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INSTALLATION, OPERATION, AND
PREVENTATIVE MAINTENANCE
M A N U A L
CHPA (COMPACT HIGH POWER 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
.01023245 R
.L
OC
EV
THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS & POWER INDUSTRIES.
REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED
For Use With Model Numbers...
VZU-6997 Series
VZU-6996 Series
VZU-6995 Series
VZC-6967 Series
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Related Manuals for CPI Satcom Division VZU-6997 Series
Summary of Contents for CPI Satcom Division VZU-6997 Series
- Page 1 INSTALLATION, OPERATION, AND PREVENTATIVE MAINTENANCE M A N U A L CHPA (COMPACT HIGH POWER AMPLIFIER) For Use With Model Numbers... VZU-6997 Series VZU-6996 Series VZU-6995 Series VZC-6967 Series Service Center Headquarters and Design Center West Coast Operations 811 Hansen Way Palo Alto, CA 94303 Manufacturing East Coast Operations...
- 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.
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Page 3: Table Of Contents
CHPA SERIES Table of Contents SAFETY..............................S-1 INTRODUCTION........................... S-1 HIGH VOLTAGE EQUIPMENT ......................S-1 PERSONNEL OPERATING GUIDELINES ..................S-1 WHEN IS VOLTAGE "HIGH"? ......................S-1 GENERAL GUIDELINES ........................S-2 MICROWAVE RADIATION........................ S-4 PERSONNEL OPERATING GUIDELINES ..................S-4 MICROWAVE DISCUSSION ......................S-5 GENERAL MICROWAVE GUIDELINES .................. - Page 4 CHPA SERIES OVERVIEW..........................2-1 PRE-INSPECTION ........................2-1 UNPACKING..........................2-1 PREPARING FOR INSTALLATION..................2-2 INSTALLATION .........................2-2 2.5.1 MECHANICAL INSTALLATION ..................2-2 2.5.2 ELECTRICAL CONNECTIONS ..................2-3 2.5.3 PRIME POWER ........................2-3 2.5.4 GROUNDING ........................2-4 2.5.5 I/O INTERFACES .........................2-4 2.5.6 RF CONNECTIONS ......................2-4 2.5.7 RF OUTPUT (WAVEGUIDE CONNECTION)(J3).............2-5 2.5.8 COOLING CONSIDERATIONS ..................2-5 CHAPTER 3 INTERFACES .........................3-1 OVERVIEW..........................3-1...
- Page 5 CHPA SERIES 3.9.5 REJECT BYTE(S) .......................3-11 3.9.6 CHECK BYTE........................3-12 3.9.7 CARRIAGE RETURNS AND LINE FEEDS ..............3-13 3.10 COMMANDS ..........................3-13 3.10.1 SLOW COMMANDS......................3-16 3.11 STATUS BYTE DEFINITIONS....................3-17 3.12 ID/VERSION MESSAGE ......................3-21 CHAPTER 4 INITIAL POWER ON AND CHECKOUT ..............4-1 OVERVIEW..........................4-1 PRE-POWER PROCEDURES....................4-1 USING THE FRONT PANEL ....................4-2 INITIAL POWER-ON PROCEDURES ..................4-3 4.4.1...
- Page 6 CHPA SERIES CHPA STATES AND DESCRIPTION..................5-4 INITIALIZATION AND POWER-ON SELF-TEST (POST) STATE........5-4 HEATER TIME DELAY (HTD) STATE..................5-5 STANDBY STATE ........................5-6 TRANSMIT STATE ........................5-7 5.10 FAULT STATE ..........................5-7 5.11 CHPA CONTROL MODES AND HIERARCHY ..............5-8 5.12 RF CONTROL MODES ......................5-9 5.13 SPECIAL CHPA FUNCTIONS ....................5-10 5.13.1 FACTORY AUTHORIZED ACCESS MODE ..............5-10...
- Page 7 CHPA SERIES POWER AND GAIN ........................6-8 CHAPTER 7 DRAWINGS AND SCHEMATICS ................7-1 CHAPTER 8 SUPPLEMENTARY DATA...................8-1 APPENDIX A SPECIFICATIONS ......................A-1 APPENDIX B CONTROL APPEARANCE AND CONTENT ............B-1 OVERVIEW..........................B-1 BUTTONS ........................... B-1 LEDS ............................B-2 BEEPER............................B-3 ALPHANUMERIC DISPLAY DEFINITION ................. B-3 METERS............................
- Page 8 CHPA SERIES B.13.4 FACTORY TESTS ......................B-19 B.13.5 RESET ELAPSED TIME METERS .................. B-19 B.13.6 RESET TO FACTORY DEFAULTS ................. B-20 B.13.7 CHPA HVPS TEST MODE ....................B-20 B.13.8 USER TESTS........................B-21 B.13.9 TIME/DATE SET ....................... B-22 B.13.10 REMOTE/COMPUTER INTERFACE PARAMETERS ..........B-23 B.13.11 SOFTWARE VERSIONS....................
- Page 9 CHPA SERIES List of Figures Figure 1-1. The CHPA ...........................1-2 Figure 1-2. CHPA RF Diagram......................1-4 Figure 1-3. Power Supply Block Diagram ..................1-6 Figure 2-1. Rear Panel of CHPA......................2-3 Figure 3-1. Setting Termination Resistors...................3-3 Figure 3-2. Setting Serial Format......................3-7 Figure 4-1. The CHPA Series Front Panel...................4-2 Figure 5-1.
- Page 10 CHPA SERIES Table 3-12. Secondary Status Bytes....................3-18 Table 3-13. Fault and Miscellaneous Status..................3-19 Table 3-13. Fault and Miscellaneous Status (continued) ..............3-20 Table 3-14. Information/Error Messages..................3-20 Table 3-14. Information/Error Messages (continued) ..............3-21 Table 4-1. Helix and RF Settings Ranges ....................4-5 Table 4-1. Helix and RF Settings Ranges (continued) ...............4-6 Table 5-1.
- Page 11 CHPA SERIES Table B-14. Software Error Codes ..................... B-29 Table C-1. Replaceable Parts Listing ....................C-1 Table C-1. Replaceable Parts Listing (continued)................C-2 THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS & POWER INDUSTRIES. .01023245 R REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED...
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Page 13: Safety
CHPA SERIES Safety Introduction In addition to the High Voltage Equipment Personnel Operating Guidelines given in this chapter, included by reference are the following pertinent sections of the International Standard EN60215, Safety Requirements for Radio Transmitting Equipment: • Appendix D, Guidance on Assessing the Competence of Personnel for Designation as Skilled, and also Sub-clause 3.1 of the Standard. -
Page 14: General Guidelines
CHPA SERIES One of the problems associated with prime power is some equipment can be "floating" above ground. In this case, if you place one hand on the equipment chassis and the other on earth ground, you can be jolted, injured, or killed. 440VAC can stimulate an involuntary muscle response that will either literally throw you across a room or seize and hold you across the voltage terminals. - Page 15 CHPA SERIES Take personal responsibility to assure that no one can turn on the high voltage circuits when you are working on the equipment. Precautions would include taping down (or installing a keeper) on controls/circuit breakers and/or disconnecting the power source to the high voltage circuits, activating interlocks that prevent high voltage turn on, etc.
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Page 16: Microwave Radiation
CHPA SERIES Shut off the high voltage when you are making low voltage measurements. It does not make sense to increase danger needlessly. While there may be times when you cannot shut off the high voltage during a low voltage measurement, this is generally not the case. -
Page 17: Microwave Discussion
The permissible levels are quite low in comparison to the power levels of the amplifiers built by CPI (e.g., less than 10 milliwatts 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 18: Physical Safety
CHPA SERIES If you damage the lens of your eyes by exposure to microwave radiation, cataracts can result. Consider that small microwave ovens are very effective in cooking foods. If you follow these guidelines you can minimize exposure of yourself and other people in the operations that you control. -
Page 19: Chapter 1 Introduction
CHPA SERIES Chapter 1 Introduction 1.1 Overview The new Compact High Power Amplifier (CHPA) series is designed for satellite communication earth stations, satellite news- gathering vehicles, and fly-away applications operating in the C and Ku and DBS frequency bands. Radio frequency (RF) power of up to 700 watts (for C- and Ku- and DBS band amplifiers) is available in this series. -
Page 20: Figure 1-1. The Chpa
CHPA SERIES Table 1-1. CHPA Model Number and Frequency Ranges (continued) Model No. Frequency Range (GHz) Rated Power (Watts) VZU-6997AA 13.00 - 13.25 VZU-6997AD 13.75 - 14.50 VZU-6997AJ 12.75 - 13.25 VZU-6995AY 17.30 - 18.40 VZU-6996AY 17.30 - 17.80 VZU-6997CY 17.30 - 18.40 VZU-6997AX 17.30 - 18.40... -
Page 21: About This Manual
Chapter 8, “Supplementary Data,” consists of five appendixes; contained are detailed specifications for the CHPA, a listing of control and display functions, and a summary of optional features that are available from CPI. Also contained are service and warranty information and a list of replaceable parts. -
Page 22: Major Subsystems And Their Functions
CHPA SERIES 1.3 Major Subsystems and Their Functions The CHPA (Figure 1-1) is packaged in an 8.75-inch-tall slide-mounted drawer suitable for standard 19-inch rack mounting. This enclosed assembly houses both the RF and power supply sections. The overall amplifier enclosure measures approximately 19" (w) x 8.75" (h) x 24" (d), plus fan and external air duct adapters, and weighs approximately 90 lb. - Page 23 The output and reflected power level readouts are also available for remote monitoring via the optional CPI remote control panel or via the Computer Interface (CIF) port located at the rear of the enclosure. The RF drive is adjustable via the Serial Remote and CIF port. Also, the RF...
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Page 24: Power Supply Subsystem
375 VDC Control Helix & DC Power Cathode Coll. 1 Flash RAM Programming Coll. 2 Switching I/F Monitor Serial Remote Control (For use with CPI Remote Panel) Micro-controller Computer I/F Linearizer (optional) User Interlocks Power Control SSIPA Power Control &... -
Page 25: Power Factor Correction Module
CHPA SERIES 1.4.3 Power Factor Correction Module Input primary power––single-phase, 208-240 VAC, 47-63 Hz––flows via an EMI filter and the main circuit breaker to both the cooling system power supply and the Power Factor Correction Module. This module provides a regulated 375 VDC to the power processor and allows the CHPA to meet the requirements of IEC-555 regarding total harmonic distortion. -
Page 26: Control And Display Modules
CHPA SERIES 1.4.7 Control and Display Modules The Control and Display modules are designed to assure correct operation of the power amplifier with minimal operator training. These microprocessor-based modules provide automatic sequencing of CHPA operation and monitoring and control of all critical parameters via both the front and rear panel interfaces. -
Page 27: Optional Features
CHPA SERIES 1.6 Optional Features To customize and enhance the functioning of the CHPA, CPI provides a range of options. These include the following: • An Internal Linearizer. The internal linearizer extends the linear operating region of the amplifier. It is easily installed inside the CHPA and is controlled through the front panel, optional remote panel, and serial computer interface. - Page 28 CHPA SERIES This page is intentionally left blank. THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS & POWER INDUSTRIES. 1-10 .01023245 R REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED...
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Page 29: Chapter 2 Unpacking And Installation
CHPA SERIES Chapter 2 Unpacking and Installation 2.1 Overview This chapter contains instructions for site preparation, unpacking, and installation of the Compact High Power Amplifier (CHPA). Instructions for the optional CHPA Remote Control and Switching/Power Combined subsystems are supplied separately with those items. The CHPA’s built-in interface connections for optional equipment are described in Chapter 3, “Interfaces,”... -
Page 30: Preparing For Installation
CHPA SERIES 2.4 Preparing For Installation It is recommended that an electrical inspection for verification of customer interface connections be performed before and after the installation of the equipment in its final operational location; the following basic steps must be completed: 1. -
Page 31: Electrical Connections
CHPA SERIES 2.5.2 Electrical Connections The locations of the connectors referred to in this section are shown in Figure 2-1. Electrical interconnections to the system consist of prime power, ground strap, and external connections including computer interface (CIF), remote control, switch interface, and user interlocks, if applicable. -
Page 32: Grounding
CHPA SERIES 2.5.4 Grounding Note: Proper grounding of the CHPA amplifier to the station ground buss or to earth ground is necessary for personnel and equipment safety. The ground screw on the CHPA rear panel must be used for this purpose. 2.5.5 I/O Interfaces I/O interface connections are made at the rear panel of the CHPA via J4-J8, which are all... -
Page 33: Rf Output (Waveguide Connection)(J3)
CHPA SERIES 2.5.7 RF Output (Waveguide Connection)(J3) The output waveguide flange of the CHPA is located on the rear panel of the CHPA. The standard RF output interface, provided by the user, to connect the CHPA to the external waveguide run is a flange termination. Use the following waveguide flange depending on the CHPA band: •... - Page 34 CHPA SERIES Generally speaking, a 0.10 inch H 0 pressure drop in a 5-inch-diameter flex-type hose corresponds to approximately 10 ft in length. It is therefore recommended that for longer duct runs, a transition be made to perhaps 8-inch duct as near the CHPA exhaust as possible; 8-inch plumbing will significantly reduce pressure drop and permit much longer duct runs.
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Page 35: Chapter 3 Interfaces
Pig-tail wiring must not be used. These interfaces are listed below: • Serial Remote Interface—The default setup for this interface is for connection to a CPI Remote Control Panel. This port can also be set up for communication with a computer via a RS-422/485 (4-wire multi-drop) serial link. -
Page 36: Serial Remote Interface
The CHPA Serial Remote Interface is typically used to support serial communications with a remote control unit, such as the CPI CHPA Remote unit. This port does support multi-drop RS- 422/485 (4-wire) serial communications; even at high baud rates (such as 9600 baud) this port will support communications over a 4000-ft (1200-m) serial cable. -
Page 37: Figure 3-1. Setting Termination Resistors
CHPA SERIES If RMTPNL is selected, no further entries are required. If USER is selected, the port becomes a second CIF port. When USER is selected, the port must be reconfigurated from the default (RMTPNL) to a user defined configuration. Refer to Table 3-1 for J6 pin assignments. Refer to the “Computer Interface”... -
Page 38: Rf Switch System Interface
CHPA SERIES Table 3-1. Serial Remote Interface Pin Assignment (J6) (continued) Pin # Signal Name Remarks Receive Data (-) Data received by CHPA (RS-422/485) Signal Ground Receive Data (+) Data received by CHPA (RS-422/485) Not used Not used Send Data (+) Data sent out of CHPA (RS-422/485) Table 3-1 Note: The Serial Remote Interface uses a protocol and command set very similar to the Computer Interface port. -
Page 39: Table 3-2. Low Rf Relay Function
CHPA SERIES In Rigid mode, the Low RF Relay will indicate that the CHPA’s RF output is below the Low RF Alarm level any time this condition occurs, except during an RF Switch port RF Inhibit command. The Rigid mode can be thought of as the strictest operation of the Low RF Relay. In Flexible mode, the Low RF Relay will indicate that the CHPA’s RF output is below the Low RF Alarm level any time this condition occurs during the Transmit state, except during any RF Inhibit, and during Fault state. -
Page 40: External Interlocks Interface
CHPA SERIES Table 3-3. RF Switch Pin Assignment (J5) Pin # Signal Name Remarks Low RF NC Relay NC 1 (Normally closed when coil is de-energized; closed to pin 2 during Low RF Alarm or the Fault state.) Low RF Common Relay Common 1 Low RF NO Relay NO 1 (Normally open when coil is de-energized;... -
Page 41: Figure 3-2. Setting Serial Format
CHPA SERIES The CHPA External Interlocks Interface is located at connector J8 on the rear panel of the CHPA. It is a 9-pin D-type connector, with pin assignments as shown in Table 3-4. Figure 3-2. Setting Serial Format Table 3-4. Interlocks Interface Pin Assignments (J8) Pin # Signal Name Remarks... -
Page 42: Computer Interface
CHPA SERIES 3.6 Computer Interface The Computer Interface (CIF) port is used to control and monitor the CHPA from an external data terminal or computer with software provided by the user. The CIF port can be configured to either RS-232 or RS-422/485 (4-wire) serial hardware format. Using the RS-422/485 serial hardware format allows an addressable multipoint buss to be implemented, providing serial communications between a computer and up to 16 other RS-422/485 equipped devices. -
Page 43: Computer Interface (Cif) Protocol
CHPA SERIES The CIF serial port parameters are set up using the CIF Configuration menu on the front panel. Refer to Chapter 4, “Initial Power-On and Checkout,” for detailed procedures regarding CIF serial port setup. Table 3-5. CIF (Computer Interface) Pin Assignment (J7) D-shell Pin Number Rear Panel Signal Name Remarks... -
Page 44: Command And Response Format
CHPA SERIES The user’s computer generates and sends packets to the CHPA that can contain only one command and associated parameters. The CHPA can process only one received packet at a time; packets are not queued for processing. If a command is sent to the CHPA CIF port, a response will be returned usually within 100 ms. -
Page 45: Address Byte
CHPA SERIES Commands: Header byte = STX (ASCII 02) Ending byte = ETX (ASCII 03) Responses: Header byte = ACK (ASCII 06) is used if the CHPA accepted the command. Header byte = NAK (ASCII 21) is used if the CHPA rejected the command. A reject code (or codes) indicates why the command was rejected. -
Page 46: Check Byte
CHPA SERIES Table 3-6. Reject Bytes (continued) ASCII Character Decimal Meaning Slow command in execution The command was not executed; high voltage is OFF. The command was not executed; RF is inhibited. The command was not accepted; unit is in Fault. 3.9.6 Check Byte (Check byte is under CIF CONFIGURATION as CHECKBYTE.) -
Page 47: Carriage Returns And Line Feeds
CHPA SERIES Notes: 1. Parity errors will cause the command to be ignored and no response message to be issued. 2. If any character is received before or during the transmission of a response message, the response message will be deleted. This will not interfere with the execution of a command. 3. -
Page 48: Table 3-7. Query Commands
CHPA SERIES Table 3-7. Query Commands ASCII Byte Decimal Commands ID/Version Query. An eight-character string will be returned that identifies the CHPA model and computer interface version. Summary Status Query. Two bytes of status are returned Secondary Status Query. Two bytes of status are returned. Fault/Miscellaneous Status Query. -
Page 49: Table 3-8. Chpa Commands
CHPA SERIES Table 3-8. CHPA Commands ASCII Byte Decimal Command Definition Transmit. This command turns the beam on. Standby. This command turns the beam off. RESET. This command is the equivalent of pushing the CANCEL button on the front panel. Set Attenuator. -
Page 50: Slow Commands
CHPA SERIES Table 3-8. CHPA Commands (continued) ASCII Byte Decimal Command Definition Reset to Defaults. Reset the unit operating state and fault/alarm trip point values to firmware defaults except Helix Over Voltage, Helix Under Voltage, and Helix Average Over Current fault trip limits. Table 3-8 Notes: If the ALC mode is active, it will be terminated. -
Page 51: Status Byte Definitions
CHPA SERIES 3.11 Status Byte Definitions Status bytes are the responses to Query commands. Each bit represents some piece of information; the bit definitions are provided in Tables 3-11 to 3-14. Bit 0 corresponds to the least significant bit (LSB) and bit 7 corresponds to the most significant bit (MSB). Bit 7 will contain the parity bit, if chosen. -
Page 52: Table 3-12. Secondary Status Bytes
CHPA SERIES Table 3-11 Notes: CHPA Operating State is indicated as follows: CHPA State Not used Heater Time Delay Standby Beam On Sequence Beam On Beam On and RF Inhibited Beam Off Sequence Fault Table 3-12. Secondary Status Bytes Byte Bit Definition 7(MSB) Parity... -
Page 53: Table 3-13. Fault And Miscellaneous Status
CHPA SERIES Table 3-13. Fault and Miscellaneous Status Byte Bit Definition 7(MSB) Parity Complement of bit 5 Helix Over Voltage Helix Under Voltage Helix Average Over Current Power Supply Arc Trip DC Buss Under Voltage 0(LSB) Helix Voltage Detected in Standby 7(MSB) Parity Complement of bit 5... -
Page 54: Table 3-13. Fault And Miscellaneous Status (Continued)
CHPA SERIES Table 3-13. Fault and Miscellaneous Status (continued) Byte Bit Definition 7(MSB) Parity Complement of bit 5 RF Inhibit—Switch Port RF Inhibit—External Interlock RF Inhibit—CIF RF Inhibit—Local RF Inhibit—Remote Panel 0(LSB) Not used Table 3-13 Note: *Bit is set for the fault condition. Table 3-14. -
Page 55: Id/Version Message
CHPA SERIES Table 3-14. Information/Error Messages (continued) Byte Bit Definition (set if condition exists since last query) 7(MSB) Parity Complement of bit 5 RF O/P power setting command terminated due to the cessation of high voltage. RF O/P power setting command terminated before reaching requested value. ALC activity terminated due to cessation of high voltage. - Page 56 CHPA SERIES This page is intentionally left blank. THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS & POWER INDUSTRIES. 3-22 .01023245 R REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED...
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Page 57: Chapter 4 Initial Power On And Checkout
CHPA SERIES Chapter 4 Initial Power On and Checkout 4.1 Overview This chapter describes the procedures for turning on the CHPA for the first time. It also describes the steps for initial checkout of the system, and for setup of the Remote and Computer Interface (CIF) serial ports. -
Page 58: Using The Front Panel
CHPA SERIES WARNING! LETHAL VOLTAGES OF UP TO 13 KVDC ARE PRESENT INSIDE THE CHPA WHEN POWER IS APPLIED TO THE SYSTEM. ALWAYS TURN POWER OFF BEFORE SERVICING THE CHPA. DO NOT ATTEMPT TO REPAIR THE CHPA UNLESS EXPERIENCED IN SERVICING BOTH MICROWAVE AND HIGH-VOLTAGE SYSTEMS. -
Page 59: Initial Power-On Procedures
Should a fault or maladjustment be discovered during initial power-on, turn to Chapter 5, “Operation,” for help in diagnosis; or contact CPI customer support (for telephone number see Appendix D). Initial power-on and checkout are to be performed in the following order: •... -
Page 60: Verifying Operational Settings
CHPA SERIES • If XMIT SELECT is shown on the display, press the TRANSMIT/STANDBY pushbutton until the XMIT SELECT is no longer shown. (This action will prevent the CHPA from transitioning to the Transmit state at the conclusion of HTD.) •... -
Page 61: Table 4-1. Helix And Rf Settings Ranges
CHPA SERIES 1. Press the SPECIAL button followed by the . (decimal) button. Key in 15; the display will change to the entry for the FAAC. 2. Enter the FAAC, then press ENTER. 3. Press FUNCTION to enter the Factory Authorized Access Mode (FAAM). The Test Mode LED will flash to indicate that the unit is in FAAM. -
Page 62: Setting Serial Remote And Cif Port Parameters
CHPA SERIES Table 4-1. Helix and RF Settings Ranges (continued) Fault Name Minimum Nominal Factory Maximum Set for TWT Preset Defaults Label High RF Alarm 700 W 900 W Rated High RF Fault 750W 900W Rated+5% High Reflected RF 50 W 80 W Helix Voltage 1.00 kV... -
Page 63: Verifying Rf Output Level
CHPA SERIES 4.8 Verifying RF Output Level After verifying the factory settings and test functions of the CHPA in Standby state, the next step will be to place the CHPA in the Transmit state to verify the RF Output operation. (Refer to Table 5-1 in Chapter 5.) Perform the following steps: 1. -
Page 64: Verifying Rf Alarm And Rf Fault Trip Points
CHPA SERIES 4.9 Verifying RF Alarm and RF Fault Trip Points This part of the procedure verifies that the RF alarm and RF fault operation is functioning normally. These settings were verified in a previous procedure. (Refer back to that procedure if necessary.) 7. -
Page 65: Testing The Chpa Via Computer Control
The CHPA uses an RS-422 serial remote interface to support a CPI CHPA Remote Control Panel. (Refer to Chapter 3 for a discussion of how to use this port as an alternative port for computer communications.) - Page 66 CHPA SERIES For the purposes of the following test, the Remote unit should be used within sight of the CHPA to assure that the Remote unit’s appearance is consistent with the CHPA’s front panel report. 1. Verify that the Remote is attached to J6, a female 9-pin D-shell connector. 2.
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Page 67: Chapter 5 Operation
CHPA SERIES Chapter 5 Operation 5.1 Overview The CHPA features a microprocessor control system that accepts control input and provides CHPA status and meters. This chapter describes CHPA operation via a control panel; details on control content are in Chapter 8, Appendix B. For CHPA operation via the Computer Interface port, see Chapter 3, “Interfaces.”... -
Page 68: Essential Chpa Operating Procedures
CHPA SERIES 5.2 Essential CHPA Operating Procedures 5.2.1 Transmit The CHPA’s sole purpose is to amplify a microwave signal. This procedure describes how to turn on the CHPA, place it in Transmit, and set the RF output. Thoroughly read this procedure before performing it. -
Page 69: Normal Shutoff
CHPA SERIES 6. Set RF output to the desired level. To do so a. Press the MENU button once. b. Enter the desired power level in the units displayed. (To change the units used to report RF readings and settings, toggle the FUNCTION button until RF DISPLAY appears on Line 4. -
Page 70: Chpa States And Description
CHPA SERIES 5.5 CHPA States and Description The operation of the CHPA may be divided into several states and sequences. They are as follows: • POST (Power-On Self-Test)—Initial power on. • HTD (Heater Time Delay)—Beam-off state while cathode heats to operating temperature. •... -
Page 71: Heater Time Delay (Htd) State
CHPA SERIES C P I A T C O M C H P A P O W E R E L F T E S T E S While the POST screen is displayed, all self-tests are performed. If the front panel fails to establish communications with the controller, the panel will report a communications failure. -
Page 72: Standby State
CHPA SERIES In the tube during the Transmit state (Beam On), a beam of electrons is accelerated from an electron cloud around the cathode, past the anode, through the helix structure, and finally coming to rest in the collector structure. To create the cloud of free electrons, the cathode is heated by the heater. -
Page 73: Transmit State
CHPA SERIES 5.9 Transmit State If the user pushes the TRANSMIT button, the unit will go through the Beam On Sequence to the Transmit state. The CHPA will be in the Beam On Sequence for approximately two seconds before reaching the Transmit state. The display shows these features: Local mode, Automatic RF Level Control (ALC), time in 12- hour format, Beam On Sequence, and default meters. -
Page 74: Chpa Control Modes And Hierarchy
CHPA SERIES While in the Fault state, the display will flash and the beeper will sound once every second. The current fault(s) is/are displayed on Line 2; press either arrow key to cycle through these faults. To view faults that occur during the Auto Fault Recycle mode, look at the Fault Log (see Appendix B for a full description). -
Page 75: Rf Control Modes
CHPA SERIES 5.12 RF Control Modes The CHPA features two RF Control modes: • ALC (Automatic Level Control) mode (ALC is displayed on Line 1) • Open Loop mode (nothing special is displayed) Either mode may be selected under the RF Control category. Press the MENU button until Line 3 displays RF CONTROL;... -
Page 76: Special Chpa Functions
CHPA SERIES 5.13 Special CHPA Functions The user may request basic features such as CHPA states and Control modes directly using front panel buttons. Most CHPA features, however, require a more sophisticated user interface. To provide logical access to this information, these special CHPA features are grouped into menu categories. -
Page 77: Exiting A Menu
CHPA SERIES 5.15 Exiting A Menu The user may return from any category to the selected meter display by pressing the buttons on either Line 3 or Line 4. 5.16 Data Entry Rules Numerical data will not take effect until the user has pressed the ENTER button. Arrow key data entry will update when the arrow keys are pressed. -
Page 78: Table 5-1. Front Panel Categories (Continued)
CHPA SERIES Table 5-1. Front Panel Categories (continued) Category Name Purpose Fault Trip Setting* Helix Over Voltage Fault Helix Under Voltage Fault Helix Avg Over Current Fault Helix Voltage Detected in Standby Factory Tests* Reset Elapsed Time Meters* Reset Heater Elapsed Time Meter Reset Beam On Elapsed Meter Reset to Factory Defaults* HVPS Test Mode**... -
Page 79: Quick Access Codes
CHPA SERIES Table 5-1. Front Panel Categories (continued) Category Name Purpose Computer Interface (CIF) Parameters Device Address Baud Parity Protocol Check Byte Type CR Enable LF Enable Accept Bad Check Byte Loopback Test Installation Test Controller Software Version Elapsed Hours Beam On Elapsed Time Meter Heater Elapsed Time Meter Flash Programming Access Code... - Page 80 CHPA SERIES To use the Quick Access Codes: 1. Press the SPECIAL button. 2. Use the numerical keypad to enter the desired two-digit QAC; pressing ENTER will not be necessary as it is for other numerical entries. L O C A L A L C O U T Q U I...
- Page 81 CHPA SERIES 20 Controller Software Version 21 Heater Elapsed Time Meter 22 Beam On Elapsed Time Meter Factory Authorized Quick Access Codes (50-99) are only accessible once the Factory Authorized Access Code (FAAC) has been entered. See previous description of the FAAC. 50 Helix Over Voltage Fault 51 Helix Under Voltage Fault 52 Helix Average Over Current Fault...
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Page 83: Chapter 6 Maintenance
CHPA SERIES Chapter 6 Maintenance 6.1 Overview This chapter provides instructions for routine maintenance of the compact high power Traveling Wave Tube Amplifier (CHPA) and performance testing. It covers procedures and test equipment for scheduled maintenance tasks, electrical calibration, and performance testing. It also explains how to diagnose and repair common problems to the circuit-card assembly level (PCB). -
Page 84: Mechanical Preventive Maintenance
CHPA SERIES Preventive maintenance is divided into mechanical maintenance, electrical calibration, and performance testing. Also provided is a description of how to care for spare TWTs and start-up procedures to follow when the HPA is turned off for extended periods. The recommended maintenance schedule is shown in Table 6-1. -
Page 85: Table 6-1. Preventive Maintenance Schedule Chpa (Continued)
Calibrated Waveguide Coupler Narda, HP, with others. Directional Coupler. Coupling factor 40 dB, directivity 30 dB. Dummy Load, 3 kW, Waveline, Narda, etc. HV Breakout Box, CPI part number 01020673. Adapter Cable Set, part numbers 01020681,01020682. 0– to 60–V, 3-A DC power supply. Power supply dummy plug, part number 01000474-02. -
Page 86: Visual Inspection
CHPA SERIES Table 6-2. Recommended Test and Service Equipment Description (continued) Digital Thermometer, Fluke or equivalent. Basic Tool Kit Time Motion tools. Crystal Detector HP 8470B—2. Radiation Detector Narda 8611 meter with 8621 probe. Fixed RF Attenuator Set (3, 6, 10, 20 dB) H11581A. Oscilloscope 100 MHz, 2 channel, 5 MV sensitivity. -
Page 87: Inspecting And Cleaning Air Filters
CHPA SERIES 6. With AC power disconnected at its source, retighten the main power line terminal (TB1) with an insulated screwdriver. The gradual failure of this terminal is indicated by a decrease of contact pressure caused by thermal expansion and contraction. 7. -
Page 88: Checking B1 Collector Blower
CHPA SERIES 6.4.4 Checking B1 Collector Blower The collector blower is a rotating component subject to wear. Inspect it every six months. Follow these steps to check operation of the collector blower: 1. With the CHPA in Standby state, open the top cover. 2. - Page 89 CHPA SERIES • Heater voltage backed off, beam off during downtime • Heater voltage full, beam off during downtime If TWT tubes are stored for extended periods of time, the TWTs should be operated at least every six months using the following procedure.
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Page 90: Performance Testing
CHPA SERIES 6.7 Performance Testing At six-month intervals, perform the tests for power and gain, gain response, and radiation levels, and record their results. If the results are not satisfactory, then you might have to troubleshoot the RF system and replace assemblies. Refer to this section as required. You will need the following equipment or equivalents as described in Table 6-1: •... -
Page 91: Table 6-3. Chpa Performance Test Results
COLLECTOR 2 VOLTAGE ____________________kV NOTE 1 BEAM CURRENT ____________________A NOTE 1 HELIX CURRENT (NO RF) ____________________mA NOTE 1: MEASURED USING OPTIONAL “BREAK-OUT BOX” AVAILABLE FROM CPI. FREQ POWER OUT—MAXIMUM GAIN (DO NOT EXCEED RATED) @ RATED/MAX POWER F1________ ___________________________ _______________________... -
Page 92: Figure 6-1. Twt Amplifier Test Setup
CHPA SERIES Figure 6-1. TWT Amplifier Test Setup THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS & POWER INDUSTRIES. 6-10 .01023245 R REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED... -
Page 93: Chapter 7 Drawings And Schematics
CHPA SERIES Chapter 7 Drawings and Schematics This chapter contains drawings and schematics for the 600W / 700W /750W Compact High Power Amplifier (CHPA). Table 7-1 contains a list of drawings and their drawing numbers. Table 7-1. Compact HPA Drawings Title Drawing Number Assy, Power Supply, Compact HPA &... - Page 94 CHPA SERIES This page is intentionally left blank. THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS & POWER INDUSTRIES. .01023245 R REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED...
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Page 95: Chapter 8 Supplementary Data
CHPA SERIES Chapter 8 Supplementary Data Appendix A: Specifications Appendix B: Control Appearance and Content Appendix C: Replaceable Parts Appendix D: Warranty/Support Information Appendix E: Options and Features THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS & POWER INDUSTRIES. .01023245 R REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED... - Page 96 CHPA SERIES This page is intentionally left blank. THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS & POWER INDUSTRIES. .01023245 R REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED...
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Page 97: Appendix A Specifications
CHPA SERIES Appendix A Specifications Chapter 7 includes specifications for all CHPAs listed in this manual. THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS & POWER INDUSTRIES. .01023245 R REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED... - Page 98 CHPA SERIES This page is intentionally left blank. THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS & POWER INDUSTRIES. .01023245 R REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED...
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Page 99: Appendix B Control Appearance And Content
CHPA SERIES Appendix B Control Appearance and Content B.1 Overview This chapter lists the function of each control key, indicator, and display item on the HPA. For operational procedures, see Chapter 5, “Operation,” and Chapter 4, “Initial Power-On and - Checkout.”... -
Page 100: Leds
CHPA SERIES Table B-1. Front Panel Button Description Button Name Button Function 0–9 Press these buttons for numerical data entry. .(decimal point) Press this button to enter a decimal point. This button is also used in conjunction with the SPECIAL button when entering Quick Access Codes (see SPECIAL button in this table). -
Page 101: Beeper
CHPA SERIES Table B-2. Front Panel LEDs Name Color Function Recycle Fault Green Flashes to indicate that the unit successfully recycled out of a fault. Test Mode Yellow (flashing) Flashes to indicate that the unit is in Factory Authorized Access Mode. - Page 102 CHPA SERIES HPA in HTD state. (HPA will change to Transmit state after HTD has elapsed.) H T D X M I E L E C T HPA in Standby state. T A N D B Y HPA in Beam On Sequence. B E A M E Q U E N C E HPA in Beam Off Sequence.
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Page 103: Meters
CHPA SERIES Line 3—This line displays either meters or menu categories; it defaults to the meter display shown. To toggle through the meters, press the Line 3 button. To toggle through the menu categories, press the MENU button. H L X X X . -
Page 104: Meter List
CHPA SERIES B.6.4 Meter List Press the Line 3/4 button to toggle through the following meter list: Default Line 3: Helix Default Line 4: Attenuator Setting Reflected RF Beam Current B.7 Fault Messages That Correspond to Digital Status Lines Interlocks Open Fault N T E R L O C K S O P E N TWT Over Temperature Fault... -
Page 105: Fault Messages Generated By Limit Comparisons
CHPA SERIES B.8 Fault Messages Generated By Limit Comparisons The microprocessor controller monitors voltages that correspond to HVPS (High Voltage Power Supply) voltage and current parameters as well as RF power (drive, output, and reflected) parameters. When a parameter falls outside of a predefined window (some windows may be active only during certain HPA states or modes), a fault is generated and one of the following messages will appear: Helix Over Voltage... -
Page 106: Alarms
CHPA SERIES B.9 Alarms When an alarm occurs, the alphanumeric display flashes (between 37 percent and 100 percent illumination). High RF Alarm O U T X X X X W Low RF Alarm O U T X X X X W L O R F The AC Power Fail Alarm and BB-RAM Error Detected Alarm may occur at any time and will be displayed on Line 2. -
Page 107: Control Menu
CHPA SERIES Line 2 RF Inhibit mode source report, continued: N H I L O C A L N H I R E M O T E N H I N H I E X T N T L K B.10 Control Menu The user may request basic features such as HPA states, Control modes, and Fault Recycle modes directly using front panel buttons. -
Page 108: Table B-3. Front Panel Categories
CHPA SERIES Table B-3. Front Panel Categories Category Name Purpose RF Control RF Output Setting Attenuator Setting RF Power Mode RF Inhibit RF Display (W, dBW, dBm) Suppress Peak Mode (disables RF peak mode metering) Linearizer Control (optional) Gain Phase Amplitude RF Trip Limits/Switch Port Relay High RF Alarm... -
Page 109: Table B-3. Front Panel Categories (Continued
CHPA SERIES Table B-3. Front Panel Categories (continued) Category Name Purpose Time/Date Set User Set Heater Time Delay 12/24 Hour Format Hour:Minute Set Month Date Year US Daylight Savings Remote Interface Parameters Mode (If RMTPNL is displayed, the other selections under this menu will not be available.) Device Address Baud... -
Page 110: Table B-4. Default Values For User Features
CHPA SERIES Table B-4 defines the default values for all user features. These values are superseded by user- chosen values, which are stored in a battery-backed RAM. All test modes default to OFF; test mode settings during HPA operation are not kept in battery-backed RAM. Table B-4. -
Page 111: Categories
CHPA SERIES B.11.1 Categories The following categories are listed in full detail. Special considerations regarding each category are listed. B.11.2 RF Control The RF Control category provides access to all RF controls and miscellaneous RF display preferences. See Table B-5. Table B-5. -
Page 112: Linearizer Control (Optional
CHPA SERIES The sample screen (Lines 1-3) for RF Control is as follows: L O C A L T A N D B Y C O N T R O L Depending on the RF Display setting, either of the first two lines will appear on Line 4 for the RF Out Setting. -
Page 113: Linearizer Adjustment
The following is an abbreviated procedure for tuning the linearizer. If you have any questions, please contact CPI Product Support. • RF Gain - this control adjusts the overall gain of the linearizer and may be adjusted after the linearizer is aligned to achieve the desired amplifier gain. -
Page 114: Rf Trip Limits/Switch Port Relay Settings
CHPA SERIES intermodulation products without linearizer. It is best to now finely tune the Phase and Magnitude controls to assure that the best tuning has been achieved - this is an iterative process, and some fine tweaking is usually necessary. B.13 RF Trip Limits/Switch Port Relay Settings Both RF alarms and faults will be active simultaneously. -
Page 115: Fault Log
CHPA SERIES Line 4 is shown for either watts (W) or dB as set by the RF Display: A L A R M X X X W A L A R M X X . X d B W A U L T X X X W A U L T X X . -
Page 116: Factory Authorized Access Code (Faac
CHPA SERIES To delete all captured fault sets, press the CANCEL button while in the Fault Log. To leave the Fault Log, press the MENU button to cycle to the next Menu category or press either the Line 3 or the Line 4 button to return to the selected meters. L O C A L T A N D B Y A U L T... -
Page 117: Fault Trip Setting
CHPA SERIES A C T O R Y A U T H M O D E T H I M O D E C A N C A U S H P A D A M A G E M E N U E X I To continue, press the FUNCTION button. -
Page 118: Reset To Factory Defaults
CHPA SERIES B.13.6 Reset to Factory Defaults Reset to Defaults allows the user to reset all parameters (fault settings, etc.) to firmware defaults. Settings not affected by this command are: Helix Avg. Over Current Fault, Helix Over Voltage Fault, Helix Under Voltage Fault, Beam On Elapsed Time meter, and Heater Elapsed Time Meter. -
Page 119: User Tests
CHPA SERIES B.13.8 User Tests User Tests includes miscellaneous hardware tests available to the user. See Table B-7. Table B-7. User Tests and Results Function Name Possible Entries/Results Description Lamp Test Press ENTER to perform test. No Illuminates all luminescent devices on the result is reported. -
Page 120: Time/Date Set
CHPA SERIES B.13.9 Time/Date Set In addition to setting the time and date, this category also includes the User Heater Time Delay setting. This delay is added to the calculated Heater Time Delay; the result is the actual Heater Time Delay. See Table B-10 for time/date settings. Table B-8. -
Page 121: Remote/Computer Interface Parameters
CHPA SERIES Line 4 displays are as follows: O R M A T : H R : E T : X X : M O N T H E T : D A T E E T : Y E A R : X X X X M E : Y E S... -
Page 122: Table B-9. Computer Interface Parameters (Continued
CHPA SERIES Table B-9. Computer Interface Parameters (continued) Function Name Possible Entries Description Bad Check Byte Toggle between YES/NO Loopback Test Press ENTER to start (sends “V”); will display PASS if unit sees itself (receives “V”), FAIL if it doesn’t. Press ENTER again or leave this item to stop the test. -
Page 123: Table B-10. Computer Interface Parameters (Continued
CHPA SERIES Table B-10. Computer Interface Parameters (continued) Function Name Possible Entries Description Loopback Test Press ENTER to start (sends “V”); will display PASS if unit sees itself (receives “V”), FAIL if it doesn’t. Press ENTER again or leave this item to stop the test. For the unit to see itself, loop TX+ to RX+ and TX- to RX-. -
Page 124: Software Versions
CHPA SERIES B.13.11 Software Versions This category will provide the software versions that reside in the CHPA controller and the control panel. See Table B-12. Table B-11. Software Versions Function Name Response Format Description Controller Version number The last character shows if the program is running from EPROM, “R”... -
Page 125: Quick Access Codes
CHPA SERIES B.14 Quick Access Codes Quick Access Codes (QAC) provide quick access to various CHPA features. If a QAC is used to access a menu category or a specific function under a menu category, that item will be displayed as if the MENU and FUNCTION buttons had been used to access that category or entry. - Page 126 CHPA SERIES 10 Low RF Fault 11 High Reflected RF Fault 12 Low RF Relay Preference 13 Fault Relay Preference 14 Fault Log 15 Factory Authorized Access Code 16 Lamp Test 17 Time/Date Set 18 Remote Interface Parameters 19 CIF Parameters 20 Controller Software Version 21 Heater Elapsed Time Meter 22 Beam On Elapsed Time Meter...
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Page 127: Post Faults
RAM size Error: If SRAM (U2) on controller is smaller than 128Kx8, this error will appear. B.16 Software Error Codes These errors should never appear—if you see a Software Error Code, contact CPI Service and report the code along with the operating condition of the unit when the error was observed. -
Page 128: Flash Ram - Operation And Programming
CHPA SERIES B.16.1 Flash RAM - Operation and Programming A Flash RAM is a memory device with the two best characteristics of a disk drive - non-volatile memory and read/write capability. In the CHPA, a Flash RAM contains the M&C system’s program contents. - Page 129 CHPA SERIES 3. The CHPA’s display will show: C H P A P R O G R A M L O A D E R T A B L I C O M M U N I C A T I H O S T E M 4.
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Page 130: Error Messages Associated With The Flash Ram
CHPA SERIES 10. After Flash RAM programming is complete, the display will show: C H P A P R O G R A M L O A D E R P R O G R A M M I C O M P L E T E P R E S A N Y K E Y... - Page 131 CHPA SERIES Multiple FLASH MEMORY ERASING ERRORS may mean that the Flash RAM device is faulty. Before arriving at that conclusion, take steps to assure a solid cable connection between the PC and CHPA; also, review troubleshooting items 3 and 4. L A S M E M O R Y P R O G R A M M I...
- Page 132 CHPA SERIES 4. If the PC and CHPA never successfully communicate, try the following: a. Check the serial cable connection. Use a nine wire pin-to-pin cable (these cables are sometimes refered to as monitor extension cables). No null modem is required (a null modem swaps the pin locations of the TX and RX lines) and none should be installed.
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Page 133: Appendix C Replaceable Parts
CHPA SERIES Appendix C Replaceable Parts Table C-1. Replaceable Parts Listing Description CPI Part Number CCA, Power Factor Correction 01020300-00 CCA, Power Processor 01020310-00 CCA, Power Processor, 750 DBS CHPA 01020310-07 HV Module 01020320-00 HV Module, 750 DBS CHPA 01022079-00... - Page 134 TWT, 600W DBS-Band (17.3 to 17.8 GHz) 01022064-01 TWT, 750W DBS-Band (17.3 to 18.4 GHz) 01022067-01 TWT, 750W DBS-Band CPI (17.3 to 18.4 GHz) 01034387-01 TWT, 750W DBS-Band (17.3 to 18.1 GHz) 01034387-00 THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS & POWER INDUSTRIES.
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Page 135: Appendix D Warranty And Support Information
CHPA SERIES Appendix D 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 (If applicable): Refer to separate folder titled “ Warranty and Support.” THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS &... - Page 136 CHPA SERIES This page is intentionally left blank. THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS & POWER INDUSTRIES. .01023245 R REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED...
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Page 137: Appendix E Options And Features
CHPA SERIES Appendix E Options and Features Options • Integral Linearizer • Remote Control Panel • Redundant and Power Combined Subsystems Features • Meets IEC-215/555 Safety/Harmonic Standards as well as 89/336 EEC/EMC Standards (CE Marked) • MTBF of 40,000 hours, including TWT •... - Page 138 CHPA SERIES This page is intentionally left blank. THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS & POWER INDUSTRIES. .01023245 R REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED...
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Page 139: Appendix F Optional L-Band Buc
12.75 - 13.25 GHz If the BUC Local Oscillator (LO) reference fails or drifts outside of the capture range, a “BUC alarm” signal will be reported on the optional CPI remote panel or through the supplied “Setup & Remote software”. -
Page 140: Precautions
CHPA SERIES • Mux Reference: Most L-band modems now have a built-in 10 MHz reference. The CPI BUC can be configured to accept this reference, which is multiplexed with the L-band signal on the same connector. This is CPI’s standard configuration, and it is recommended for most applications.