultiplexing with non-monotonic channel sequence to simplify waveguide routingThinwall INVAR waveguide filter technologyFully integrated subsystems available (incl. isolators and switches) for optimum RF performanceFull RF, mechanical, and thermal custom design and layout capability

Koreasat 3Ka-BandInput Multiplexer

Combline, herring bone and mixed configurations

Heritage with assemblies with aluminium and honeycomb

base plate

Intelsat 805/806 C-Band output multiplexer assembly

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Filters and Passive Components

Receive/Transmit BandDiplexers

Satellite antenna feed systems aregenerally exposed to extremeenvironmental conditions as forexample temperatures ranging from–120 °C to +140 °C. Especially forsuch applications, Tesat-Spacecomhas established a unique highperformance diplexer approach forseparation of the receive andtransmit bands each served by onepolarisation of a common antenna.The design is based on a com-pletely integrated unit – comprisinga high pass and a corrugated lowpass filter that are directly inter-connected with a sophisticatedbroadband waveguide branching.

This integrated approach allows therealisation of the diplexer by state-of-the-art CNC milling techniquesfrom silverplated aluminium.

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Tuning is avoided to cope with theinherent demands for feed systemapplications, namely

low insertion loss (<0.15 dB),good matching properties (<26 dB),high receive/transmit band isolation,flat amplitude and group delay response andhigh power handling capability.

Passive Components for Space Applications

Tesat-Spacecom’s passivecomponent product scope isrounded up by components forcommunication satellite payloadsand higher level integrated sub-assemblies or stand-alone units.

The products include ferrite devices,couplers, power combiners andsplitters, transitions and low/highpower terminations for L, S, C, X,Ku- and Ka-Bands.

Ka-Band Diplexer

PassiveComponents for SpaceApplications

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Microwave Switches

Tesat-Spacecom also manufacturesand supplies waveguides switchesoperating in the range from 4 to 40 GHz for redundancy switchmatrices in satellite payloads.

The main features of the Tesat-Spacecom switches are:

Optimum RF performanceCovering C, X, Ku-, Ka-BandC-type and R-type switchesSingle switches, switch blocks and switch matricesSequential access actuators with high torque margin

Magnetically latching in every positionMechanically simple design with minimum number of piece partsHighest switching reliabilty (life test up to 280,000 actuations under extreme conditions)RF power handling capability(up to 1400 W in Ku-Band)High level vibration and shock load capability (up to 70 grms)Reed switch telemetryTM/TC interface with 9-pin connector

Tesat-Spacecomswitch family

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Microwave Solid-state Equipment for Space Applications

Tesat-Spacecom supplies a widespectrum of microwave solid-stateequipment in frequency rangesfrom 1 GHz up to 30 GHz. Coreproducts are linearizers, channelamplifiers, modulators anddemodulators. The equipment isdesigned for applications wherehigh reliability is required,corresponding to an orbital lifetimefrom 7 up to 15 years, which isproven in several satellite programse. g. ECS, TV-Sat, DFS, Intelsatand Inmarsat.

The concept of modular designused in these equipment allows ahigh degree of flexiblity and customdesign capability for particulartechnical requirements. The micro-wave modules are realized in MICand MMIC technologies, whereasthe regulators and control circuitsare assembled on PCBs. The MICand PCB circuits are manufacturedby Tesat-Spacecom in accordancewith ESA and NASA standards.

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X-Band Modulator

PPF Ka-Band Modulator

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Optical Terminals for Inter-Satellite Links

Tesat-Spacecom Coherent LaserCommunication Terminals for Inter-satellite Links (ISL) are the result ofmore than a decade of develop-ment expertise in the field of freespace optical communications andTesat-Spacecom’s broad know-ledge of commercial spacesystems production. The terminalform is a coherent, high data ratecommunication system withhomodyne receivers operating at1064 nm. They provide

user data rates of up to 10 Gbpsduplex ample link margins

interruption free communication even during sun pointing immunity to commercial space vehicle micro-vibrationshigh operational flexibilitylow mass and small dimensionssimple integration on space vehiclegood reliability for extended lifetime

The Tesat-Spacecom CoherentLaser Communication Terminal(CLT) product family for LEO-LEOand GEO-GEO commercial ISLapplications derives its high-gradematurity from proven and extensive

European precursor activities in thefield of optical communications.Direct advantage has been taken ofthe current Tesat-Spacecom opticalterminal development programs ofthe German National Space Agency(DLR-LCT) and the European SpaceAgency ISL-TFE program for thedevelopment of an ISL opticalreceiver frontend. These activitiesled to the current world-class-bestmodular product family optimizedfor customized commercial appli-cations. Space qualification andproduction start for LEO-LEOterminals is scheduled for the year2002.

LEO satellite system with optical inter-satellite links

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Future Developments

V-Band 60 GHz TWTA

Technical characteristics:Frequency range: 59 to 64 GHzRF output power: <25 WInput voltage: 50/70/100 VDC input power: 70 WDC output power (EPC): 62 WEfficiency (EPC): 91 %Cathode voltage (max): 20 kVDimension (w/o TWT): 296x90 x135 mm 3

Mass: EPC: <2300 g, TWT: <1200 g

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X-Band Modulator/Transmitter (XTRA)

Technical characteristics:Frequency Range: 7.2 to 8.5 GHzModulation: BPSK/QPSK/O-QPSK Encoding Differential (configurable) Data Rate: 700 MBps max Phase Imbalance: < 4 Deg. pp Amplitude Imbalance: < 0.4 dB pp Symbol Transition Time: < 300 psec Duty Cycle (Symbol) 48% to 52% Output Power: XMOD –10 to +0 dBm commandable

XTRA 3 Watt Carrier Frequency 7.2 GHz to 8.5 GHz Commandable Synthesizer Bandwidth 500 MHzFrequency Resolution 5 MHz Frequency Stability: +1 ppm vs. temp.

± 5 ppm over 5 years Mass XMOD 650 gramm, XTRA 950 gramm Volume: XMOD 165 x 7 x 40 mm (0,5 ltr.)

XTRA 165 x 75 x 55 mm (0,7 ltr.)Power Consumption: XMOD 7 Watt, XTRA 23 Watt Data Interface I/Q Data + Clock or 8 Bit Parallel +

Byte Clock Main Bus Voltage 21 Volt to 35 Volt

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Parts Procurement AgencyActive phased-array antennas

Based on its extensive experience with a variety of components, Tesat-Spacecomis well qualified to tackle any space parts engineering and procurement job

A major factor in planning andimplementing space projectssuccessfully is to select andprocure the optimum electroniccomponents.

Tesat-Spacecom’s in-house Hi-Relparts procurement departmentcarries out the selection,specification, most economicprocurement, approval and supplyof all Hi-Rel parts for Tesat-Spacecom space projects.

In addition to covering its ownneeds, Tesat-Spacecom offers thisservice to other companies as aprocurement agent service.

Tesat-Spacecom has acted ascentral parts procurement agent fornumerous space projects of whichthe most recent projects are theEuropean Robotic Arm, MeteosatSecond Generation and theColumbus Orbital Facility.

Our service bundles the productsthat are available on the worldmarket in a parts procurementsystem that is geared to our

customers’ requirements and cancope with tasks of all kinds andsizes.

Tesat-Spacecom has gainedexcellent knowledge of part types,their performance and technologiesfrom extensive procurement activityon the world market. This isrounded off by our outstandingknow-how and connections withthe Hi-Rel component market.

Tesat-Spacecom’s parts procure-ment department has been inoperation without interruption since1972: Procurement for more than 90 projects, including 10 completeprojects, and more than 30 as aprocurement agent, with over14,000 different lots and 8 millionpiece parts being procured. Parts have been procured from 42European, 77 US and 3 Japanesemanufacturers.

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Tesat-Spacecom GmbH & Co.KGGerberstraße 49D-71522 BacknangGermany

Tel +49 (0) 71 91 – 930 – 11 77Fax +49 (0) 71 91 – 930 – 18 01

www.tesat.deinfo@tesat.de

Our Representative in the USAand Canada:

Peter LüstElectronic Note Space Systems300 Esplanade Drive,9th floor, Suite 900,Oxnard, California 93030, USA

Telephone 805– 981 – 91 78Telefax 805– 981 – 91 47peter.lust@electronicnote.com

This publication is issued to provide outline information only which (unless agreed by Tesat-Spacecom in writing) may not be used, applied or reproduced for any purpose or form part of any order or contract or be regarded as a representation relating to the products or services concerned.Tesat-Spacecom reserves the right to alter without notice the specification, design, price or conditions of supply of any product or service.

© Tesat-Spacecom 2002. Alll rights reserved. Code: TE1001 Printed in Germany