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CPI T02KO Installation & Operation Manual

250w ka-band twt amplifier
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INSTALLATION
&
OPERATION
MANUAL
250W Ka-Band TWT Amplifier
Service Center Headquarters and Design Center
West Coast Operations
811 Hansen Way
Palo Alto, CA 94303
Manufacturing
East Coast Operations
45 River Drive
Georgetown, ON Canada L7G 2J4
D
. 01031492 R
. 3
OC
EV
For Use With Model Numbers . . .
T02KO
T03KO

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  • Page 1 INSTALLATION & OPERATION MANUAL 250W Ka-Band TWT Amplifier For Use With Model Numbers . . . T02KO T03KO Service Center Headquarters and Design Center West Coast Operations 811 Hansen Way Palo Alto, CA 94303 Manufacturing East Coast Operations 45 River Drive Georgetown, ON Canada L7G 2J4 .
  • Page 2 CPI equipment. Except for rights expressly granted by contract, all such information is the exclusive property of CPI Satcom Division. This document may not be duplicated, in whole or in part, or be used for manufacture without written permission of CPI, Satcom Division.

  • Page 3: Table Of Contents

    KA BAND OUTDOOR TWT AMPLIFIER Table of Contents CHAPTER Safety ............................S-1 Introduction............................S-1 High Voltage Equipment .........................S-1 S.2.1 Personnel Operating Guidelines....................S-1 S.2.2 When is Voltage "High"? ......................S-2 S.2.3 General High Voltage Guidelines....................S-2 Microwave Radiation........................S-5 S.3.1 Personnel Operating Guidelines....................S-5 S.3.2 Microwave Discussion .......................
  • Page 4 KA BAND OUTDOOR TWT AMPLIFIER 2.4.1 Amplifier Installation ......................... 2-2 2.4.2 Cooling Considerations ......................2-2 2.4.3 Electrical Power Connections ....................2-3 2.4.3.1 Prime Power (J1)........................2-3 2.4.3.2 Grounding ..........................2-3 2.4.4 Remote Control Interface (J6) ....................2-4 2.4.5 Switch Interface Connector (J5) ....................2-5 2.4.6 RF Coaxial Cable Connections (J4) ..................
  • Page 5 KA BAND OUTDOOR TWT AMPLIFIER Overview ............................4-1 4.1.1 Control Mode Hierarchy......................4-1 Serial Interface ..........................4-1 4.2.1 Interface Configuration......................4-1 RF Switch Interface (J5)........................4-2 4.3.1 Relay Definitions........................4-2 Ethernet Interface ..........................4-6 4.4.1 IP Setup............................4-7 4.4.2 Web Interface ..........................4-9 4.4.3 Configuring Email ........................
  • Page 6 KA BAND OUTDOOR TWT AMPLIFIER 5.3.2 Remote Control Mode, Computer Control................. 5-3 Shutdown ............................5-3 5.4.1 Normal Shutdown........................5-3 5.4.2 Prime Power Interrupts ......................5-4 Making Routine Safety Checks....................... 5-4 Description of Amplifier States....................... 5-4 5.6.1 Post ............................5-5 5.6.2 Heater Time Delay (HTD) ......................
  • Page 7 KA BAND OUTDOOR TWT AMPLIFIER B.2.3 Settings Window.........................B-5 B.2.3.1 General ..........................B-5 B.2.3.2 Configuration ........................B-7 B.2.3.3 Engineering ........................B-7 B.2.3.4 CIF ............................ B-8 B.2.4 Meter Log...........................B-8 B.2.4.1 Auto Update ........................B-9 B.2.4.2 Auto Log Time........................B-9 B.2.4.3 Search..........................B-9 B.2.4.4 Save File..........................
  • Page 8 KA BAND OUTDOOR TWT AMPLIFIER List of Figures 1-1. K TWTA (F ) ______________________________________________ 1-2 IGURE RONT 1-2. T TWTA RF D ________________________________________ 1-3 IGURE YPICAL IAGRAM 2-1. K -BAND TWTA C _____________________________________ 2-4 IGURE ONNECTOR OCATIONS RS-232 C __________________________________________________________ 2-5 IGURE ABLES TWTA R...
  • Page 9 KA BAND OUTDOOR TWT AMPLIFIER List of Tables 1-1. K -BAND TWT A _________________________________________________ 1-1 ABLE MPLIFIERS TWTA F ______________________ 3-3 ABLE RONT ANEL ONTROLS AND NDICATORS 3-2. F _________________________________________________ 3-7 ABLE RONT ANEL ONTROL LED G _______________________________________ 3-8 ABLE ROUP AND ISPLAY ESCRIPTION...

  • Page 11: Chapter Safety

    KA BAND OUTDOOR TWT AMPLIFIER CHAPTER Safety S.1 Introduction This chapter provides the following safety guidelines for personnel: • High Voltage Equipment Operating Guidelines • Microwave Radiation Operating Guidelines • Physical Safety Guidelines In addition to the above items addressed in this chapter, included by reference are the following pertinent sections of the International Standard EN60215, Safety Requirements for Radio Transmitting Equipment: •...

  • Page 12: When Is Voltage "High

    KA BAND OUTDOOR TWT AMPLIFIER NOTE: THE GUIDELINES PRESENTED IN THIS DOCUMENT ARE NOT ACADEMIC. THEY ARE BASED ON THE EXPERIENCE OF ENGINEERS AND TECHNICIANS WHO HAVE YEARS OF EXPERIENCE WITH HIGH VOLTAGE CIRCUITS. S.2.2 When is Voltage "High"? As stated earlier, any voltage that will kill you should be treated as high voltage. Voltages associated with prime power generally do not jump the air gap between people and the equipment.
  • Page 13 KA BAND OUTDOOR TWT AMPLIFIER f) Do not assume that the level of risk is a function of size. Some large high power voltage equipment looks docile. One reason the equipment is so big is to get the proper separation between high voltage points. On the other hand, just because the equipment is small is no assurance of safety.
  • Page 14 KA BAND OUTDOOR TWT AMPLIFIER p) If you do not know how the equipment works and what the hazards associated with the equipment are in specific terms, do NOT handle the equipment. The greatest protection you can have when dealing with high voltage equipment is specific detailed knowledge on that particular piece of equipment.

  • Page 15: Microwave Radiation

    The permissible levels are quite low in comparison to the power levels of the amplifiers built by CPI (e.g., less than 10 mW vs. 20 to 10,000 Watts delivered by different units) Local radiation levels can be detected with the proper equipment. The permissible levels are currently being studied by a number of organizations.

  • Page 16: General Microwave Guidelines

    General Microwave Guidelines The purpose of these guidelines is to provide practical approaches to control unwanted microwave energy associated with the operation and servicing of CPI Satcom Division equipment. The following approaches are effective in both laboratory or field environments: a.

  • Page 17: Physical Safety

    KA BAND OUTDOOR TWT AMPLIFIER S.4 Physical Safety S.4.1 Lifting Heavy Objects Back and other injuries can result from one person trying to lift too much weight. Use extreme caution when lifting the klystron. Klystrons weigh up to 100 pounds (45 kg) and require two persons to lift them.

  • Page 19: Chapter 1 Introduction

    CHAPTER 1 Introduction 1.1 Overview The CPI Ka-Band TWTA (Traveling Wave Tube) ODU Amplifiers are designed for satellite communication earth stations, satellite newsgathering vehicles, and flyaway applications. The key feature of these amplifiers permits direct mounting to antenna structures, thereby eliminating transmission line losses encountered in conventional remotely mounted arrangements.

  • Page 20: Figure 1-1. K A -Band Twta

    KA BAND OUTDOOR TWT AMPLIFIER Figure 1-1. Ka-Band TWTA (Front View) The Ka-Band TWTAs operate with AC input (line) voltages of 100 - 240 ± 10% V at any frequency between 47 and 63 Hz. All of the Ka-Band TWTAs are the same size and nearly the same weight. The typical model weighs 52 pounds (23.6 kg.), the overall dimensions, excluding switches, connectors, and handles and mounting brackets, are 10.25 by 9.5 by 20.0 inches (260.4 X 508 X 241.3 mm).

  • Page 21: Optional Features

    KA BAND OUTDOOR TWT AMPLIFIER The Ka-Band TWTAs can be operated in either local or remote mode, the latter being the primary mode of operation. Remote operation is performed using either a CPI Remote Control Unit or a user-supplied IBM compatible computer.

  • Page 22: Conventions

    Chapter 3, “Initial Power ON and Checkout”, describes the controls and indicators on the front panel of the amplifier, the CPI Remote Control Unit controls and indicators, and the procedures to use for initial checkout after the amplifier has been installed.

  • Page 23: Warnings

    KA BAND OUTDOOR TWT AMPLIFIER 1.4.2 Warnings There are three different warnings, Electrical Hazards, Radiation (microwave) Hazards, and Physical Hazards (mechanical, chemical, miscellaneous). ELECTRICAL HAZARD! DENTIFY CONDITIONS, OPERATIONS, OR PROCEDURES THAT EXPOSE THE OPERATOR TO POTENTIALLY LETHAL HIGH VOLTAGES. RADIATION HAZARD! IDENTIFY CONDITIONS, OPERATIONS, OR PROCEDURES THAT EXPOSE PEOPLE TO MICROWAVE RADIATION SOURCES THAT COULD CAUSE SERIOUS INJURIES, PARTICULARLY TO YOUR EYES.
  • Page 24 KA BAND OUTDOOR TWT AMPLIFIER This page is intentionally left blank. INSTALLATION AND OPERATION MANUAL...

  • Page 25: Chapter 2 Unpacking And Installation

    KA BAND OUTDOOR TWT AMPLIFIER CHAPTER 2 Unpacking And Installation 2.1 Overview This chapter contains instructions for unpacking and installing the Ka-Band TWTA. 2.2 Pre-Inspection Inspect the exterior of the shipping container(s) for evidence of damage in shipment. If damage is evident, immediately contact the carrier that delivered the equipment and submit a damage report.

  • Page 26: Amplifier Installation

    KA BAND OUTDOOR TWT AMPLIFIER 2.4.1 Amplifier Installation Refer to the appropriate Outline Drawing in Chapter 7 “Drawings” for outline and mounting information. The amplifier may be mounted using the six tapped holes located on the side (refer to the Outline Drawing, 01031382, in Chapter 7, “Drawings”).

  • Page 27: Electrical Power Connections

    KA BAND OUTDOOR TWT AMPLIFIER 2.4.3 Electrical Power Connections All electrical connections to the amplifier are located on the front panel (Figure 2-1). 2.4.3.1 Prime Power (J1) ELECTRICAL HAZARD! ELECTRICAL HAZARD! DO NOT APPLY POWER TO THE AMPLIFIER UNTIL YOU ARE DIRECTED TO DO SO IN THE PROCEDURE.

  • Page 28: Remote Control Interface (J6)

    2.4.4 Remote Control Interface (J6) The operator can use either a PC or the optional CPI Remote Control Unit connected to J6 (“REMOTE”) to remotely monitor and control the amplifier. J6 is a 10-pin MS type connector, ITT Canon KPT07E12-10S. (A mating connector is supplied in the ship kit.) The PC can use either RS- 232 or RS-422/485 communication standards, while the CPI Remote Control Panel uses only RS- 422.

  • Page 29: Switch Interface Connector (J5)

    KA BAND OUTDOOR TWT AMPLIFIER Figure 2-2 RS-232 Cables 2.4.5 Switch Interface Connector (J5) Connector J5 is a round 26-pin female (socket) connector that is used for redundant system operation. NOTE: A mating, wired connector (jumper plug) is supplied with the unit.

  • Page 30: Rf Input Waveguide Flange Connection (J3)

    KA BAND OUTDOOR TWT AMPLIFIER CAUTION! Only use a 2.92mm SMA or “K” type connector. Other connector types will NOT properly interface with J4, and could cause damage to the connector center conductor. 2.4.7 RF Input Waveguide Flange Connection (J3) The input waveguide flange of the Ka-Band TWTA is located on the front panel (Figure 2-1).

  • Page 31: Figure 2-3 K A -Band

    KA BAND OUTDOOR TWT AMPLIFIER a) Install the O-ring gasket (supplied) in the output flange. 6. Position the interconnecting waveguide so that it aligns precisely with the waveguide flange at the rear of the unit. Figure2-3 Ka-Band TWTA Rear Panel CAUTION! If flange alignment is not precise or if the installation is subject to motion or severe vibration, a flexible waveguide section should be installed between the output of the Ka-Band...
  • Page 32 KA BAND OUTDOOR TWT AMPLIFIER This page is intentionally left blank. INSTALLATION AND OPERATION MANUAL...

  • Page 33: Chapter 3 Initial Power On And Checkout

    The Ka-Band TWTA is normally operated in the REMOTE mode via the serial interface. The remote control device can be an optional CPI Remote Control Unit (01032300), an IBM compatible computer with an RS-232 or RS-422/485 serial port or an Ethernet connection. In the LOCAL mode, three push button switches control the amplifier and its state is monitored by five LEDs.

  • Page 34: Front Panel Controls And Indicators

    KA BAND OUTDOOR TWT AMPLIFIER 3.2 Front Panel Controls and Indicators The front panel of the Hub-Mount Ka-Band TWTA is shown in Figure 3-1. Table 3-1, which is keyed to Figure 3-1, lists the front panel controls and indicators and defines the function of each listed item.
  • Page 35 KA BAND OUTDOOR TWT AMPLIFIER Table 3-1 Ka-Band TWTA Front Panel Controls and Indicators Classification Type Function / Label RESET Momentary When pressed, resets the amplifier after a latched fault. After Pushbutton reset, the FLT (fault) LED is OFF and the STBY (STANDBY) (Note 2) Switch LED is lighted.

  • Page 36: Optional Rcu Controls And Indicators

    KA BAND OUTDOOR TWT AMPLIFIER 3.3 Optional RCU Controls and Indicators The Rack Mount Remote Control Unit is normally operated in the REMOTE mode via the one of three serial interface types connected to an M&C system (via LAN for Ethernet). The front and rear panels of the Remote Control Unit are shown in Figure 3-2.

  • Page 37: Operational Summary Of The Remote Control Unit (Rcu)

    KA BAND OUTDOOR TWT AMPLIFIER 3. Press MENU and verify unit 1 and SETTINGS are selected. Press ENTER and then down arrow four times until UNIT ADDRESS: is displayed in the bottom left of screen. Press ENTER and then the left arrow until UNIT ADDRESS: is highlighted. 4.
  • Page 38 KA BAND OUTDOOR TWT AMPLIFIER When an amplifier is found, the type and address will show briefly before scanning resumes. Scanning stops at address 111 or restarts at 48 if no amplifiers are found. FOUND 400W AT 55 After the address scanning is complete, the display will show the Amplifier status screen or the System screen if a switch system was found.

  • Page 39: Control Keys

    KA BAND OUTDOOR TWT AMPLIFIER □ UNITS □ BUZZER □ DISPLAY □ IP CONFIG □ CIF PORT □ VERSION 3.3.2 Control Keys The Remote Control Unit Control Keys are functionally grouped as described in Table 3-2. These keys are shown in Figure 3-3. Table 3-2.

  • Page 40: Led Group And Display

    KA BAND OUTDOOR TWT AMPLIFIER S Y S T E M M E N U R E S E T LC L A M P M & C FA U LT S YS TE M M EN U R ES E T LC L A M P M &...

  • Page 41: Figure 3-5. Remote Control

    KA BAND OUTDOOR TWT AMPLIFIER S Y S T E M M E N U R E S E T LC L A M P M & C FA U LT M E N U R E S E T FA U LT S Y S TE M R M T...

  • Page 42: Figure 3-6- A . Remotec

    KA BAND OUTDOOR TWT AMPLIFIER SYSTEM MENU RESET M&C FAULT AMPLIFIER SELECT MANUAL RF OUT: NNN W ALC RF OUT: NNN W ENTER ENTER MENU SETTINGS REFL RF FAULT: NN W RF OUT: NNN W ATTENUATION: NN.N dB ONCE THE DESIRED WINDOW IS REACHED, PRESS HELIX V: NN.NN kV TO HIGHLIGHT THE SELECT ITEM TO BE CHANGED.

  • Page 43: Operation With Pc Computer And Setup & Remote Control Software

    This software allows the user to set up and remotely control the Ka-Band TWTA via a PC computer running in Windows with the CPI supplied GUI (Graphical User Interface) remote software provided with the amplifier, 01033839. The functions, controls and monitors are the same as those accessed by the remote control panel.

  • Page 44: Operation With Ethernet

    KA BAND OUTDOOR TWT AMPLIFIER 3.5 Operation with Ethernet Refer to chapter 4 “External Interfaces” for detailed information on utilizing the Ethernet communication feature. Figure 3-7. Ethernet Option 3.6 First Time Pre-Power Procedure Before applying prime AC power to the Ka-Band TWTA, verify that the following conditions are met: •...

  • Page 45: Power-On Sequence

    KA BAND OUTDOOR TWT AMPLIFIER • The optional Remote Control Unit is connected to a single-phase 100-240 +/- 10% 47-63 Hz prime power source. • There is at least 4 inches of clearance at the front and rear of the amplifier and 2 inches of clearance of the bottom of the amplifier.

  • Page 46: Check Factory Set Values Via A Computer

    Power up the amplifier with high-voltage OFF (XMT LED not blinking or lighted). Refer to Appendix B, for a description of the CPI supplied Setup & Remote control software program. Refer to tables 3-2 through 3-4 and record factory set values for each parameter.
  • Page 47 KA BAND OUTDOOR TWT AMPLIFIER Table 3-4. Helix and RF Settings Fault and Alarm Ranges: 120W CW/250W Peak Fault Name Minimum Factory Default Maximum Remarks Setting Preset Settings Setting Low RF 120 W See 3.8 for normal Alarm operation. Low RF 120 W See 3.8 for normal Fault...

  • Page 48: Table 3-5. Helix And Rf S

    KA BAND OUTDOOR TWT AMPLIFIER Table 3-5. Helix and RF Settings Fault and Alarm Ranges: 175W CW / 250W Peak Fault Name Minimum Factory Default Maximum Remarks Setting Preset Settings Setting Low RF 170 W See 3.8 for normal Alarm operation.

  • Page 49: Table 3-6. Helix And Rf S

    KA BAND OUTDOOR TWT AMPLIFIER Table 3-6. Helix and RF Settings Fault and Alarm Ranges: 250W/275W CW Fault Name Minimum Factory Default Maximum Remarks Setting Preset Settings Setting Low RF 250 W See 3.8 for normal Alarm operation. Low RF 250 W See 3.8 for normal Fault...

  • Page 50: Initial Check, High Voltage On

    KA BAND OUTDOOR TWT AMPLIFIER Successful completion of steps (a) through (c) and 3.6.1.1 and 3.6.1.2 indicates: • Self-tests were successfully completed. • Alarm and fault limit levels are properly set. • The TWT (Traveling Wave Tube) heater is warmed up. •...

  • Page 51: Verify Rf Output

    KA BAND OUTDOOR TWT AMPLIFIER 3.8 Verify RF Output If you want to verify RF output levels, connect a power meter to J4 before you power-up the amplifier. Proceed as follows: 1. Verify that the amplifier output is terminated with a RF Load capable of dissipating full rated output.

  • Page 52: Setup For Operational Service

    KA BAND OUTDOOR TWT AMPLIFIER 3.9 Setup for Operational Service Before committing the amplifier to operational service, you can set the amplifier operating and interface parameters (for computer controlled operations). If computer controlled operation is desired, refer to Chapter 4 to select the desired interface configuration and to drawings in chapter 7 for CIF protocol document.

  • Page 53: Chapter 4 External Interfaces

    KA BAND OUTDOOR TWT AMPLIFIER CHAPTER 4 External Interfaces 4.1 Overview This chapter describes the external interfaces available to the user. The Ka-Band TWTA external interface connectors (J5 and J6) are located on the front panel of the unit (Figure 2-1). 4.1.1 Control Mode Hierarchy The Ka-Band TWTA may be controlled from the front panel of the unit (LOCAL mode), via a...

  • Page 54: Rf Switch Interface (J5)

    KA BAND OUTDOOR TWT AMPLIFIER In the multi-drop configuration, up to sixteen other addressable RS-422/485 equipped devices may share the same serial bus. Termination resistors should be installed on the last device on the bus. If the bus has multiple runs, the terminating resistor should be engaged on the last device at the end of each run.
  • Page 55 KA BAND OUTDOOR TWT AMPLIFIER FAULT Fault status indicates that the Ka-Band TWTA ODU is in the Fault state. The MPA ODU features Auto Fault Recycle capabilities and is capable under some circumstances of cycling back to a normal operating state. Note: During normal operation, the relay is energized.
  • Page 56 KA BAND OUTDOOR TWT AMPLIFIER Note: When the amplifier is in the Transmit state, the relay is energized. (There is continuity between the “NO” and “COM” contacts.) The relay will de-energize when a fault occurs. BEAM ON Beam On tracks the Beam state (HV applied to TWT). Note: When the Beam is On, the relay is energized.
  • Page 57 KA BAND OUTDOOR TWT AMPLIFIER Table 4-1. RF Switch Pin Assignment (J5): 1:1 Switch Option Pin # Signal Name Remarks Status Relay 1 NO Relay 1 normally-open contact. Function defined by switch S1. Status Relay 1 NC Relay 1 normally-closed contact. Function defined by switch S1.

  • Page 58: Ethernet Interface

    KA BAND OUTDOOR TWT AMPLIFIER Table 4-1 Notes: 1. Outputs are dry-circuit relay contacts rated up to 50 V , 50 mA. 2. External interlocks and RF Inhibit inputs are optically isolated. Maximum open circuit voltage present is 16 V .

  • Page 59: Ip Setup

    IP-address/mask of the PC to 192.168.0.100/255.255.255.0. In the address field of the web-browser, type in the IP-address of the amplifier, e.g. http://192.168.0.254. If a login-prompt appears, type in cpi for both the login name and the password. .01031492 R...
  • Page 60 KA BAND OUTDOOR TWT AMPLIFIER Change the IP-settings to the desired configuration and hit “Apply”. The changes will take effect when the amplifier is restarted. When configuring the SMTP address, make sure to enter a domain-name that is recognized by the SMTP server.

  • Page 61: Web Interface

    KA BAND OUTDOOR TWT AMPLIFIER 4.4.2 Web Interface The amplifier can be monitored over the Internet by connecting to the amplifier using a web browser like Internet Explorer. The main screen shows the Amplifier state, Power mode, RF Output, Switch Control and the meter readings. Also the last 10 latched fault events can be checked using the drop-down menu.

  • Page 62: Configuring Email

    KA BAND OUTDOOR TWT AMPLIFIER 4.4.3 Configuring Email The amplifier can be configured to send emails on alarms or faults. Up to 4 groups with up to 8 email recipients each can be configured. Select any combination of events to trigger email and select “Send Meter Log” to have the amplifier attach a file containing the log.

  • Page 63: Changing The Login

    To change the login user name and password, select the “Set Login” menu on the left hand side of the screen. Type in the old user name and password (default is cpi), the new user name and password and hit the apply button.

  • Page 64: Amplifier Information

    KA BAND OUTDOOR TWT AMPLIFIER 4.4.5 Amplifier Information Select “Amp Info” on the menu-bar to show the Amplifier type and firmware version numbers. To change the name of the amplifier, type in a name and hit Apply. The amplifier name will show on the top of the Main menu and is also used as the senders name for emails.

  • Page 65: Download / Upload Files Using Ftp

    Connect to the amplifier using an FTP client or a web browser. The login user name and password is the same as for the web-interface (default is cpi). The window should contain two files: config.ini and the meter log for the amplifier.

  • Page 66: Firmware Updates

    Using an FTP client or web browser, new firmware can be uploaded to the TWTA. Simply drag and drop the new firmware file to the FTP window. When the transfer is done, close the FTP window and the amplifier will reprogram the flash and restart. Contact CPI for latest firmware updates.

  • Page 67: Lan Interface Port Numbers

    KA BAND OUTDOOR TWT AMPLIFIER 4.4.8 LAN Interface Port Numbers Table 4-3. Ethernet Interface Port Numbers Port Number Description Protocol FTP Server HTTP Server NTP Client 50000 CIF Protocol Server 4-15 .01031492 R...

  • Page 68: Java Cif Remote Program

    Ex: If the IP address of the ODU is 172.23.10.20, type http://172.23.10.201 in the Address field of the browser and hit enter. Type in login and password info when the login prompt appears. The default login and password is ‘cpi’ 4-16 INSTALLATION AND OPERATION MANUAL...
  • Page 69 KA BAND OUTDOOR TWT AMPLIFIER To start the CIF Remote application, click on “CIF Remote” in the side bar. The Java program will load and automatically make a connection to the TWTA. 4-17 .01031492 R...

  • Page 70: Meters

    KA BAND OUTDOOR TWT AMPLIFIER 4.5.2 Meters Shows the CIF control state (Local/Remote), Amplifier state, RF Output power, Power mode (Manual/ALC) and the meter readings. Any faults/alarms will be shown in the status bar above the meter readings. The buttons on the bottom of the screen are used to put the amplifier in Transmit or Standby mode, Reset a fault or enable/disable RF Inhibit.

  • Page 71: Setup

    KA BAND OUTDOOR TWT AMPLIFIER 4.5.3 Setup The Setup menu shows the IP address, Amplifier address and the CIF traffic status. 4-19 .01031492 R...

  • Page 72: Settings

    KA BAND OUTDOOR TWT AMPLIFIER 4.5.4 Settings In this menu the trip-point settings can be adjusted. The “RF Power” windows sets the power output, attenuation and Manual/ALC gain control. The “Faults” and “Alarms” windows shows the high/low faults and alarm trip points. Use the up/down arrow on the side to adjust a setting or click in the text-field and type a new value and hit enter.

  • Page 73: Engineering

    KA BAND OUTDOOR TWT AMPLIFIER 4.5.5 Engineering The “Linearizer” window shows the current linearizer settings. To adjust the offsets use the up/down arrows on the side or click in the text field and type a new number (0-255) and hit enter. The “Software Versions”...

  • Page 74: Configuration

    KA BAND OUTDOOR TWT AMPLIFIER 4.5.6 Configuration The “Time” window shows the current time and date. The other fields show the Standby, Transmit and Unit on elapsed time. To set the time, click in the time/date field and type in a new time and date in the correct format.

  • Page 75: Meter Log

    KA BAND OUTDOOR TWT AMPLIFIER 4.5.7 Meter Log Shows the Meter Log (up to 2000 entries). The columns in the table can be re-arranged by clicking on the header and dragging it either left or right. Use the scrollbars to browse the log and click on an event to see more details in the “Event Detail” window.

  • Page 76: Switch System

    KA BAND OUTDOOR TWT AMPLIFIER 4.5.8 Switch System The Switch System screen shows the current switch configuration. In the “Switch Control” window switch control mode can be set (Auto/Manual) and clicking a “Rotate sw” button can rotate each switch. 4-24 INSTALLATION AND OPERATION MANUAL...

  • Page 77: Chapter 5 Normal Operation

    • Remote Control via a CPI Remote Control Unit • Remote Control via an IBM PC compatible computer with CPI supplied Remote Control Software or custom monitor and control equipment developed & supplied by the user. •...

  • Page 78: Overview Of Operation

    KA BAND OUTDOOR TWT AMPLIFIER 5.2 Overview of Operation The amplifier can be turned on using the front panel controls. When operated in this manner (LOCAL), the following sequence of events occurs after the AC power is applied by the operator: •...

  • Page 79: Remote Control Mode, Computer Control

    Remote Control Mode, Computer Control Refer to Chapter 2 for connection details and 01033829 (CIF protocol) for communication and command details. Also refer to Appendix B for operation with CPI supplied Setup & Remote Control Software (ODUremote.exe). In the LOCAL mode, turn the amplifier ON and set it for the REMOTE control mode. Install the supplied ODUremote.exe program or a user-supplied amplifier control program in the computer...

  • Page 80: Prime Power Interrupts

    KA BAND OUTDOOR TWT AMPLIFIER 5.4.2 Prime Power Interrupts The amplifier will automatically recover after a prime power failure. Transient prime power interrupts result in proportional time delays before the amplifier returns to the pre-interrupt operational state. (See 5.6.2.) The purpose of the proportional delay cycle is to re-establish the proper cathode operating temperature before the high voltage is turned ON.

  • Page 81: Post

    KA BAND OUTDOOR TWT AMPLIFIER 5.6.1 Post The microprocessor-based controller performs a list of tests that establish its ability to control and monitor the amplifier. Some areas covered by POST include checking validity of information in the battery-backed RAM, EPROM checksum, and other controller specific aspects. During this test the amplifier will accept no user inputs that affect the beam state.

  • Page 82: Beam On Sequence

    KA BAND OUTDOOR TWT AMPLIFIER 5.6.4 Beam On Sequence Beam on sequence (BONS) covers the transition from Standby (beam off) to Transmit (beam on). During BONS the green Transmit light will flash. 5.6.5 Transmit State Transmit is the normal beam-on state (high voltage on, heater reduce off). RF Inhibit may be on or off.

  • Page 83: Meter Log

    5.6.7.2 Meter log A meter log is available to the user via either the remote panel or the CPI supplied remote software. Refer to either chapter 3 (Figure 3-5) or to Appendix B for more information on how to access the log.
  • Page 84 KA BAND OUTDOOR TWT AMPLIFIER Intentionally Left Blank. INSTALLATION AND OPERATION MANUAL...

  • Page 85: Chapter 6 Operator Maintenance

    KA BAND OUTDOOR TWT AMPLIFIER CHAPTER 6 Operator Maintenance 6.1 Introduction This chapter describes the procedures for Preventive Maintenance tasks that can be performed by operators. NOTE: There are additional Preventive Maintenance tasks that require that the service technician has attended a formal training program for service of the amplifier.

  • Page 86: Visual Inspection

    KA BAND OUTDOOR TWT AMPLIFIER Table 6-1 Preventive Maintenance Performed by Operators Tasks Daily 1 Mo. 3 Mo. 6 Mo. 1 Yr. Log meter readings Perform visual inspection (Note 1) Air system maintenance Cooling fan (Note 2) Perform external cleaning (Note 1) Note 1 Cleaning may be required more or less frequently than shown, depending on the site environment.

  • Page 87: Air System Maintenance

    KA BAND OUTDOOR TWT AMPLIFIER (AC Power Off Task) Perform the following visual inspection: 1. With the AC power removed, check that all connector plugs are properly seated in their mating connectors and have not been damaged. Have the service technician replace any bad connector plugs and reset any that are dislodged.

  • Page 88: Other Preventive Maintenance Tasks

    (Requires a service technician who has attended a formal training program for service of the amplifier to perform these tests). 6.4 Customer Service Refer to Appendix A, “Warranty and Support Information”, for CPI Satcom contact, service, and return information. INSTALLATION AND OPERATION MANUAL...

  • Page 89: Chapter 7 Drawings

    KA BAND OUTDOOR TWT AMPLIFIER CHAPTER 7 Drawings The Ka-Band TWTA drawings listed below are included in this chapter. Table 7-1 Drawings Drawing Number Title 01031048-02 Ship Kit, Ka-Band LM 01031370 Power Supply, Ka-Band TWTA* 01031371-00 Interconnect Diagram, Power Supply Assembly, Anode version 01031372 Specification, Ka-Band TWTA, 250W Peak...
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  • Page 91: Appendix A Warranty And Support Information

    KA BAND OUTDOOR TWT AMPLIFIER APPENDIX A Warranty And Support Information For details, refer to separate supplement included with this manual. HARD COPY: Refer to Warranty and Support supplement located at the front of this manual. CD: Refer to separate folder titled “Warranty and Support.” .01031492 R...
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  • Page 93: Appendix B

    KA BAND OUTDOOR TWT AMPLIFIER APPENDIX B .01031492 R...

  • Page 94: Introduction

    KA BAND OUTDOOR TWT AMPLIFIER B.1 Introduction The Outdoor Unit Remote Panel Software (ODU Remote) provides a basic means of remotely monitoring and controlling up to ten outdoor power amplifiers from a single PC. It is not a substitute to a professional M&C program, but a utility program used for amplifier configuration and troubleshooting.

  • Page 95: Figure B-2 Configuration

    KA BAND OUTDOOR TWT AMPLIFIER 6. From the Setup menu select Configuration. Figure B-2 Configuration Screen / Amplifiers 1-5 Tab 7. Select the Interface tab. Figure B-2a Configuration Screen / Interface Tab 8. Select the Baud Rate, Parity, Word Length, Protocol, and CR/LF settings that match the amplifier’s configuration.

  • Page 96: Meters Window

    KA BAND OUTDOOR TWT AMPLIFIER 11. Click the checkboxes to enable the amplifier(s) connected to the host PC. The default address is 48, with each additional amplifier having a consecutive address (49,50,51...). Each amplifier can also be given a reference name for clarification. This name will appear in the title bar of all windows associated with that amplifier.

  • Page 97: Settings Window

    KA BAND OUTDOOR TWT AMPLIFIER Each meter can be configured for a different reading by right clicking on the meters and selecting the desired reading. (See below) The control buttons are located at the bottom of the window. TRANSMIT places the amplifier in transmit state.

  • Page 98: Figure B-4 Typical Setting

    KA BAND OUTDOOR TWT AMPLIFIER Heater Enable can remotely disable the heater on the TWT. It is recommended to keep this selected. Note: (Millitron/ EIK/ TriBand products) If a unit is left in Standby state for more than 3 hours, the amplifier will go into Heater Time Out (HTO) where the TWT heater is disabled to prolong life.

  • Page 99: Configuration

    KA BAND OUTDOOR TWT AMPLIFIER B.2.3.2 Configuration The Configuration tab contains the system clock, timers, switch system and relay configuration settings. Figure B-4a Configuration Tab B.2.3.3 Engineering The Engineering tab contains the version of the amplifier’s controller software, factory-adjusted settings for the optional linearizer and the system reset. The linearizer settings should not be changed, as it can affect the RF performance of the amplifer.

  • Page 100: Cif

    KA BAND OUTDOOR TWT AMPLIFIER B.2.3.4 The CIF tab is used to change an amplifier’s CIF configuration. The default address is ‘48’. Figure B-4c CIF tab B.2.4 Meter Log From the View menu select Meter Log. The meter log displays up to sixteen meter log entries at a time.

  • Page 101: Auto Update

    KA BAND OUTDOOR TWT AMPLIFIER B.2.4.1 Auto Update The software automatically checks the amplifier meter log for changes at a frequency of once per second. Adjusting the Auto Log Time can change this value (see section B.2.4.2). If a change is detected then the amplifier refreshes the display with the new data. Clearing the Auto Update check box will disable this feature.

  • Page 102: Figure B-6 Save Log Files

    KA BAND OUTDOOR TWT AMPLIFIER Figure B-6 Save Log File Screens Press OK once the desired range is selected. The save log file dialog box will appear with the filename set to the current time and date. Specify a new filename and directory if desired, and then press Save.

  • Page 103: Switch Systems

    KA BAND OUTDOOR TWT AMPLIFIER B.2.5 Switch Systems When an optional switch system is present, from the View menu select Switch Diagram. A schematic representation of the system will be displayed, based on the setting in the Settings/Configuration tab, such as 1:1A, 1:1B, etc. The amplifier/system identifier should match the switch diagram in order for proper switching control.

  • Page 104: Switch Configuration Diagrams

    KA BAND OUTDOOR TWT AMPLIFIER B.2.5.1 Switch Configuration Diagrams Figure B-8a 1:1A Figure B-8b 1:1B Figure B-8c 1:1C Figure B-8d 1:1D-P B-12 INSTALLATION AND OPERATION MANUAL...

  • Page 105: Figure B-8E 1:1E

    KA BAND OUTDOOR TWT AMPLIFIER Figure B-8e 1:1E Figure B-8f 1:1E-P Figure B-8g 1:2A B-13 .01031492 R...

  • Page 106: Figure B-8H 1:2B

    KA BAND OUTDOOR TWT AMPLIFIER Figure B-8h 1:2B Figure B-8i 1:2C B-14 INSTALLATION AND OPERATION MANUAL...

  • Page 107: Alerts

    KA BAND OUTDOOR TWT AMPLIFIER B.2.6 Alerts From the Setup menu select Configuration then select the Alerts tab. Select the amplifier to be configured using the Amplifier list box. Figure B-8 Alerts Tab B.2.6.1 Media Player The Media Player feature plays a user specified media clip if a fault occurs or the amplifier is latched into fault state.

  • Page 108: Restore Window

    KA BAND OUTDOOR TWT AMPLIFIER B.2.6.2 Restore Window The Restore Window feature restores a minimized Meters Window if a fault occurs or the amplifier is latched into fault state. B.2.6.3 Confirmation There are confirmation options available which will prompt the user to confirm when changes are made to the transmit state of the amplifier, such as Transmit, Standby and RF inhibit.

  • Page 109: Troubleshooting

    Along with voltage settings, each band will also store linearizer adjustments. CAUTION! The tuning voltages and DAC settings are preset at the factory and should NOT be changed except by factory-trained technicians. Consult the CPI service center for training class information. B.3 Troubleshooting B.3.1 Communication If communications problems are occurring, check to make sure the addresses set in the amplifier’s...
  • Page 110 KA BAND OUTDOOR TWT AMPLIFIER NOTES: To improve the response time of Meter Log and Settings windows when connected to multiple PAs, it is recommended that the Meters Windows of other PAs be minimized. Setting changes are only accepted if the amplifier control point is set to REMOTE.

  • Page 111: Appendix C Replaceable Parts

    KA BAND OUTDOOR TWT AMPLIFIER APPENDIX C Replaceable Parts Table C-1 Replaceable Parts Description CPI Part Number CCA, Power Factor Correction 01024660-00 CCA, Power Processor 01024980-04 HV Module (Anode 250W Peak) 01031469-00 HV Module (Anode 250W CW) 01031469-02 CCA, Fan Power...
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  • Page 113: Appendix D Optional Linearizer

    (below) before making any changes. Linearizer Adjustment Factory set value (0-255) Gain Phase Magnitude The Linearizer settings can be accessed via the optional CPI remote panel or through the supplied “Setup & Remote control” Software (see Appendix B). .01031492 R...
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  • Page 115: Appendix E 250W Odu Functional Trees

    KA BAND OUTDOOR TWT AMPLIFIER APPENDIX E 250w ODU Functional Trees The trees displayed in Figures E-1 and E-2 are a roadmap to viewing, selecting and modifying the various functions of the RCU. Figure E-1 describes the controls that will be found using the MENU key.
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  • Page 117 K A - B A N D T W T A O D U A M P L I F I E R SYSTEM MENU RESET M&C FAULT AMPLIFIER SELECT MANUAL RF OUT: NNN W ALC RF OUT: NNN W ENTER ENTER MENU...
  • Page 118 K A - B A N D T W T A O D U A M P L I F I E R SYSTEM MENU RESET M&C FAULT SYSTEM DISPLAY DISPLAY LOWER LINE SHOWS: 1:1 System 1:1 Power Combined System ATTEN: NN.N dBm CABINET: NNN C TUBE: NNN C FAN CTRL: N.N V A1: XMIT NN.N dBm MANUAL ON-line...

  • Page 119: Appendix F Optional Internal 1:1 Switch Controller

    This harness and the necessary wave-guide between the switch and the two amplifiers can be custom designed by CPI as part of a redundant 1:1 system or designed by the user into their own custom configuration. Connection details are shown in Figure F-1.

  • Page 120: Figure F-1. Interconnect Diagram

    KA BAND OUTDOOR TWT AMPLIFIER Figure F-1. Interconnect diagram (optional SW controller) INSTALLATION AND OPERATION MANUAL...

  • Page 121: Drawing List

    KA BAND OUTDOOR TWT AMPLIFIER F.2 Drawing List Table F-1. Ka Band TWTA Drawings Title Drawing Number Ka-Band Assembly 1:1 Switch Ka Band TWTAs Switch Interface Cable Assembly 01031513 - 01* Switch Interface Assembly 01031514 - 01* Interconnect Diagram 1: 1 Switch 01031553 RF Block Diagram NOTE:...
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