Professional Documents
Culture Documents
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
Manufacturing
East Coast Operations
45 River Drive
Georgetown, ON
Canada L7G 2J4
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PROPRIETARY INFORMATION
The design and other information contained in this document are provided solely for the
installation, operation, and maintenance of 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.
Copyright © 2011 by Communications & Power Industries, Inc. All rights reserved.
Table of Contents
SAFETY................................................................................................................................................... S-1
INTRODUCTION................................................................................................................................... S-1
1.1 OVERVIEW.................................................................................................................................1-1
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2.1 OVERVIEW.................................................................................................................................2-1
2.3 UNPACKING...............................................................................................................................2-1
3.1 OVERVIEW.................................................................................................................................3-1
4.1 OVERVIEW.................................................................................................................................4-1
CHAPTER 5 OPERATION...................................................................................................................5-1
5.1 OVERVIEW.................................................................................................................................5-1
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6.1 OVERVIEW.................................................................................................................................6-1
6.6 SPARE TWT MAINTENANCE AND PERIODIC OPERATION OF THE AMPLIFIER .6-6
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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. 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. CHPA Model Number and Frequency Ranges ...............................................................1-1
Table 1-1. CHPA Model Number and Frequency Ranges (continued) ..........................................1-2
Table 3-1. Serial Remote Interface Pin Assignment (J6)....................................................................3-3
Table 3-1. Serial Remote Interface Pin Assignment (J6) (continued) ..............................................3-4
Table 3-2. Low RF Relay Function .......................................................................................................3-5
Table 3-3. RF Switch Pin Assignment (J5) ..........................................................................................3-6
Table 3-4. Interlocks Interface Pin Assignments (J8).........................................................................3-7
Table 3-5. CIF (Computer Interface) Pin Assignment (J7)................................................................3-9
Table 3-6. Reject Bytes .........................................................................................................................3-11
Table 3-6. Reject Bytes (continued) ....................................................................................................3-12
Table 3-7. Query Commands..............................................................................................................3-14
Table 3-8. CHPA Commands .............................................................................................................3-15
Table 3-8. CHPA Commands (continued)........................................................................................3-16
Table 3-9. Slow Commands ................................................................................................................3-16
Table 3-10. Interface Commands........................................................................................................3-16
Table 3-11. Summary Status Bytes.....................................................................................................3-17
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S-1
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.
• Appendix E, Guidance on Safety Precautions to be Observed by Personnel Working on
Radio Transmitting Equipment, and also Sub-clauses 3.2, 3.7, and 22.1 of the Standard.
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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. 600 or more volts can hold you indefinitely. If the potential is sufficient to drive 200
milliamps through your body you will be held indefinitely. Some people consider the 200 to 600
volt range to be worse than potentials of thousands of volts.
General Guidelines
In addition to the above, the following practices have proven effective for personnel who deal
with high voltage equipment.
a. Hands off. Avoid contact with any potential source of high voltage. Keep hands out
of the equipment when it is operating.
b. Avoid accidental contact. Make sure that some other part of your body does not come
in contact with the high voltage circuits. It is easy to forget the hazards when you are
concentrating on a frustrating or interesting task. Pens and badges in shirt pockets
could contact the equipment.
c. Never work on high voltage circuits when you are alone. If anything should happen
to you, your only chance may be prompt action by some other person. Be sure
someone else is present and knows what to do in any emergency (e.g., how to shut
equipment off, first aid, who to call, etc.)
d. Use one hand when working with high voltage circuits. Many people recommend
that you put one hand in your pocket when you use a probe or other piece of
equipment inside a high voltage section.
e. Do not float measuring equipment above ground. Make all measurements with
respect to ground. If you float an instrument, do not reach inside the equipment.
Although it is more difficult to get the right setup, it is well worth the effort.
f. Do not assume that the level of risk is a function of size. Some large high power
voltage equipment looks docile. One reason the equipment is so big is to get the
proper separation between high voltage points. On the other hand, just because the
equipment is small is no assurance of safety. Dense packaging results in more difficult
access and increases the chance that you will accidentally hit the wrong point.
g. Always discharge high voltage capacitors. High voltage capacitors store a lot of
energy for long periods of time. High voltage capacitors also exhibit a "memory" in
that they can recover after discharge and reach lethal levels. In addition to the
"memory" problem, there have been instances where the built-in safety features have
failed or have been miswired. Each and every time you go to work on a piece of high
voltage equipment, use a discharge device with a long handle to discharge every
high voltage capacitor.
h. Do not depend on the automatic features of the equipment to save you. You never
know when someone has left a circuit disabled, if there has been a wiring error, or if a
component has failed.
i. 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. Know where the power disconnects are and use them. Do NOT
rely on anyone not to turn on the high voltage.
j. Set up your test equipment with the power off. Conduct the power-on operations
when you have your hands out of the equipment.
k. Do not use short probes for high voltage measurements. A short probe does not
allow any margin for error. If your hand slips you could accidentally come into contact
with a danger point. A long probe avoids the whole problem.
l. Read the instruction manual. The best insurance is foreknowledge of hazards.
m. Create a favorable environment for safe operations. This means that if people are
crowding you, stop the operation if it involves high voltage. Pressure can lead to
carelessness. In the same way, fatigue is also an enemy. STAY ALERT AT ALL TIMES
WHEN WORKING WITH HIGH VOLTAGE.
n. Do not become over-confident. Maintain a healthy respect for high voltage.
o. A good operating practice is to check the potential between the equipment chassis
and earth ground before you complete the circuit with your body. As voltage levels
increase, the protection you get from insulation and air gap diminishes. For example,
in a piece of equipment that involves beam voltages of about 16kV, the beam
transformers look very safe with massive insulation on the outside of the coils.
Physical contact with the beam coil when the system is operating can be fatal.
Although the equipment is placard to warn people of the presence of high voltage, it is
virtually impossible to placard every point of danger in a system.
p. If you do not know how the equipment works and what the hazards associated with
the equipment are in specific terms, do NOT handle the equipment. The greatest
protection you can have when dealing with high voltage equipment is specific detailed
knowledge on that particular piece of equipment.
q. Avoid "haywire" test setups. It is easy to get in trouble if the setup you are using has a
jumble of wires.
r. Make sure your connections are secure. Do NOT allow leads to slip off and move
about in an uncontrolled fashion. Even if it is not one of the high voltage leads, a free
lead could (and generally does) move exactly to where you do not want it. The only
safe connection is a mechanically secure one.
s. Watch out for unterminated high voltage leads. Some connectors depend on circuit
loading to avoid arcing between closely spaced terminals. Unloaded high voltage lines
or plugs can lead to arcing situations.
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t. 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.
u. Remove the test equipment when you have finished a measurement program. There
have been many instruments destroyed or damaged because a test program was
conducted in a haphazard manner, rather than in an orderly progression from start to
finish. Experience has shown in many instances when a little order would have
prevented a tragedy or avoided an expensive mistake.
v. Be extremely wary when making filament voltage measurements. The cathode of
tubes is elevated above (or below) ground and the filament voltages usually cannot be
measured with reference to ground. Do everything you can to assure that the high
voltage cannot be turned on when you are making your measurements. This includes
disconnecting the high voltage drive source, shorting out appropriate leads, taping
down switches, and anything else you can think of to protect yourself.
w. When troubleshooting a unit, assume that the switches and components are
defective. You may shut off the high-voltage switch in some systems, but if the switch
were defective, the high voltage would still be on. Returned units are potential booby
traps.
x. Make sure that your workstation is stable. Flimsy work surfaces or supports for the
equipment or the test instruments represent a real threat. Do NOT use a setup that you
know is unstable and/or dangerous.
y. Use a 1-minute rule. Wait 1 minute or more after you have shut off the equipment
before you work on a unit. Part of the reason for a 1-minute rule is that some of the
dielectrics (insulators) used for high voltage circuits can store a charge. While the
amount of charge stored is a function of the size of the object, a 1-minute rule provides
an additional margin of safety.
z. Maintain a healthy respect for any kind of live circuit. Complacency can hurt or kill
you. Your continued wariness is your best insurance against injury or death.
Microwave Radiation
Personnel Operating Guidelines
This guideline presents operating practices appropriate for operators and technicians who work
with equipment involving microwave radiation. Keep in mind that levels of microwave radiation
that do not induce immediate physical discomfort in most individuals can be sufficiently high to
induce longer-term effects.
CPI Satcom Division equipment usually is related to amplification of a RF signal from an external
source. Even if a source is not connected to the amplifier you are working with, there are
situations where the amplifier can go into a self-induced mode and generate high levels of RF
energy. This condition can exist if the unit is operated with high voltage ON and without proper
termination on the input and output of the amplifier.
Microwave Discussion
Limit exposure to microwave radiation to prevent unwanted biological effects. There are other
effects that can lead to problems if you are careless in operating or servicing microwave
equipment. 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. In the past the U.S. Safety Codes
established a dosage rate of 10mw/cm. Sq. Recently the permissible level has been reduced to
1mw/cm. sq. in the United States, as has been the case in several European countries.
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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.
Physical Safety
Lifting Heavy Objects
Back and other injuries can result from one person trying to lift too much weight.
Use extreme caution when lifting klystrons. Klystrons weigh up to 100 pounds (45 kg) and
require two persons to lift them.
Due to the weight of the drawers, at least two persons are required for installation of the drawers
to the final rack assembly. At least two people are also required for removal of the drawers from
the rack assembly.
1-1
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.
The model numbers, frequency ranges, and rated output power at the waveguide flange of the
high power CHPA series are as follows:
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The CHPA series has been specifically designed for enhanced performance and ease of
operation. In addition, the CHPA incorporates the use of a microprocessor control system,
thereby simplifying interfacing with remote control and monitor facilities. Flash RAM allows
firmware updates to be made without opening the unit. Implementation of a compact,
lightweight, wideband TWT (traveling wave tube) permits continuous, efficient use across the
entire frequency band. The CHPA also supports the unique internal linearizer, which can be
controlled from the front panel, optional remote panel, and serial computer interface.
Design of the CHPA is also based on the extensive use of LRUs (line replaceable units).
Comprehensive diagnostic procedures allow field personnel to quickly isolate a faulty LRU;
extensive use of captive hardware on the LRU helps to speed the replacement of the LRU so
that the CHPA can be returned to service with a minimum of downtime.
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A low-level RF input signal is applied to the CHPA via a type “N” connector (isolator) located
at the rear of the enclosure. The isolator limits the input voltage standing wave ratio (VSWR) to
a level of 1.3:1 or less back to the source. The RF input is then routed to the SSIPA, which
includes an integrated PIN diode attenuator. The attenuator, controlled via the front panel, has
a control range of a nominal 20 dB with quick response and excellent linearity. Built-in memory
circuits are provided to return the attenuator to a previously set level in the event of prime
power outages.
The SSIPA is designed to be transparent to final amplifier RF parameters and is temperature
compensated to minimize drift. As a result, the overall TWT CHPA gain is specified to be
stable within ± 0.25 dB/24 hours with 10 percent line voltage variations. The output of the
SSIPA is connected to an isolator that protects the SSIPA from TWT failure. The SSIPA and
TWT provide a combined subsystem gain of at least 75 dB at maximum rated power for the C-
band and 75 dB for the Ku-band.
The TWTs employed in this power amplifier feature air-cooled, dual depressed collectors for
efficient operation, and periodic permanent magnet (PPM) focused helix design. They are
designed especially for compact, lightweight applications involving satellite uplink service. The
output waveguide assembly interfaces to the TWT and protects the tube from abnormal or
transient conditions that could permanently damage the TWT. This assembly consists of a four-
port circulator, harmonic filter, receive reject filter, and three-port directional coupler. The
high-power isolator provides a low VSWR to the external waveguide run and antenna feed.
The isolator assists in protecting the TWT from excessive reflected power due to
damaged/broken waveguides or antenna components. The isolator is rated such that it will
safely dissipate all reflected power equal to the full rated output of the CHPA for the duration
of time until the protection circuits shut off the high-voltage power supplies. In addition, the
isolator is designed such that it can safely dissipate a VSWR mismatch of 2.0:1 (12 percent of
forward RF power) indefinitely.
The harmonic filter contained in the output waveguide assembly provides a minimum of 60 dB
attenuation at the second harmonic and 45 dB attenuation at the third harmonic. The receive
reject filter serves as a high-pass filter cutting off below-band signals. Finally, the three-port
directional coupler provides one reflected power port coupled via a detector to the RF power
monitor assembly for reverse power protection, and two for forward power: one for the user to
monitor forward RF power via a type “N” connector on the front panel, and one for use by the
optional forward power metering circuit, which uses a similar detector to process the RF signal.
The RF sample port, calibrated in coupling ratio versus frequency, permits independent
monitoring of CHPA output power levels through the use of an external spectrum analyzer or
portable power meter. High reflected RF protection circuitry is standard, and reflected power
information is sent to the front panel for display. User-settable low and high RF power alarms
are also available.
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
sample port, calibrated in coupling ratio versus frequency, permits independent monitoring of
CHPA output power levels through the use of an external spectrum analyzer or portable power
meter.
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The standard RF output interface, provided by the user, to connect the CHPA to the external
waveguide run is a CPR-137F (flange) termination for the C-band, and WR-75F for the Ku-band.
AC Circuit
Input EMI Fans
Filter Breaker
220-240
VAC
Control Helix
&
DC Power
Cathode
Coll. 1 TWT
Flash RAM Programming Coll. 2
Switching I/F Monitor
SSIPA
DC
Power
Control
&
Display
RF Metering
& Faults
RF Monitor
DC
Power
The traveling wave tube derives its operation from four DC power supplies: a low-voltage
filament (heater) supply, a high-voltage helix supply, and two high-voltage collector supplies.
The power supply design utilized in the CHPA is of the SMPC (switch mode power
conditioner) type, which has an excellent reputation for reliability and stability. An added
advantage of the SMPC approach over outdated linear power supplies is its intrinsic high
efficiency and safe operation. By limiting the amount of the instantaneous stored energy in the
power supply, the risk of permanent damage to the CHPA due to abnormal or transient
conditions is avoided. The momentary level of stored energy (measured in joules) is well below
the maximum limit of energy that the tube can safely dissipate during normal operation. The
principal circuit modules are discussed in the following paragraphs.
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2-1
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,” of this manual.
2.2 Pre-Inspection
Inspect the exterior of each for evidence of damage in shipment. If damage seems evident,
immediately contact the carrier that delivered the equipment and submit a damage report.
Failure to do so could invalidate future claims.
2.3 Unpacking
Carefully unpack and remove all items (inspect the interior of the container for damage). Save
all packing material until all inspections are complete. It is recommended that all packing
material be saved for potential future use. Verify that all items listed on the packing slips have
been received.
Inspect all items for evidence of damage in shipment. If damage seems evident, immediately
contact the carrier that delivered the equipment and file a claim. Failure to do so could
invalidate future claims. Check the unit thoroughly for damaged or loose parts. To remove the
top cover of the unit, remove the screws around the sides of the cover and lift the cover off.
After visual inspection is complete, reinstall the cover and carefully tighten all screws.
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2.5 Installation
Installation of the CHPA includes four phases:
• Mechanical installation
• Electrical connections
• RF connections
• Cooling considerations
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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.
Note: Install 9-pin M-F adapter connector (part of ship kit) to CIF port (J7).
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. See details below.
• The following (optional) RF connection is made on the front panel of the CHPA:
• RF Output (sample) Monitor—Type “N” female provided. User needs type “N” male on
interface connection.
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Generally speaking, a 0.10 inch H20 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. Use of 4-
inch-diameter ducting should be strictly avoided.
It is highly recommended that a heating, ventilation, and air-conditioning (HVAC) engineer be
consulted before ducting is installed as insufficient cooling will significantly impact TWT
(traveling wave tube) longevity.
3-1
Chapter 3
Interfaces
3.1 Overview
Each CHPA is provided with interfaces that can be used to connect it with several optional
external devices. All remote and computer interface cables must be foil or braid-foil shielded to
meet EMC/EMI standards. The shields must be connected 3600 to metallic D-sub connectors.
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.
• RF Switch System Interface—This interface enables switch system controllers, such as 1:1
or 1:n, and combiner system controllers to interface with the CHPA.
• External Interlocks Interface—These interlocks enable the user to interlock the CHPA with
external safety devices.
• Computer Interface—This interface enables the user’s computer equipment to control the
CHPA via RS-422/485 or RS-232 serial communication. Users must write all necessary
software for their computers.
• Auxiliary Serial—This RS-232 or RS-422/485 serial port is factory configured for RS-232
operation and is used for Flash RAM programming. Refer to Appendix B for Flash RAM
programming details.
Interface connectors for these devices are located at the rear panel of the CHPA, and are
described in the sections that follow.
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The Local, Remote, and Computer modes are the main user interface modes.
• All control points will always provide status.
• Front panel push-button labeled LCL/RMT will toggle between all control points. The front
panel is the “super-user” and may transfer the control point at any time.
• If the control point is transferred from the front panel (LOCAL) to the remote panel
(REMOTE) or the CIF, the remote panel may transfer control between itself and CIF.
• No control transfer may be commanded via the CIF port.
Note: The physical size of the Remote Control Panel is not the same as the
Front Panel of the CHPA.
In the remote computer control mode (USER), this port provides a second computer control
interface that has all of the functions and capability of the “CIF” port (J7). This port supports
multi-drop RS-422/485 (4-wire) serial communciations at high band rates (e.g., 9600 baud) over
a 4000 ft, (1200 m) serial cable.
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” discussion later in this chapter for information on how to
configure J6 for computer control operation.
Note: Use a shielded cable and ground the shield on both ends for
EMC/EMI compliance.
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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. The Flexible mode allows the user to operate a switch controller
in Automated Switching mode without triggering waveguide switch action while operating the
CHPA in any normal operating state or issuing RF Inhibit commands. Table 3-2 describes the
two modes in more precise detail.
The Fault relay indicates that the CHPA is in the Fault state—the CHPA features Auto Fault
Recycle capabilities and is capable under some circumstances of cycling back to a normal
operating state. This relay may be reassigned to indicate other conditions. Press the MENU
button until the selection RF TRIP LIMITS is displayed. Press the FUNCTION button until the
selection FAULT RELAY is displayed; use the arrow keys to select one the following:
• FAULT—Fault state
• LOW RF—Mimics the action of the Low RF Relay
• SUMFLT—Mimics the action of the Sum Fault Relay
• HV ON—Reports the result of the logical equation: (High Voltage On) and (NOT(RF
Inhibit))
• XMIT—Reports High Voltage ON (See note 6)
The Sum Fault Relay indicates that the CHPA is latched into the Fault state. When the CHPA is
latched into the Fault state, the user must clear the fault source and issue a Reset command to
the CHPA to return it to a normal operating condition.
The RF switch system interface is located at connector J5 on the rear panel of the CHPA. J5 is a
15-pin D-type connector with pin assignments as shown in Table 3-3.
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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.
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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.
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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. Commands requiring long execution times,
such as changing power level, generate an immediate response indicating if the command was
accepted and whether or not execution has begun.
If the CHPA was able to execute a command received via the CIF, the response message will
indicate what command was executed and return any necessary parameters. In the case of a
query command, the returned parameters are referred to as status bytes and are described in
detail later in this section.
If the CHPA was not able to execute a command received via the CIF, a reject code (or codes) is
included in the response message. If the STX/ETX header/ending byte message format was
used, the header byte is NAK, thus indicating a rejection.
To avoid problems with control characters, and so on, device addresses, commands,
parameters, and responses are limited to standard ASCII values 32 through 126.
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.
Ending byte = ETX (ASCII 03)
ASCII option (ASCII on front panel)
All commands and responses:
Header byte = { (ASCII 123)
Ending byte = } (ASCII 125)
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i=1
where:
• MOD95 is the operation modulo 95.
• N is the total number of bytes in the message including header and ending bytes and
excluding CR or LF if chosen.
• message bytei is the ith message byte where 1 ≤ i ≤ N.
Example: Calculate the check byte for the message {A1} using the checksum rule.
Character: { A 1 }
ASCII: 123 65 49 125
i: 1 2 3 4
Check Byte = 32 + MOD95[(123+65+49+125) – (32*4)]
= 32 + MOD95[234]
= 32 + 44
= 76 which translates to the ASCII character L
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. The CIF port can be set to accept bad check bytes (it will expect a character in the check
byte’s place). Press the MENU button to select CIF CONFIGURATION; press the
FUNCTION button to select BAD CHCK BYTE. Use the arrow keys to select the desired
choice—YES will allow the CHPA to accept bad check bytes; NO will prevent the CHPA
from accepting bad check bytes.
3.10 Commands
Commands are sent from a computer to the CHPA. Refer to information given earlier in this
section for the proper formats for commands. There are four types of commands:
• Query commands. These commands cause the CHPA to return information. The returned
bytes are called status bytes; they are described in detail later in this section. Refer to Table
3-7.
• CHPA commands. These commands cause the CHPA to take some action. Refer to Table 3-
8.
• Slow commands. A subset of CHPA commands, these commands may require several
seconds to complete. Refer to Table 3-9.
• Interface commands. These commands invoke special interface features. Refer to Table 3-10.
A table for each command type is provided. The tables include the ASCII code associated with
the commands and its base 10 representation, and the command name and a description of the
command.
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ASCII Byte Decimal Commands (for description and note, see Table 3-8)
D 68 Set RF O/P power in dBm. (see note 1)
E 69 Set RF O/P power in Watts. (see note 1)
F 70 Set ALC RF O/P in dBm.
G 71 Set ALC RF O/P in watts.
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4 Not used
3 Power Fail Signal Timeout. This bit is set if the AC Power Fail signal is detected true
for more than 10 seconds and corresponds to the front panel “PFAL” report.
2 Not used
1 Not used
0(LSB) Not used
4 PS Thermal/Interlocks Open
4 Not used
3 Not used
2 Not used
1 Not used (this was originally Low Airflow Fault)
0(LSB) SSIPA Over Current Fault
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4 RF Inhibit—External Interlock
3 RF Inhibit—CIF
2 RF Inhibit—Local
1 RF Inhibit—Remote Panel
0(LSB) Not used
Table 3-13 Note:
*Bit is set for the fault condition.
(Response is port sensitive and will reflect the status of the port [Remote or CIF] queried.)
Byte Bit Bit Definition (set if condition exists since last query)
1 7(MSB) Parity
6 Complement of bit 5
5 Control of the CHPA has been given to the computer interface.
Byte Bit Bit Definition (set if condition exists since last query)
2 7(MSB) Parity
6 Complement of bit 5
5 RF O/P power setting command terminated due to the cessation of high voltage.
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4-1
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.
Before proceeding with the steps in this chapter, read it completely. Also read the next chapter,
“Operation,” to become familiar with normal operation of the CHPA.
Warning: The information presented in this chapter is addressed to
technicians who have specific training in, and knowledge of, high-power
amplifiers. Inappropriate use of the CHPA can cause harm to the operator
or equipment. Do not attempt the procedures outlined in this chapter
before becoming thoroughly familiar with its contents.
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Note: Before switching on power for the first time, become familiar with all
CHPA controls and indicators, and with the procedures in this chapter.
If a self-test fails, the error is reported on the front panel display. (Refer to Chapter 5,
“Operation,” for further steps if this occurs.)
2. The display will then light to indicate that the self-tests passed. Look for the following:
• HTD countdown starts at 3:00 minutes and counts down to 0 minutes.
• During countdown, verify that LOCAL is indicated in the upper left corner of the
display. If it is not, press the LCL/RMT pushbutton until it does light. (This indicates
that the front panel has complete control of the CHPA.)
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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.
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.
6. After examining the settings, press the SPECIAL key followed by the . (decimal) button. Key
in 15; the display will change to the entry for the FAAC.
7. Enter the FAAC, and then press ENTER to exit the FAAM. The Test Mode LED should now
be dark.
To change RF Faults and Alarms perform the following steps:
1. Press the SPECIAL button followed by the . (decimal) button. Key in 07; the display will
change to the entry for RF Faults and Alarms.
2. Repeatedly press the FUNCTION key to cycle through the RF faults and alarms.
3. For the purposes of the following procedures, set the High RF Alarm to 600 W and the High
RF Fault to 620 W (High RF Alarm to 415W and the High RF Fault to 425W DBS band unit).
All numerical entries should be followed by ENTER.
For more details on the Low RF Relay and Sum Fault Relay, refer to Chapter 3, “Interfaces,”
under “RF Switch System Interface.”
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6. Slowly increase the RF output by repeatedly pressing the down arrow key to decrease the
attenuator setting in 0.1 dB increments until the output reaches 600(500W for the 600W DBS
Band unit 415W for the 500W DBS band unit) as indicated on the front panel. Write down
this attenuation value because it will be used later.
a. The FAULT LED should remain off.
b. While adjusting the RF power, LoRF or HiRF (Low RF Alarm or High RF Alarm) should
not appear on Line 2 of the display. Recheck the alarm settings if necessary.
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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. If the CHPA Remote panel is used, verify that the Remote Configuration is set for RMTPNL.
3. Verify that the CHPA is powered on and in the Standby state as indicated by the STANDBY
LED being lit.
4. Press the LCL/RMT pushbutton on the front panel until REMOTE appears in the upper left
corner of the display. (This indicates that the Remote Control Panel can now control the
CHPA.)
5. Perform tests at the Remote Control Panel to confirm that it not only has complete control of
the CHPA but that it has complete monitoring capabilities of all of the metering available on
the front panel.
6. If no more options are to be tested, switch off the main power to the CHPA, remove the RF
Input and Output test loads, and make the normal RF Input and RF Output connections.
5-1
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.”
The control panel, as shown in Figure 5-1, accepts input via the pushbutton keypad and
provides CHPA status and meters on the alphanumeric display and associated LEDs.
Individual pushbuttons control essential CHPA functions, such as transmitting and selecting
the Control mode. The keypad and alphanumeric display form a simple terminal through
which the user accesses CHPA features, which are grouped in menu categories, such as RF
Control, Fault Log, and Time/Date Setting.
This chapter consists of the following parts: “Essential CHPA Operating Procedures” provides
step-by-step instructions for essential CHPA operation. “Basic CHPA Operation” describes each
CHPA operating state, CHPA Control mode, and RF Control mode. Sample control panel
screens are included. “Special CHPA Functions” describes the menu category system, which
contains most CHPA features. This chapter concludes with “Quick Access Codes.”
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C P I S A T C O M
6 0 0 / 7 0 0 C H P A
P O W E R O N S E L F T E S T
Once communication with the CHPA controller is established, the control panel displays the
following:
C P I S A T C O M
6 0 0 / 7 0 0 C H P A
P O W E R O N S E L F T E S T
T E S T I N G
C P I S A T C O M
6 0 0 / 7 0 0 C H P A
P O S T F A U L T T E S T # 1
A / D C A L I B R A T I O N
During POST the microprocessor controller performs tests that check the integrity of the
microprocessor controller hardware, software, and CHPA subsystems. Each test is assigned a
number for troubleshooting purposes. In the event of a POST Fault, the fault will be indicated.
(See Appendix B Table B-13.) At the successful completion of the POST, the CHPA will
automatically enter the HTD state.
L O C A L 5 : 3 0 P
H T D 2 : 3 9 X M I T S E L E C T
H L X 0 . 0 0 K V 0 . 0 m A
A T T E N U A T O R 1 0 . 0 d B
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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. Ideally, the cathode should be maintained at a specific temperature.
Cathode temperature is difficult to measure; however, there is a relationship between heater
time after prime power on and cathode temperature. HTD, therefore, is of variable length
(based on prime power off time) to provide optimum cathode temperature in minimum time
after power is applied to the CHPA.
HTD proportional time delay: If time off ≤5 seconds, no HTD.
If 5 seconds <time off<1.5 minutes,
HTD 1.5 x time off + existing HTD
If time off ≥1.5 minutes,
HTD = 3 minutes
During HTD, the user may press the TRANSMIT button to select Beam On when HTD has
elapsed; this action is displayed on the front panel as XMIT SELECT. The user may also press
the MENU button to scroll through available menu categories. See later in this chapter under
“Special CHPA Functions” for a description of the menu category hierarchy. See Appendix B
for a complete description of all menu categories.
L O C A L 9 : 4 5 A
S T A N D B Y
H L X 0 . 0 0 K V 0 . 0 m A
A T T E N U A T O R 1 0 . 0 d B
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). To facilitate access to menu categories, use the Quick Access Codes described later
in this chapter.
L O C A L A L C 1 0 : 0 7 A
B E A M O N S E Q U E N C E
H L X 0 . 0 0 K V 0 . 0 m A
A T T E N U A T O R 1 0 . 0 d B
At the successful completion of the Beam On Sequence, the following example screen will be
displayed. The display shows these features: Local mode, Automatic RF Level Control (ALC),
time in 12-hour format, RF output power in dBW, default meters.
L O C A L A L C 1 0 : 0 7 A
R F O U T 2 3 . 0 d B W
H L X 1 2 . 0 1 K V 0 . 0 m A
A T T E N U A T O R 1 0 . 0 d B
The Beam Off Sequence (BOFS) is the transition from any Transmit state to any Beam Off state.
It occurs so quickly that the message for this sequence may not be seen.
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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). The following screen shows the unit after it is latched in the
Fault state.
L O C A L A L C 4 : 3 7 A
H I G H R E F L R F F A U L T
H L X 0 . 0 0 K V 0 . 0 m A
A T T E N U A T O R 1 0 . 0 d B
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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. Category names
appear on Line 3.
Function—When the t symbol appears next to a category, press the FUNCTION button to
toggle through the accessible functions (viewed on Line 4) under that category.
Entry—When the symbols appear next to a function, press either the up or down arrow
keys to toggle through valid entries.
Category—Computer Interface Parameters
Function—Baud Rate (Pressing the FUNCTION button would toggle through other
available entries such as Parity, Print ASCII, and so on.)
Entry—9600 (Pressing either arrow key will cycle through the other potential entries:
4800, 2400, 1200, 600, 300.)
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L O C A L A L C 1 1 : 1 7 A
R F O U T 0 . 0 W
Q U I C K A C C E S S C O D E
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
01 Attenuator Setting
02 RF Power Mode
03 RF Inhibit
04 Suppress Peak Mode
05 Not used
06 Linearizer Control (if installed)
07 High RF Alarm
08 High RF Fault
09 Low RF Alarm
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
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6-1
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).
Note: Improper maintenance of the CHPA may void the warranty. For
details, see Appendix D, “Warranty and Support Information.”
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(Listed equipment below may be substituted by any equivalent piece of test equipment.)
Sweep Signal Generator, frequency range HP 8360, 8350 DC to 20 GHz, capable of CW and sweep
operation, compatible with Scalar Analyzer, item.
RF Power Meter complete with power HP 437B, 438A with 8481A Power Head sensors, Type N, 50
Ohms, power measurement range -30 to +20 dBm.
Variable Attenuator 0 to 25 dB, DC to 20 GHz, Merrimac ASM25-11K 50 Ohms.
Scalar Network Analyzers, frequency range HP 8757 with two sensors DC to 20 GHz, complete with dual
detector probes. Should have dual markers, with Delete mode. Compatible with Sweep Signal Generator
(item 1).
RF Splitter, precision 2-way, 50 Ohms, Type N, HP 11667A DC to >20 GHz.
High quality, low loss RF test cables as required for test set up.
Microwave Frequency Counter, 3.DC to 20 GHz.* HP 5340A
*Required only if Sweep Generator is not digitally controlled or phase locked.
Clip-On mA Meter HP 428B Clip-On DC Millimeter 1 mA to 10 A +/- 3%.
Voltmeter-Fluke 8050 DVM 4-digit and Triplett Multimeter.
Couplers Input and Output Coaxial, and Waveguide.
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.
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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. Check for other defects. These include, but are not limited to, wear, breakage, deterioration,
fungus, excess moisture, and mounting integrity.
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Note: Running the TWT at 0.3 V above the heater voltage on the label can
reduce the TWT life by as much as one half.
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DATE ___________________________
CHPA MODEL S/N_______________________
TWT MODEL S/N_______________________
TESTED BY _________________________
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7-1
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.
Note:
Drawings are in numerical order
Paper Manual: Printed drawings follow this page.
CDROM Manual: Drawing files are in the “Drawing” folder.
* Refer to the service manual, 01021149, for the respective LMs.
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8-1
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
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A-1
Appendix A
Specifications
Chapter 7 includes specifications for all CHPAs listed in this manual.
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B-1
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.”
B.2 Buttons
The front panel displays data using a 4-line by 20-character vacuum fluorescent alphanumeric
display and six LEDs (see Figure B-1). A push-button keypad is used for operating the HPA and
entering data. Numerical data will not be entered until the user has pressed the ENTER button.
Data entry that relies on the arrow keys will be updated when the arrow keys are pressed. The
Quick Access Codes are the only exceptions to these rules
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B.3 LEDs
Six LEDs are located below the alphanumeric display and indicate unit states and other
important information. The LEDs appear in Table B-2 in the order they appear on the front
panel from left to right.
B.4 Beeper
The front panel assembly includes a beeper. The beeper sounds once to indicate that a button
has been pressed successfully. When the HPA is in Fault state or Alarm mode, the beeper
sounds approximately every second.
C I F A L C 1 1 : 0 0 P
H T D 3 : 0 0
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HPA in HTD state. (HPA will change to Transmit state after HTD has elapsed.)
H T D 3 : 0 0 X M I T S E L E C T
S T A N D B Y
B E A M O N S E Q U E N C E
B E A M O F F S E Q U E N C E
R F O U T X X X X W
R F O U T X X . X d B W
R F O U T X X X X W L O R F
R F O U T X X . X d B W H I R F
R F P E A K X X X X W
R F P E A K X X . X d B W
HPA in Fault state (a list of all Fault messages is described later in this document), for example:
I N T E R L O C K S O P E N F L T
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 . X X K V X X . X m A
Line 4—This line displays either meters or Menu category entries; it defaults to the meter
display shown. To toggle through the meters, press the Line 4 button. To toggle through the
menu categories, press the MENU button.
A T T E N U A T O R X X . X d B
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 E A M C U R R E N T X X X X m A
B.6.2 RF Meters
A T T E N U A T O R X X . X d B
R E F L R F X X X W X X . X d B W
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I N T E R L O C K S O P E N F L T
T W T O V E R T E M P F A U L T
P S A R C D E T E C T E D F L T
DC Buss Fault
D C B U S S F A U L T
E X T I N T E R L O C K F A U L T
S S I P A O V E R I F A U L T
L O W A I R F L O W F A U L T
* Units built prior to March 1997 are equipped with a pressure differential switch to provide
this fault. Units built after march 1997 do not have this switch.
H E L I X O V E R V F A U L T
H E L I X U N D E R V F A U L T
H E L I X A V G O V E R I F L T
H I G H R F O U T F A U L T
L O W R F O U T F A U L T
H I G H R E F L R F F A U L T
H L X V D E T E C T I N S T B Y
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B.9 Alarms
When an alarm occurs, the alphanumeric display flashes (between 37 percent and 100 percent
illumination).
High RF Alarm
R F O U T X X X X W H I R F
Low RF Alarm
R F 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. If multiple alarms exist at the same time, the display will automatically
cycle among those alarms.
AC Power Fail Alarm
R F O U T X X X X W P F A L
R F O U T X X X X W B R A L
C P I S A T C O M
6 0 0 / 7 0 0 C H P A
N O C O M M W I T H C H P A
If an RF Inhibit is issued, the source should be reported on Line 2 (sample screen shown):
L O C A L 2 : 3 2 A
R F I N H I B I T S W I T C H
H L X 0 . 0 0 K V 0 . 0 m A
A T T E N U A T O R 1 0 . 0 d B
R F I N H I B I T L O C A L
R F I N H I B I T R E M O T E
R F I N H I B I T C I F
R F I N H I B I T E X T I N T L K
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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.
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.
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L O C A L 1 5 : 2 7
S T A N D B Y
R F C O N T R O L t
Depending on the RF Display setting, either of the first two lines will appear on Line 4 for the
RF Out Setting. Pressing the FUNCTION button will toggle through the remaining entries:
S E T R F O U T X X X X W
S E T R F O U T X X . X d B W
S E T A T T N X X . X d B
R F M O D E : A L C
R F M O D E : O P E N L O O P
R F I N H I B I T : Y E S
R F D I S P L A Y : d B W
P E A K S U P P R E S S : Y E S
L O C A L 1 5 : 2 7
S T A N D B Y
L I N E A R I Z E R C O N T R O L t
G A I N : 2 5 0
P H A S E : 2 5 0
A M P L I T U D E : 2 5 0
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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.
L O C A L 1 5 : 2 7
S T A N D B Y
R F T R I P L I M I T S t
H I R F A L A R M X X X W
H I R F A L A R M X X . X d B W
H I R F F A U L T X X X W
H I R F F A U L T X X . X d B W
L O R F A L A R M X X X W
L O R F A L A R M X X . X d B W
L O R F F A U L T X X X W
L O R F F A U L T X X . X d B W
H I R E F L F L T X X X W
H I R E F L F L T X X . X d B W
L O W R F 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
Refer to Table 4-1 for the settings for the faults and alarms in this category.
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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 5 : 2 7 A
S T A N D B Y
F A U L T L O G 1 O F 2
J A N 2 3 4 : 3 7 A
H I G H R E F L R F F A U L T
F A U L T L O G
N O R E C O R D E D F A U L T S
L O C A L 6 : 1 1 P
S T A N D B Y
F A A C :
F A C T O R Y A U T H M O D E
U S E O F T H I S M O D E C A N
C A U S E H P A D A M A G E
H I T M E N U T O E X I T
To continue, press the FUNCTION button. The Factory Authorized Quick Access Codes (50-99)
will be valid for data entry until prime power is cycled or the FAAC is reentered. If any other
key is pressed, the front panel will cycle to the next non-Factory Authorized mode category:
User Tests. Otherwise, the control panel will display the next Menu category: Fault Trip Setting.
F A U L T T R I P S E T T I N G S t
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H V P S T E S T M O D E
H V P S T E S T : N O
To select this test mode, press either arrow key to select YES on Line 4. In this test mode, any
meter may be selected. All other CHPA features and controls (aside from the STANDBY and
TRANSMIT button) will be inactive. If a fault occurs, the HVPS TEST will be turned off.
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 O N S E Q U E N C E P S T
Once the Beam On Sequence is complete, Line 2 will display the following:
H I G H V O L T A G E O N P S T
To exit this test mode, return to the HVPS TEST MODE menu. Use the arrow keys to choose
NO. The display (Lines 3 and 4) will return to the following:
H V P S T E S T M O D E
H V P S T E S T : N O
U S E R T E S T t
L A M P T E S T : E N T E R
If a test is performed, the result (as described above) will be reported in place of ENTER.
B E E P E R : E N A B L E
A U X L O O P B A C K : E N T E R
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L O C A L 1 5 : 2 7
S T A N D B Y
T I M E / D A T E S E T t
U S E R H T D : 0 0 S E C
1 2 / 2 4 F O R M A T : 1 2 H R
H R : M I N S E T : X X : X X
M O N T H S E T : J A N
D A T E S E T : X X
Y E A R : X X X X
U S D L S V G T I M E : Y E S
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The screen for Computer Interface Parameters is as follows: (Line 3 is RMT CONFIGURATION
for the Remote Configuration menu. Also, Remote Configuration has an additional entry on
Line 4 to determine if the port is used with the Remote panel or as a port similar to the CIF
port.)
L O C A L 1 5 : 2 7
S T A N D B Y
C I F C O N F I G U R A T I O N t
P O R T A D D R E S S : X X X
B A U D R A T E : X X X X
P A R I T Y : E V E N
P R O T O C O L : S T X / E T X
C H E C K B Y T E : L O N G
C R E N A B L E : N O
L F E N A B L E : N O
B A D C H C K B Y T E : Y E S
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L O C A L 1 5 : 2 7
S T A N D B Y
S O F T W A R E V E R S I O N S t
C O N T R O L L E R V E R X . X X X
L O C A L A L C 1 1 : 1 7 A
R F O U T 2 0 0 W
Q U I C K A C C E S S C O D E t
The following list correlates UA QAC and FA QAC with menu categories and functions:
User Authorized Quick Access Codes (00-49)
00 RF Output Setting
01 Attenuator Setting
02 RF Power Mode
03 RF Inhibit
04 Suppress Peak Mode
05 Upconverter Control (if installed)
06 Linearizer Control (if installed)
07 High RF Alarm
08 High RF Fault
09 Low RF Alarm
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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
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
51 Helix Under Voltage Fault
52 Helix Average Over Current Fault
53 Helix Voltage Detected in Standby
54 CHPA HVPS Test Mode
55 Reset Heater Elapsed Time Meter
56 Reset Beam On Elapsed Time Meter
57 Reset to Factory Defaults
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F P A C:
C H P A P R O G R A M L O A D E R
E S T A B L I S H I N G
C O M M U N I C A T I O N
W I T H H O S T S Y S T E M
4. Connect the PC’s serial port (either COM1 or COM2) to the CHPA’s auxiliary serial port
(J10). The CHPA’s auxiliary serial port is factory configured for RS-232, pin 2 is TX (data
leaves unit) and pin 3 is RX (data enters unit).
5. Be sure that the new Flash RAM program and the PC’s loader program are in the same
directory.
6. On the PC, start the loader program, which is called FLASHCOM.EXE. On the PC from the
DOS prompt, type FLASHCOM then press the Enter key.
7. Enter 2 digit Rev number of Flash RAM program as displayed on PC disk label; then select
COM1 or COM2 depending upon which PC serial port you are using.
8. As soon as the PC and CHPA establish communication, the display will show:
C H P A P R O G R A M L O A D E R
E R A S I N G F L A S H M E M O R Y
P L E A S E W A I T
The PC screen will display a similar message. If after ten seconds this message does not appear,
the PC and CHPA aren’t communicating and the source of this problem needs to be found. See
the end of this procedure for troubleshooting suggestions.
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
P L E A S E W A I T
At the same time, the PC screen will show the percentage of memory programmed. The
programming takes approximately 2.5 minutes.
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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 N G C O M P L E T E
P R E S S A N Y K E Y T O
R E S T A R T C H P A
Press any key to restart the CHPA. The CHPA should then successfully complete the POST
(Power On Self Test) and be available for use. Disconnect the PC from the CHPA. Refer to the
Troubleshooting section below if errors related to the Flash RAM appear.
I N C O R R E C T M E S S A G E
L E N G T H E R R O R
P R E S S A N Y K E Y T O
R E T R Y
Incorrect message length error means that the CHPA hasn’t received all of the characters that it
expected to receive. This error will appear if the serial cable is removed during Flash RAM
programming.
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 T O
R E T R Y
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.
F L A S H M E M O R Y P R O G R A M M I N G
E R R O R
P R E S S A N Y K E Y T O
R E T R Y
Multiple FLASH PROGRAMMING ERRORS may mean that the Flash RAM device is faulty.
Before arriving at that conclusion, take steps to assure a solid cable connection from the PC and
CHPA; also, review troubleshooting items 3 and 4.
I N C O R R E C T M E S S A G E
C H E C K S U M
P R E S S A N Y K E Y T O
R E T R Y
This message will appear at the end of programming if the checksum for the Flash RAM
contents do not match the expected checksum. This message may mean that the Flash RAM
device is faulty. Before arriving at that conclusion, take steps to assure a solid cable connection
from the PC and CHPA; also, review troubleshooting items 3 and 4.
2. If you complete the procedure, but see this message upon recycling the CHPA’s prime
power:
C P I S A T C O M C H P A
F L A S H M E O R Y E R R O R
P R E S S E N T E R K E Y T O
U S E D E F A U L T P R O G R A M
The CHPA was unable to start using the Flash RAM. Try the loading procedure again - be sure
to carefully follow all steps properly. If the loading procedure is successfully completed, but
this message appears again, check that the correct Flash RAM file was used.
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.
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C-1
Appendix C
Replaceable Parts
Table C-1. Replaceable Parts Listing
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D-1
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.
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E-1
Appendix E
Options and Features
Options • Integral Linearizer
• Remote Control Panel
• Redundant and Power Combined Subsystems
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F-1
Appendix F
Optional L-Band BUC
F.1 Overview
The optional Block Upconverter (BUC) allows the user to operate the KHPA with L-band input
frequencies 900 -1750 MHz for Ku-Band and 950-1825 MHz for C-Band. The L-band input signal
can be translated to the following microwave bands:
1. C-Band:
5.85 – 6.425 GHz
5.85 – 6.65 GHz
5.85 – 6.725 GHz
2. KU-Band:
14.0 – 14.5 GHz
13.75 – 14.5 GHz
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”.
The “alarm” will be reported via the CIF port, but the amplifier will take no action.
Alternatively, the “BUC alarm” can be set to a latched “fault” via a user setting in the CIF
protocol (using the supplied utility software or the 1RU remote control). In the event that the
BUC LO becomes unlocked, a fault will be reported, and the amplifier will inhibit RF and
shutdown HV to the TWT. A reset command will restore the amplifier to normal operation once
the fault has cleared.
The Local Oscillator reference can be supplied in one of three formats below:
• Multiplexed Local Oscillator reference frequency on the L-Band signal through the type N
RF input connector.
• An internal LO reference integrated into the BUC.
• An external LO reference through a separate BNC connector.
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• 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. The level of 10 MHz should be –5 to +5 dBm at the
KHPA’s input.
• Internal Reference: An internal 10MHz reference signal with ±1 ppm stability includes
in the BUC module. This oscillator performance is not as precise as a GPS reference, but
it is adequate for many applications.
• External Reference: This allows the user to connect a system 10 MHz reference through
a BNC cable. This is used for systems that need to slave all KHPAs to a common timing
reference, such as the GPS signal. The level required is –5 to +5 dBm.
Note: Refer to the Drawing chapter of the respective Service manual for
more information.
Refer to the amplifier specifications in the documents section of this
manual for performance of the amplifier with a BUC.
F.2 Precautions
• The modulator’s gain should be adjusted for the best signal to noise ratio (-60dBc). The
power level adjustment can be done by adding fixed attenuators at the modulators’ output
if it’s necessary.
• A multiplexer should be used rather than a combiner. In case of using a combiner, band
pass filters should be added to modems’ output or a 10 dB fixed attenuator can be added to
each combiner’s input.
• Please take care to ensure that the proper L-band frequency range is not exceeded or
damage may result.
• The L-band input signal must be free of the spurious signals that can cause poor
performance or even cause the amplifier to fail.
• The level of 10 MHz should be –5 to +5 dBm at the KHPA’s input.