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CPI 0102324500rR Manual

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INSTALLATION, OPERATION, AND
PREVENTATIVE MAINTENANCE
M A N U A L
CHPA (COMPACT HIGH POWER AMPLIFIER)
0102324500rR
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
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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  • Page 1 INSTALLATION, OPERATION, AND PREVENTATIVE MAINTENANCE M A N U A L CHPA (COMPACT HIGH POWER AMPLIFIER) 0102324500rR 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...
  • 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

    CHPA S ERIES 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 ......................
  • Page 4 CHPA S ERIES 2.2  PRE-INSPECTION ........................2-1  2.3  UNPACKING ..........................2-1  2.4  PREPARING FOR INSTALLATION ..................2-2  2.5  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 ...
  • Page 5 CHPA S ERIES 3.9.7  CARRIAGE RETURNS AND LINE FEEDS ..............3-12  3.10  COMMANDS ..........................3-12  3.10.1  SLOW COMMANDS ......................3-15  3.11  STATUS BYTE DEFINITIONS ....................3-16  3.12  ID/VERSION MESSAGE ......................3-20  CHAPTER 4 INITIAL POWER ON AND CHECKOUT ..............4-1  4.1 ...
  • Page 6 CHPA S ERIES 5.7  HEATER TIME DELAY (HTD) STATE .................. 5-5  5.8  STANDBY STATE ........................5-5  5.9  TRANSMIT STATE ........................5-6  5.10  FAULT STATE ..........................5-7  5.11  CHPA CONTROL MODES AND HIERARCHY ..............5-7  5.12  RF CONTROL MODES ......................5-8  5.13 ...
  • Page 7 CHPA S ERIES APPENDIX A WARRANTY AND SUPPORT INFORMATION ............ A-1  APPENDIX B CONTROL APPEARANCE AND CONTENT ............B-1  B.1  OVERVIEW ..........................B-1  B.2  BUTTONS ........................... B-1  B.3  LEDS ............................B-2  B.4  BEEPER ............................B-3  B.5  ALPHANUMERIC DISPLAY DEFINITION ................. B-3  B.6 ...
  • Page 8 CHPA S ERIES B.13.7  CHPA HVPS TEST MODE ....................B-18  B.13.8  USER TESTS ........................B-19  B.13.9  TIME/DATE SET ....................... B-20  B.13.10  REMOTE/COMPUTER INTERFACE PARAMETERS ..........B-21  B.13.11  SOFTWARE VERSIONS ....................B-23  B.13.12  ELAPSED HOURS INFORMATION ................B-23  B.14  QUICK ACCESS CODES......................B-24  B.15 ...
  • Page 9 CHPA S ERIES FIGURE 4-1. THE CHPA SERIES FRONT PANEL ..............4-2  FIGURE 5-1. CONTROL PANEL ....................5-1  FIGURE 5-2. EXAMPLE: ACCESSING CHPA FEATURES ............. 5-9  FIGURE 6-1. TWT AMPLIFIER TEST SETUP ............... 6-10  FIGURE B-1. FRONT PANEL PICTURE ................. B-1  List of Tables TABLE 1-1.
  • Page 10 CHPA S ERIES TABLE 4-1. HELIX AND RF SETTINGS RANGES ..............4-5  TABLE 5-1. FRONT PANEL CATEGORIES ................5-11  TABLE 5-1. FRONT PANEL CATEGORIES (CONTINUED) ..........5-12  TABLE 6-1. PREVENTIVE MAINTENANCE SCHEDULE CHPA ..........6-2  TABLE 6-2. RECOMMENDED TEST AND SERVICE EQUIPMENT DESCRIPTION ....6-3  TABLE 6-3.

  • Page 11: Safety

    CHPA S ERIES Safety Introduction In addition to the High Voltage Equipment Personnel Operating Guidelines 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 12: General Guidelines

    CHPA S ERIES General Guidelines In addition to the above, the following practices are proven effective for personnel who deal with high voltage equipment. a. Hands off. Avoid contact with potential sources of high voltage. Keep hands out of the equipment when it is operating.
  • Page 13 CHPA S ERIES A good operating practice is to check the potential between the equipment chassis and the earth ground. As voltage levels increase, the protection from insulation and air gap diminishes. For example, in a piece of equipment that involves beam voltages of about 16kV, the beam transformers appear safe with massive insulation on the outside of the coils.

  • Page 14: Microwave Radiation

    Levels of microwave radiation that do not cause immediate physical discomfort can cause long term complications. CPI Satcom Division equipment amplifies an RF signal from an external source. Operating amplifiers with the input not terminated may cause oscillation and high levels of RF radiation.

  • Page 15: Physical Safety

    CHPA S ERIES e. If it is only possible to detect the source of the leak with the amplifier in transmit. Drive the amplifier at a low output power level and use an RF radiation meter to locate the leak. Once the leak is found, put the amplifier in standby or turn it off.
  • Page 16 CHPA S ERIES 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...

  • Page 17: Chapter 1 Introduction

    CHPA S ERIES 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 18: Figure 1-1. The Chpa

    CHPA S ERIES Table 1-1. CHPA Model Number and Frequency Ranges (continued) Model No. Frequency Range (GHz) Rated Power (Watts) VZU-6997AA (obsolete) 13.00 - 13.25 VZU-6997AD 13.75 - 14.50 VZU-6997AJ (obsolete) 12.75 - 13.25 VZU-6995AY 17.30 - 18.40 VZU-6996AY 17.30 - 17.80 VZU-6997CY 17.30 - 18.40 VZU-6997AX...

  • Page 19: About This Manual

    CHPA S ERIES 1.2 About This Manual This manual contains information that describes installation, operation, and maintenance procedures for the Compact High Power Amplifier (CHPA) series. Because specialized training is required for some phases of installation and repair, certain parts of this manual are directed only to trained personnel.

  • Page 20: Major Subsystems And Their Functions

    CHPA S ERIES 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 21 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...

  • Page 22: 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 23: Power Processor Module

    CHPA S ERIES 1.4.4 Power Processor Module The power processor circuits provide the necessary line and load regulation of the input 375 VDC bus, which is converted via the switch regulator and bridge circuit to a nominal 230 VAC, 25 kHz to drive the high-voltage module. A sample of the helix high-voltage output is returned to the switch regulator for error feedback correction and sends a pulse-width modulated signal through an optical isolator to the switching transistors.

  • Page 24: Lru Philosophy

    Personnel safety is of utmost importance and is safeguarded by proper grounding and also by access interlocks and covers that prevent physical entry into the high-voltage sections. 1.6 Optional Features To customize and enhance the functioning of the CHPA, CPI provides a range of options. These include the following: •...

  • Page 25: Chapter 2 Unpacking And Installation

    CHPA S ERIES 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 26: Preparing For Installation

    CHPA S ERIES 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 27: Electrical Connections

    CHPA S ERIES 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 28: Grounding

    THE CHPA UNTIL COMPLETION OF THE INSTALLATION. WARNING! CONSTRUCT THE AC PRIME POWER CABLE ASSEMBLY IN ACCORDANCE WITH LOCAL AND/OR NATIONAL ELECTRICAL CODES. CPI RECOMMENDS THAT A LICENCED ELECTRICIAN FABRICATE THE PRIME POWER CABLE ASSEMBLY FOR USE AT THE INSTALLATION SITE. 2.5.4...

  • Page 29: Rf Connections

    CHPA S ERIES 2.5.6 RF Connections The following two RF connections are made at the rear of the CHPA: • RF Input (J2)—Type “N” female provided. User needs type “N” male on interface connection. • RF Output (J3)—Either a CPR-137 (C-band), WR-75 (Ku-band), WR-62 (high Ku-band) waveguide flange.

  • Page 30: Cooling Considerations

    CHPA S ERIES 2.5.8 Cooling Considerations The CHPA is forced-air cooled. The exhaust air from the CHPA may be at a relatively high temperature (approximately 35°C above ambient temperature), and heat dissipation may be as high as 2000 watts. To prevent excessive heat buildup in the rack cabinet, it is recommended that the exhaust air be ducted away from the CHPA;...

  • Page 31: 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 32: Serial Remote Interface

    Selection of RMTPNL automatically configures the port for “plug and play” operation with a CPI CHPA Remote Control Panel. In this mode, the remote panel is connected to the port with a “straight” cable (pin to pin connection) and after connection is immediately available for normal REMOTE operation.

  • Page 33: Figure 3-1. Setting Termination Resistors

    CHPA S ERIES Note: Use a shielded cable and ground the shield on both ends for EMC/EMI compliance. Refer to the “Computer Interface” discussion later in this chapter for information on how to configure J6 for computer control operation. Figure 3-1. Setting Termination Resistors Table 3-1.

  • Page 34: Rf Switch System Interface

    CHPA S ERIES 3.4 RF Switch System Interface The RF Switch System interface provides the relay-reported CHPA status and RF Inhibit command required by a waveguide switch controller. Three relays provide CHPA status: Low RF, Fault, and Sum Fault. The relay coil is de-energized to indicate a condition; this fail-safe mode means that a loss of power will provide condition indications on all relays.

  • Page 35: Table 3-2. Low Rf Relay Function

    CHPA S ERIES Table 3-2. Low RF Relay Function Mode Compact HPA Operational State Standby BONS Transmit Fault (NOTE4) (NOTE4) (NOTE5) Flexible No LoRF No LoRF No LoRF Yes/No LoRF Yes LoRF Rigid Yes LoRF Yes LoRF Yes LoRF Yes/No LoRF Yes LoRF (NOTE3) Table 3-2 Notes:...

  • Page 36: External Interlocks Interface

    CHPA S ERIES 3.5 External Interlocks Interface The External Interlocks Interface allows the user to connect the CHPA to external safety interlocks; this interface features two signals: External Interlock Non-Latching and External Interlock Latching. External Interlock Non-Latching is RF Inhibit; this command is always executed.

  • Page 37: Computer Interface

    CHPA S ERIES 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 38: Computer Interface (Cif) Protocol

    CHPA S ERIES 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 39: Command And Response Format

    CHPA S ERIES 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 40: Address Byte

    CHPA S ERIES 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. Ending byte = ETX (ASCII 03) ASCII option (ASCII on front panel) All commands and responses:...

  • Page 41: Check Byte

    CHPA S ERIES 3.9.6 Check Byte (Check byte is under CIF CONFIGURATION as CHECKBYTE.) Two options are available: Longitudinal Parity—The check byte is the exclusive OR of all message bytes including the header and ending bytes and excluding CR or LF if chosen. (LONG on front panel.) Checksum—This formula provides a printable ASCII checksum.

  • Page 42: Carriage Returns And Line Feeds

    CHPA S ERIES 3.9.7 Carriage Returns and Line Feeds The user may choose to use carriage returns (CR) and line feeds (LF); they are appended to the command/response. If both CR and LF are chosen, they will be appended in the order CR LF. Be sure that the CIF port’s setting matches the user’s monitor and control computer settings—...

  • Page 43: Table 3-7. Query Commands

    CHPA S ERIES 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 44: Table 3-8. Chpa Commands

    CHPA S ERIES 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 45: Slow Commands

    CHPA S ERIES 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 46: Status Byte Definitions

    CHPA S ERIES 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 47: Table 3-12. Secondary Status Bytes

    CHPA S ERIES 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)

  • Page 48: Table 3-13. Fault And Miscellaneous Status

    CHPA S ERIES 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 49: Table 3-13. Fault And Miscellaneous Status (Continued)

    CHPA S ERIES 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 50: Id/Version Message

    CHPA S ERIES 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 51: Chapter 4 Initial Power On And Checkout

    CHPA S ERIES 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 52: Using The Front Panel

    CHPA S ERIES 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 53: 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 A). Initial power-on and checkout are to be performed in the following order: •...

  • Page 54: Verifying Operational Settings

    CHPA S ERIES 3. When HTD countdown reaches 0:00, verify that the STANDBY LED lights. Reaching this point in the procedure indicates that the following conditions have been met: • Self-tests were successful. • The TWT (traveling wave tube) heater is warmed up. •...

  • Page 55: Table 4-1. Helix And Rf Settings Ranges

    CHPA S ERIES 4. Repeatedly press the MENU button until Line 3 indicates FAULT TRIP SETTINGS. 5. Repeatedly press the FUNCTION key to cycle through the following settings: • Helix Over Voltage • Helix Under Voltage • Helix Over Current Each setting should fall within the range set in Table 4-1.

  • Page 56: Setting Serial Remote And Cif Port Parameters

    CHPA S ERIES 4.7 Setting Serial Remote and CIF Port Parameters The serial port parameters for both the Remote and CIF (Computer Interface) ports are set through the front panel. The Remote port can be configured either for use with the CHPA Remote panel or as a user-configurable port that supports the same protocols and command set as the CIF port.

  • Page 57: Verifying Rf Alarm And Rf Fault Trip Points

    CHPA S ERIES e. Press the Line 3 button located below the display. Lines 3 and 4 will now display the default meters (Line 3–Helix Voltage and Current; Line 4–Attenuator). 4. Ensure that the attenuator is set to maximum attenuation. a.

  • Page 58: Testing The Chpa Via Computer Control

    CHPA S ERIES d. Once the CHPA is in the Transmit state, the High RF Fault will be detected and steps a through c will occur two more times before the CHPA latches into the Fault state. e. Once the CHPA is latched into the Fault state, the FAULT LED will flash. 9.

  • Page 59: Testing Optional Equipment

    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 60 CHPA S ERIES This page is intentionally left blank. 4-10 THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS & POWER INDUSTRIES. .01023245 R REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED...

  • Page 61: Chapter 5 Operation

    CHPA S ERIES 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 Appendix B. For CHPA operation via the Computer Interface port, see Chapter 3, “Interfaces.”...

  • Page 62: Essential Chpa Operating Procedures

    CHPA S ERIES 5.2 Essential CHPA Operating Procedures 5.2.1 Transmit The CHPA’s purpose is to amplify a microwave signal. This procedure describes how to turn on, enter Transmit state, and set RF output. Thoroughly read this procedure before proceeding. Note: Before starting the CHPA for the first time, be sure that initial power- on and checkout procedures have been performed.

  • Page 63: Normal Shutoff

    CHPA S ERIES 5.3 Normal Shutoff When transmission is completed and no other activity is planned for an hour or so, the CHPA’s AC power should be switched off to conserve electricity and prolong TWT life. The following procedure describes normal shutoff: 1.

  • Page 64: Initialization And Power-On Self-Test (Post) State

    CHPA S ERIES 5.6 Initialization and Power-On Self-Test (POST) State To start the CHPA, turn on the Main Power circuit breaker. The microprocessor controller will perform self-tests and CHPA tests. Once these tests are completed successfully, the user will have control over the CHPA. After prime power is applied to the unit, the control panel displays the following: C P I S A T C O M...

  • Page 65: Heater Time Delay (Htd) State

    CHPA S ERIES 5.7 Heater Time Delay (HTD) State Following the POST, if no fault was detected, the unit will automatically enter HTD. The display shows these features: Local mode, time in 12-hour format, Heater Time Delay countdown, Beam On (XMIT) selected upon conclusion of HTD, and default meters. 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.

  • Page 66: Transmit State

    CHPA S ERIES The user now has complete control over the CHPA. Press the TRANSMIT button to move through the Beam On Sequence to the Transmit state. Press the MENU button to scroll through a list of CHPA features (described in “Quick Access Codes” later in this chapter and in Appendix B).

  • Page 67: Fault State

    CHPA S ERIES 5.10 Fault State The CHPA features Auto Fault Recycle mode; this feature allows the unit to return to a normal operating state after a transient fault. When a fault occurs, the unit enters the Fault state. After a brief interval, the unit tries to return to the previous state.

  • Page 68: Rf Control Modes

    CHPA S ERIES For the Local, Remote, and Computer modes: On the front panel, press the LCL/RMT button to toggle through all of the valid control modes (Local, Remote, CIF). If the CHPA is in the Remote mode, the Serial Remote port may toggle control between the Remote panel (RMT) and the Computer interface (CIF).

  • Page 69: Special Chpa Functions

    CHPA S ERIES When this triangular symbol appears, press L O CAL 1 1 : 0 0 P the FUNCTION button to scroll through the S T A N D B Y available Functions. Catagory Title C O N F I G U R A T Press the MENU button to toggle through available B A U D...

  • Page 70: Terminology

    CHPA S ERIES 5.14 Terminology Various CHPA features, settings, and controls are grouped according to the following hierarchy: Category—Top-level group Function—Data entry or data display selection within a category Entry—Data entry or data review within a function Access to the hierarchy is as follows: Category—Press the MENU button to toggle through the accessible categories.

  • Page 71: Table 5-1. Front Panel Categories

    CHPA S ERIES Table 5-1. Front Panel Categories Category Name Purpose RF Control -RF Output Setting -RF Inhibit -Attenuator Setting -RF Display (W, dBW, dBm) -RF Power Mode -Suppress Peak Mode (disables RF peak mode metering) Linearizer Control (optional) -Gain -Amplitude -Phase RF Trip Limits/Switch Port Relay...

  • Page 72: Quick Access Codes

    CHPA S ERIES Table 5-1. Front Panel Categories (continued) Category Name Purpose Controller Software Version Elapsed Hours -Beam On Elapsed Time Meter -Heater Elapsed Time Meter Flash Programming Access Code Table 5-1 Note: * Only available once the Factory Authorized Access Code has been entered. ** Only available during FAAM and when unit is in Standby See appendix B for a complete list of Quick Access Codes.
  • Page 73 CHPA S ERIES The following lists correlates UA QACs and FA QACs with menu categories and functions. User Authorized Quick Access Codes (00-49) 00 RF Output Setting 12 Low RF Relay Preference 01 Attenuator Setting 13 Fault Relay Preference 02 RF Power Mode 14 Fault Log 03 RF Inhibit 15 Factory Authorized Access Code...
  • Page 74 CHPA S ERIES This page is intentionally left blank. 5-14 THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS & POWER INDUSTRIES. .01023245 R REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED...

  • Page 75: Chapter 6 Preventative Maintenance

    CHPA S ERIES Chapter 6 Preventative Maintenance 6.1 Overview This chapter provides instructions for routine maintenance and performance testing of the compact high power Traveling Wave Tube Amplifier. 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 76: Mechanical Preventive Maintenance

    CHPA S ERIES Preventive maintenance is divided into mechanical maintenance, electrical calibration, and performance testing. A description of how to care for spare TWTs and start-up procedures to follow when the HPA is turned off for extended periods is provided. The recommended maintenance schedule is shown in Table 6-1.

  • Page 77: Table 6-2. Recommended Test And Service Equipment Description

    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 78: Visual Inspection

    CHPA S ERIES 6.4 Visual Inspection At one-month intervals, the CHPA should be inspected visually for physical defects. If the equipment is subjected to severe environmental conditions, inspections should be performed more frequently. The daily equipment readings log is a good source for clues that indicate intermittent or marginal conditions.

  • Page 79: Checking A3 Leds And Display

    CHPA S ERIES 6.4.2 Checking A3 LEDs and Display At least once a month, run the CHPA’s built-in test to verify proper operation of all indicators. To run this test, press the Menu key repeatedly until LAMP TEST appears in the display. Press Enter.

  • Page 80: Electrical Preventive Maintenance

    CHPA S ERIES 6.5 Electrical Preventive Maintenance Operating voltages and metering accuracy must be verified every six months. If any voltage is not within the range stated in the maintenance chapter for the assembly, it should be adjusted; the daily log for the equipment should note the indication before and after adjustment. In addition, perform the entire initial power-on and checkout as described in Chapter 4, “Initial Power-on and Checkout.”...

  • Page 81: Performance Testing

    CHPA S ERIES 5. If the TWT will operate in Transmit without a limit trip, continue this procedure. If not refer to “Maintenance and Troubleshooting” in the CHPA Service Manual for V2. 6. The TWT should be run without RF until the helix current has stabilized. 7.

  • Page 82: Power And Gain

    CHPA S ERIES 6.8 Power and Gain Follow these steps to test the HPA power and gain. Record the results on the chart provided in Table 6-3. 1. Connect the equipment as shown in Figure 6-1. 2. Set the input drive level to minimum and the HPA gain to maximum. 3.

  • Page 83: 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 84: Figure 6-1. Twt Amplifier Test Setup

    CHPA S ERIES Figure 6-1. TWT Amplifier Test Setup 6-10 THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS & POWER INDUSTRIES. .01023245 R REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED...

  • Page 85: Chapter 7 Drawings And Schematics

    CHPA S ERIES 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 (500W to 750W)
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  • Page 87: Appendix A Warranty And Support Information

    CHPA S ERIES 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 (If applicable): Refer to separate folder titled “Warranty and Support.” .01023245 R THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS &...
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  • Page 89: Appendix B Control Appearance And Content

    CHPA S ERIES 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 90: Leds

    CHPA S ERIES 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 91: Beeper

    CHPA S ERIES 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 92 CHPA S ERIES HPA in Beam Off Sequence. B E A M O F F S E Q U E N C E HPA in Beam On state. O U T X X X X W (or when dB scale is chosen) O U T X X .

  • Page 93: Meters

    CHPA S ERIES B.6 Meters In the following screen displays, X indicates a placeholder. Leading zeros, except for those in the ones place, will be replaced with blanks. With regard to the RF meters, refer to the RF Display feature under the RF Control category. B.6.1 HVPS Meter Display List: H L X X X .

  • Page 94: Fault Messages That Correspond To Digital Status Lines

    CHPA S ERIES B.7 Fault Messages That Correspond to Digital Status Lines Interlocks Open Fault I N T E R L O C K S O P E N F L T TWT Over Temperature Fault T W T O V E R T E M P F A U L T Power Supply Arc Detected Fault...

  • Page 95: Alarms

    CHPA S ERIES Helix Over Voltage H E L I X O V E R F A U L T Helix Under Voltage H E L I X U N D E R F A U L T Helix Average Over Current H E L I X A V G O V E R...

  • Page 96: B.10  General Status Screens

    CHPA S ERIES B.10 General Status Screens If any remote panel assembly can’t communicate (after six seconds) with the CHPA, the following message flashes (between 37 percent and 100 percent illumination): C P I S A T C O M 6 0 0 / 7 0 0 C H P A C O M M...

  • Page 97: B.11  Data Entry Rules

    CHPA S ERIES Entry—When the symbols appear next to a function, press either the up or down arrow keys to toggle through valid entries. The user may return from any category to the selected meter display by pressing the buttons on either Line 3 or Line 4.

  • Page 98: Table B-3. Front Panel Categories (Continued

    CHPA S ERIES Table B-3. Front Panel Categories (continued) Category Name Purpose Time/Date Set User Set Heater Time Delay Date 12/24 Hour Format Year Hour:Minute US Daylight Savings Set Month Remote Interface Parameters Mode (If RMTPNL is displayed, the other selections under this menu will not be available.) -Device Address -CR Enable...

  • Page 99: Table B-4. Default Values For User Features

    CHPA S ERIES 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 100: Table B-5. Rf Display Preferences

    CHPA S ERIES 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 101 CHPA S ERIES The sample screen (Lines 1-3) for RF Control is as follows: L O C A L 1 5 : 2 7 S 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 102: B.12  Linearizer Adjustment

    Although the linearizer has been adjusted at the factory, tube replacement would call for readjustment of the linearizer. 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 103: Table B-6. Rf Alarms And Faults

    CHPA S ERIES Table B-6. RF Alarms and Faults Function Name Possible Entries Description High RF Alarm Numerical entry - format dictated If the RF output exceeds this limit, the panel by the RF Display setting will indicate an alarm condition. High RF Fault Numerical entry - format dictated If the RF output exceeds this limit, the CHPA...

  • Page 104: Fault Log

    CHPA S ERIES R E F L F L T X X X W R E F L F L T X X . X D B W L O W R E L A Y : F L E X F A U L T R E L A Y : S U M F L T...

  • Page 105: Factory Authorized Access Code (Faac

    CHPA S ERIES B.13.2 Factory Authorized Access Code (FAAC) Entry of the Factory Authorized Access Code provides entry to the Factory Authorized Access Mode (FAAM). Upon entering the FAAC and pressing the FUNCTION button, the CHPA will be in FAAM. This mode provides unlimited read/write access to all data (fault trip points, special test modes, etc.) until prime power is cycled or the code is reentered.

  • Page 106: Factory Tests

    CHPA S ERIES B.13.4 Factory Tests (This category appears only during FAAM.) This category is used for factory testing and is not for customer use. Unauthorized use of this mode could cause damage to the unit. B.13.5 Reset Elapsed Time Meters (This category will appear only during FAAM.) Data entry (separate entry for each item listed): •...

  • Page 107: User Tests

    CHPA S ERIES When Line 4 indicates YES, press the TRANSMIT button to turn the beam on. Provided no fault occurs, Lines 1 and 2 will appear as follows (Lines 3 and 4 will display the selected meters): L O C A L 5 : 2 7 A B E A M S E Q U E N C E...

  • Page 108: Time/Date Set

    CHPA S ERIES 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.

  • Page 109: Remote/Computer Interface Parameters

    CHPA S ERIES B.13.10 Remote/Computer Interface Parameters (There is one menu per interface.) These two categories allow the user to configure each serial interface. Refer to Chapter 3 “Interfaces,” for a thorough description of the serial interfaces and their command sets and protocols.

  • Page 110: Table B-10. Computer Interface Parameters

    CHPA S ERIES Table B-10. Computer Interface Parameters Function Name Possible Entries Description Device Address Numerical entry: 32 to 126 Baud Rate 9600, 4800, 2400, 1200, 600, Parity Odd, Even, Mark, None Protocol ASCII, STX/ETX Check Byte Toggle between Long and If the protocol is set to STX/ETX, the Check Byte must be Long (short for longitudinal).

  • Page 111: Software Versions

    CHPA S ERIES 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 112: B.14  Quick Access Codes

    CHPA S ERIES 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 113: B.15  Post Faults

    CHPA S ERIES Factory Authorized Quick Access Codes (50-99) are only accessible once Factory Authorized Access Code (FAAC) has been entered. See previous description of the FAAC. 50 Helix Over Voltage Fault 54 CHPA HVPS Test Mode 51 Helix Under Voltage Fault 55 Reset Heater Elapsed Time Meter 52 Helix Average Over Current Fault 56 Reset Beam On Elapsed Time Meter...

  • Page 114: B.16  Software Error Codes

    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. Table B-14. Software Error Codes...

  • Page 115: Reprogramming The Flash Ram

    CHPA S ERIES Note: When the CHPA is forced to turn-on with the EPROM program, all the users settiable parameter like the serial settings and trip points are set to default. The user needs to go back and reset to the desired values. B.16.3 Reprogramming the Flash RAM To update the CHPA’s firmware, connect a PC (using either COM1 or COM2 serial ports) to the Auxiliary serial port (J10).

  • Page 116: Error Messages Associated With The Flash Ram

    CHPA S ERIES 9. After erasing the Flash RAM, the PC’s program will start programming the Flash RAM. The CHPA’s 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 N G F L A S H M E M O R Y...
  • Page 117 CHPA S ERIES F L A S H M E M O R Y E R A S I N G E R R O R P R E S S A N Y K E Y R E T R Y Multiple FLASH MEMORY ERASING ERRORS may mean that the Flash RAM device is faulty.
  • Page 118 CHPA S ERIES 3. If you have trouble running the PC based loader program, be sure that you are operating the program directly from DOS (not in a DOS window while Windows is running). Also, be sure that no mouse or other accessory drivers are loaded that may use the serial port that is used for Flash RAM programming.

  • Page 119: Appendix C Replaceable Parts

    CHPA S ERIES 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/-01(SuperLinear® Version) HV Module, 750 DBS CHPA...

  • Page 120: Table C-1. Replaceable Parts Listing (Continued

    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 TWT, 750W Peak, Ku-Band (12.75 – 14.50GHz) 01036808-01 THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS &...

  • Page 121: Appendix D Options And Features

    CHPA S ERIES Appendix D 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 •...
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  • Page 123: Appendix E Optional L-Band Buc

    CHPA S ERIES Appendix E Optional L-Band BUC E.1 Overview The L-Band RF input signal is converted by the Block Up-Converter (BUC) to the frequency band of the amplifier. Each amplifier is provided with a label indicating the correct L-Band input frequencies accepted by the BUC.

  • Page 124: General Operation

    Most L-band modems now have a built-in 10 MHz reference. A multiplexed reference BUC is configured to accept this reference multiplexed with the L-band input signal on the same connector. This is CPI’s standard configuration and is recommended for most applications. The level of the F reference should be +5 to -5 dBm at the amplifiers input.

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