CPI 0102324500rR User manual
INSTALLATION, OPERATION, AND
PREVENTATIVE MAINTENANCE
MANUAL
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
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
CHPA SERIES
ii THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS &POWER INDUSTRIES.
REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED DOC.01023245 REV.R
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, LLC. All rights reserved.
CHPA SERIES
DOC.01023245 REV.R THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS &POWER INDUSTRIES.
REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED iii
Table of Contents
SAFETY................................................................................................................................................... S-1
INTRODUCTION................................................................................................................................... S-1
HIGH VOLTAGE EQUIPMENT ......................................................................................................... S-1
PERSONNEL OPERATING GUIDELINES ....................................................................................... S-1
WHEN IS VOLTAGE "HIGH"? .......................................................................................................... S-1
GENERAL GUIDELINES ................................................................................................................... S-2
MICROWAVE RADIATION................................................................................................................ S-4
PERSONNEL OPERATING GUIDELINES ....................................................................................... S-4
MICROWAVE DISCUSSION ............................................................................................................. S-4
GENERAL MICROWAVE GUIDELINES ......................................................................................... S-4
PHYSICAL SAFETY........................................................................................................................... S-5
GENERAL LIFTING GUIDELINES ..................................................................................................S-5
EXTENDING RACK SLIDES.............................................................................................................S-5
CHAPTER 1 INTRODUCTION ...........................................................................................................1-1
1.1OVERVIEW.................................................................................................................................1-1
1.2ABOUT THIS MANUAL............................................................................................................1-3
1.3MAJOR SUBSYSTEMS AND THEIR FUNCTIONS..............................................................1-4
1.4TECHNICAL DESCRIPTION...................................................................................................1-4
1.4.1RF SUBSYSTEM ..................................................................................................................1-4
1.4.2POWER SUPPLY SUBSYSTEM .........................................................................................1-6
1.4.3POWER FACTOR CORRECTION MODULE ....................................................................1-6
1.4.4POWER PROCESSOR MODULE........................................................................................1-7
1.4.5HIGH-VOLTAGE MODULE ...............................................................................................1-7
1.4.6RF POWER MONITOR MODULE ......................................................................................1-7
1.4.7CONTROL AND DISPLAY MODULES .............................................................................1-7
1.5LRU PHILOSOPHY ...................................................................................................................1-8
1.6OPTIONAL FEATURES ............................................................................................................1-8
CHAPTER 2 UNPACKING AND INSTALLATION .........................................................................2-1
2.1OVERVIEW.................................................................................................................................2-1
CHPA SERIES
iv THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS &POWER INDUSTRIES.
REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED DOC.01023245 REV.R
2.2PRE-INSPECTION .....................................................................................................................2-1
2.3UNPACKING...............................................................................................................................2-1
2.4PREPARING FOR INSTALLATION.......................................................................................2-2
2.5INSTALLATION.........................................................................................................................2-2
2.5.1MECHANICAL INSTALLATION .......................................................................................2-2
2.5.2ELECTRICAL CONNECTIONS ..........................................................................................2-3
2.5.3PRIME POWER ....................................................................................................................2-3
2.5.4GROUNDING .......................................................................................................................2-4
2.5.5I/O INTERFACES .................................................................................................................2-4
2.5.6RF CONNECTIONS .............................................................................................................2-5
2.5.7RF OUTPUT (WAVEGUIDE CONNECTION)(J3).............................................................2-5
2.5.8COOLING CONSIDERATIONS ..........................................................................................2-6
CHAPTER 3 INTERFACES .................................................................................................................3-1
3.1OVERVIEW.................................................................................................................................3-1
3.2CHPA CONTROL MODE HIERARCHY................................................................................3-1
3.3SERIAL REMOTE INTERFACE .............................................................................................3-2
3.4RF SWITCH SYSTEM INTERFACE.......................................................................................3-4
3.4.1RELAY DEFINITIONS ........................................................................................................3-4
3.5EXTERNAL INTERLOCKS INTERFACE .............................................................................3-6
3.6COMPUTER INTERFACE........................................................................................................3-7
3.6.1CIF HARDWARE CONFIGURATION ...............................................................................3-7
3.7COMPUTER INTERFACE (CIF) PROTOCOL .....................................................................3-8
3.8PROTOCOL MESSAGE STRUCTURE...................................................................................3-8
3.9COMMAND AND RESPONSE FORMAT ...............................................................................3-9
3.9.1HEADER AND ENDING BYTES........................................................................................3-9
3.9.2ADDRESS BYTE................................................................................................................3-10
3.9.3COMMAND BYTE.............................................................................................................3-10
3.9.4RESPONSE BYTE(S) .........................................................................................................3-10
3.9.5REJECT BYTE(S) ...............................................................................................................3-10
3.9.6CHECK BYTE.....................................................................................................................3-11
CHPA SERIES
DOC.01023245 REV.R THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS &POWER INDUSTRIES.
REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED v
3.9.7CARRIAGE RETURNS AND LINE FEEDS .....................................................................3-12
3.10COMMANDS .............................................................................................................................3-12
3.10.1SLOW COMMANDS..........................................................................................................3-15
3.11STATUS BYTE DEFINITIONS...............................................................................................3-16
3.12ID/VERSION MESSAGE .........................................................................................................3-20
CHAPTER 4 INITIAL POWER ON AND CHECKOUT ..................................................................4-1
4.1OVERVIEW.................................................................................................................................4-1
4.2PRE-POWER PROCEDURES...................................................................................................4-1
4.3USING THE FRONT PANEL ....................................................................................................4-2
4.4INITIAL POWER-ON PROCEDURES ....................................................................................4-3
4.4.1POWER-ON SELF-TEST AND HEATER TIME DELAY..................................................4-3
4.5VERIFYING OPERATIONAL SETTINGS .............................................................................4-4
4.6SETTING THE FAULT AND ALARM TRIP POINTS..........................................................4-4
4.7SETTING SERIAL REMOTE AND CIF PORT PARAMETERS.........................................4-6
4.8VERIFYING RF OUTPUT LEVEL ..........................................................................................4-6
4.9VERIFYING RF ALARM AND RF FAULT TRIP POINTS..................................................4-7
4.10TESTING THE CHPA VIA COMPUTER CONTROL ..........................................................4-8
4.11TESTING OPTIONAL EQUIPMENT ......................................................................................4-9
4.11.1REMOTE CONTROL INTERFACE ....................................................................................4-9
CHAPTER 5 OPERATION...................................................................................................................5-1
5.1OVERVIEW.................................................................................................................................5-1
5.2ESSENTIAL CHPA OPERATING PROCEDURES ...............................................................5-2
5.2.1TRANSMIT ...........................................................................................................................5-2
5.3NORMAL SHUTOFF .................................................................................................................5-3
5.4BASIC CHPA OPERATION ......................................................................................................5-3
5.5CHPA STATES AND DESCRIPTION......................................................................................5-3
5.6INITIALIZATION AND POWER-ON SELF-TEST (POST) STATE...................................5-4
CHPA SERIES
vi THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS &POWER INDUSTRIES.
REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED DOC.01023245 REV.R
5.7HEATER TIME DELAY (HTD) STATE..................................................................................5-5
5.8STANDBY STATE ......................................................................................................................5-5
5.9TRANSMIT STATE ....................................................................................................................5-6
5.10FAULT STATE............................................................................................................................5-7
5.11CHPA CONTROL MODES AND HIERARCHY ....................................................................5-7
5.12RF CONTROL MODES .............................................................................................................5-8
5.13SPECIAL CHPA FUNCTIONS .................................................................................................5-9
5.13.1FACTORY AUTHORIZED ACCESS MODE .....................................................................5-9
5.14TERMINOLOGY ......................................................................................................................5-10
5.15EXITING A MENU ...................................................................................................................5-10
5.16DATA ENTRY RULES .............................................................................................................5-10
5.17QUICK ACCESS CODES.........................................................................................................5-12
CHAPTER 6 PREVENTATIVE MAINTENANCE............................................................................6-1
6.1OVERVIEW.................................................................................................................................6-1
6.2SCHEDULED PREVENTIVE MAINTENANCE ....................................................................6-1
6.3MECHANICAL PREVENTIVE MAINTENANCE.................................................................6-2
6.4VISUAL INSPECTION...............................................................................................................6-4
6.4.1INSPECTING AND CLEANING AIR FILTERS.................................................................6-4
6.4.2CHECKING A3 LEDS AND DISPLAY...............................................................................6-5
6.4.3COLLECTOR AIR SYSTEM MAINTENANCE .................................................................6-5
6.4.4CHECKING B1 COLLECTOR BLOWER ...........................................................................6-5
6.4.5MISCELLANEOUS CLEANING.........................................................................................6-5
6.5ELECTRICAL PREVENTIVE MAINTENANCE ..................................................................6-6
6.6SPARE TWT MAINTENANCE AND PERIODIC OPERATION OF THE AMPLIFIER .6-6
6.7PERFORMANCE TESTING .....................................................................................................6-7
6.8POWER AND GAIN ...................................................................................................................6-8
CHAPTER 7 DRAWINGS AND SCHEMATICS ...............................................................................7-1
CHPA SERIES
DOC.01023245 REV.R THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS &POWER INDUSTRIES.
REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED vii
APPENDIX A WARRANTY AND SUPPORT INFORMATION ....................................................A-1
APPENDIX B CONTROL APPEARANCE AND CONTENT ......................................................... B-1
B.1OVERVIEW ................................................................................................................................ B-1
B.2BUTTONS ................................................................................................................................... B-1
B.3LEDS ............................................................................................................................................ B-2
B.4BEEPER....................................................................................................................................... B-3
B.5ALPHANUMERIC DISPLAY DEFINITION ......................................................................... B-3
B.6METERS...................................................................................................................................... B-5
B.6.1HVPS METER DISPLAY LIST: ......................................................................................... B-5
B.6.2RF METERS......................................................................................................................... B-5
B.6.3METER ORDER .................................................................................................................. B-5
B.6.4METER LIST........................................................................................................................ B-5
B.7FAULT MESSAGES THAT CORRESPOND TO DIGITAL STATUS LINES................... B-6
B.8FAULT MESSAGES GENERATED BY LIMIT COMPARISONS ..................................... B-6
B.9ALARMS ..................................................................................................................................... B-7
B.10GENERAL STATUS SCREENS ............................................................................................... B-8
B.10CONTROL MENU ..................................................................................................................... B-8
U
B.11DATA ENTRY RULES .............................................................................................................. B-9
B.11.1CATEGORIES.................................................................................................................... B-12
B.11.2RF CONTROL.................................................................................................................... B-12
B.11.3LINEARIZER CONTROL (OPTIONAL).......................................................................... B-13
B.12LINEARIZER ADJUSTMENT............................................................................................... B-14
B.13RF TRIP LIMITS/SWITCH PORT RELAY SETTINGS.................................................... B-14
B.13.1FAULT LOG ...................................................................................................................... B-16
B.13.2FACTORY AUTHORIZED ACCESS CODE (FAAC) ..................................................... B-17
B.13.3FAULT TRIP SETTING .................................................................................................... B-17
B.13.4FACTORY TESTS ............................................................................................................. B-18
B.13.5RESET ELAPSED TIME METERS .................................................................................. B-18
B.13.6RESET TO FACTORY DEFAULTS ................................................................................. B-18
CHPA SERIES
viii THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS &POWER INDUSTRIES.
REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED DOC.01023245 REV.R
B.13.7CHPA HVPS TEST MODE ............................................................................................... B-18
B.13.8USER TESTS...................................................................................................................... B-19
B.13.9TIME/DATE SET............................................................................................................... B-20
B.13.10REMOTE/COMPUTER INTERFACE PARAMETERS ............................................... B-21
B.13.11SOFTWARE VERSIONS............................................................................................... B-23
B.13.12ELAPSED HOURS INFORMATION............................................................................ B-23
B.14QUICK ACCESS CODES........................................................................................................ B-24
B.15POST FAULTS ......................................................................................................................... B-25
B.16SOFTWARE ERROR CODES................................................................................................ B-26
B.16.1FLASH RAM - OPERATION AND PROGRAMMING................................................... B-26
B.16.2TO FORCE THE CHPA TO USE EPROM CONTENTS.................................................. B-26
B.16.3REPROGRAMMING THE FLASH RAM......................................................................... B-27
B.16.4ERROR MESSAGES ASSOCIATED WITH THE FLASH RAM.................................... B-28
APPENDIX C REPLACEABLE PARTS ............................................................................................C-1
APPENDIX D OPTIONS AND FEATURES ......................................................................................D-1
APPENDIX E OPTIONAL L-BAND BUC ......................................................................................... E-1
E.1OVERVIEW ................................................................................................................................ E-1
E.2GENERAL OPERATION.......................................................................................................... E-2
E.2.1MULTIPLEXED REFERENCE........................................................................................... E-2
E.2.2INTERNAL REFERENCE................................................................................................... E-2
E.2.3EXTERNAL REFERENCE.................................................................................................. E-2
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...............................................................................3-6
CHPA SERIES
DOC.01023245 REV.R THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS &POWER INDUSTRIES.
REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED ix
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 3-2. LOW RF RELAY FUNCTION ................................................................................3-5
TABLE 3-3. RF SWITCH PIN ASSIGNMENT (J5) ...................................................................3-5
TABLE 3-4. INTERLOCKS INTERFACE PIN ASSIGNMENTS (J8).........................................3-6
TABLE 3-5. CIF (COMPUTER INTERFACE) PIN ASSIGNMENT (J7) ....................................3-8
TABLE 3-6. REJECT BYTES..................................................................................................3-10
TABLE 3-7. QUERY COMMANDS .........................................................................................3-13
TABLE 3-8. CHPA COMMANDS ............................................................................................3-14
TABLE 3-8. CHPA COMMANDS (CONTINUED) ...................................................................3-15
TABLE 3-9. SLOW COMMANDS ...........................................................................................3-15
TABLE 3-10. INTERFACE COMMANDS................................................................................3-15
TABLE 3-11. SUMMARY STATUS BYTES ............................................................................3-16
TABLE 3-12. SECONDARY STATUS BYTES........................................................................3-17
TABLE 3-13. FAULT AND MISCELLANEOUS STATUS........................................................3-18
TABLE 3-13. FAULT AND MISCELLANEOUS STATUS (CONTINUED) ...............................3-19
TABLE 3-14. INFORMATION/ERROR MESSAGES ..............................................................3-19
TABLE 3-14. INFORMATION/ERROR MESSAGES (CONTINUED) .....................................3-20
CHPA SERIES
x THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS &POWER INDUSTRIES.
REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED DOC.01023245 REV.R
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. CHPA PERFORMANCE TEST RESULTS............................................................6-9
TABLE 7-1. COMPACT HPA DRAWINGS ...............................................................................7-1
TABLE B-1. FRONT PANEL BUTTON DESCRIPTION .......................................................... B-2
TABLE B-2. FRONT PANEL LEDS ......................................................................................... B-3
TABLE B-3. FRONT PANEL CATEGORIES ........................................................................... B-9
TABLE B-3. FRONT PANEL CATEGORIES (CONTINUED)................................................. B-10
TABLE B-4. DEFAULT VALUES FOR USER FEATURES.................................................... B-11
TABLE B-5. RF DISPLAY PREFERENCES .......................................................................... B-12
TABLE B-6. RF ALARMS AND FAULTS ............................................................................... B-15
TABLE B-7. USER TESTS AND RESULTS .......................................................................... B-19
TABLE B-8. TIME/DATE SETTINGS..................................................................................... B-20
TABLE B-9. COMPUTER INTERFACE PARAMETERS ....................................................... B-21
TABLE B-10. COMPUTER INTERFACE PARAMETERS ..................................................... B-22
TABLE B-11. SOFTWARE VERSIONS ................................................................................. B-23
TABLE B-12. ELAPSED HOURS FEATURE......................................................................... B-23
TABLE B-13. POST FAULTS ................................................................................................ B-25
TABLE B-14. SOFTWARE ERROR CODES......................................................................... B-26
TABLE C-1. REPLACEABLE PARTS LISTING ....................................................................... C-1
TABLE C-1. REPLACEABLE PARTS LISTING (CONTINUED) .............................................. C-2
CHPA SERIES
DOC.01023245 REV.R THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS &POWER INDUSTRIES.
REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED S-1
S-1
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.
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.
High Voltage Equipment
Personnel Operating Guidelines
This document presents operating practices for operators and technicians who work with high
voltage equipment. Any voltage above 48V is viewed as "high voltage." Prime power (115 to
440VAC) is dangerous because potentials are known to cause death or injury.
Electrical circuits operate quickly and do not provide a careless individual with a second
chance. Hazards associated with high voltage are consistent and predictable. A switch that is
in the OFF position does not indicate the unit is safe.
Warning: The guidelines presented in this chapter are not academic. They
are based on the experience of engineers and technicians who have years
of experience with high voltage circuits and equipment.
When Is Voltage "High"?
Any voltage that can kill or injure is considered high voltage. Prime power voltages generally
do not jump the air gap between the operator and equipment. Usually, exposed circuit
elements such as a terminal, exposed wire, or a non-insulated surface must be touched.
Prime power in some equipment can be "floating" above ground. If one hand is placed on the
equipment chassis and the other on an earth ground, there is potential to be injured, or killed.
440VAC can stimulate an involuntary muscle response that either throws a person across a
room or seizes and holds a person across the voltage terminals. Potential sufficient to drive 200
milliamps through the body will hold it indefinitely.
CHPA SERIES
S-2 THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS &POWER INDUSTRIES.
REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED DOC.01023245 REV.R
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.
b. Create a favorable environment for safe operations. It is easy to forget high voltage
hazards when distracted. Stop all high voltage work when there is a crowd of people
around. Check and remove trip hazards in the area. Do not operate high voltage
equipment when tired or on medication that may cloud judgment or perception. Make sure
pens, jewelry, and employee badges do not come in contact with high voltage equipment.
c. Never work on high voltage circuits alone. Be sure the person watching knows what to do
in an emergency (e.g., how to shut equipment off, first aid, who to call, etc.)
d. Use the one hand when working with high voltage circuits. Many people recommend that
one hand be put in a pocket or behind the back when using a probe or other piece of
equipment inside a high voltage section. Receiving a shock through the right hand keeps
the path of damage away from the heart.
e. Do not float measuring equipment above ground. Make all measurements with respect to
ground.
f. Discharge high voltage capacitors. High voltage capacitors store a lot of energy for long
periods of time. High voltage capacitors can recover high voltage after discharge and reach
lethal levels.
g. Do not depend on the automatic features to save you. It is difficult to tell if a circuit is
disabled. Component errors or miss wiring can disable the function of built in safety
features. Each and every time a piece of high voltage equipment is powered on, use a
discharging device with a long handle to discharge all high voltage capacitor.
h. Take personal responsibility to assure that equipment is tagged and locked out so high
voltage cannot be turned on during service. Precautions include a lock on circuit breakers,
disconnecting the high voltage power source, and using interlocks that prevent high voltage
turn on. Know where power disconnects are and use them. DO NOT rely on others to turn
off the high voltage and make sure equipment is tagged and locked out.
i. Set up test equipment with the power off. Double check power cords for cracks or breaks
before powering on equipment. Apply power to the unit when the operator’s hands are out
of the equipment.
j. Use probes rated for high voltage measurements. The voltage rating of the probe should
exceed the maximum possible voltage at the test point. Length of the probe should be
adequate to prevent accidental contact of the circuitry
k. Do not become over-confident. Always maintain a healthy respect for high voltage.
Equipment may be dangerous to the operator unless proper safety and operation practices
are observed.
CHPA SERIES
DOC.01023245 REV.R THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS &POWER INDUSTRIES.
REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED S-3
l. 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.
Physical contact with the beam coil when the system is operating can be fatal. Although
the equipment has warnings of the presence of high voltage, it is virtually impossible to pin
point every danger in a system.
m. If an operator is not trained on the function and hazards associated with the equipment,
they should not handle the equipment. The greatest protection, when dealing with high
voltage equipment, is detailed knowledge of that equipment.
n. Avoid unorganized equipment setups. Take the time to make sure equipment setups are
organized to allow proper operation and maintenance to occur.
o. Make sure all high voltage and ground connections are secure. Fasten leads using all the
hardware provided. The only safe connection is a mechanically secure one.
p. Watch out for exposed high voltage leads. Some connectors depend on circuit loading to
avoid arcing between closely spaced terminals. Loaded high voltage lines or plugs can lead
to arcing.
q. Shut off the high voltage when performing a low voltage measurement. It does not make
sense to increase the danger of being shocked needlessly. There are times when high
voltage cannot be shut off during a low voltage measurement. Most of the time this is not
the case.
r. Remove test equipment when finishing a measurement program. Many instruments have
been destroyed or damaged because a test program was conducted in a haphazard manner,
rather than in an orderly progression from start to finish. Tragedy can be avoided by
applying an order to the operator’s method.
s. Be cautious when making filament voltage measurements. The cathode of the tube is
elevated above (or below) ground and the filament voltage usually cannot be measured
with reference to ground. Assure the high voltage cannot be turned on when making
measurements. This includes disconnecting the high voltage drive source, locking breakers,
shorting out appropriate leads, enabling interlocks, and anything else to prevent accidental
injury.
t. When troubleshooting, assume switches are defective. A high voltage switch may be shut
off, but if the switch were defective, the high voltage would still be on. Units have the
potential to shock or kill if a switch has failed.
u. Make sure that workstations are sturdy. Flimsy work surfaces, and supports for
equipment present a real threat to the operator. DO NOT use a setup that is known to be
unstable and/or dangerous.
v. Use a 5-minute rule. Wait at least 5 minutes after shutting off equipment before working on
it. The 5-minute rule pertains to the dielectrics or insulators used in high voltage circuits
that can store a charge. While the amount of charge stored is a function of the size of the
dielectric, a 5-minute rule provides an adequate margin for safety.
CHPA SERIES
S-4 THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS &POWER INDUSTRIES.
REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED DOC.01023245 REV.R
Microwave Radiation
Personnel Operating Guidelines
This guideline presents operating practices appropriate for operators and technicians who work
with equipment involving 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.
WARNING! PROTECT YOURSELF AND OTHERS AROUND FROM
UNWANTED RF RADIATION. ALWAYS TERMINATE THE AMPLIFIERS
INPUT AND OUTPUT WITH A TERMINATION BEFORE TURNING THE HIGH
VOLTAGE ON. THIS WILL REDUCE THE CHANCE OF OSCILLATION DUE
TO NOISE OF THE INTERNAL AMPLIFIER.
Microwave Discussion
Limiting exposure to microwave radiation prevents unwanted biological effects. Local
radiation levels can be detected with the proper equipment. The suggested permissible level of
RF radiation is 1mW/cm² for duration of 30 minutes. This is only a suggested guideline and it is
up to the end user of the product to establish the permissible RF radiation exposure level.
General Microwave Guidelines
These guidelines provide practical approaches to control unwanted RF radiation associated
with the operation and servicing of CPI Satcom Division equipment. The following approaches
have proven effective in both laboratory and field environments:
NOTE! IF THESE GUIDELINES ARE FOLLOWED THE POTENTIAL FOR RF
RADIATION EXPOSURE WILL BE MINIMIZED.
a. Always terminate the output waveguide with an RF load capable of dissipating full CW RF
power. Fasten loads with hardware provided before applying prime power to the amplifier.
b. Terminate the input to avoid the possibility of the amplifier oscillating. Terminate the input
before applying prime power to the amplifier.
c. Do not look into the output port of the powered RF amplifier. Eyes are particularly
vulnerable. Looking into an output waveguide flange may cause cataracts.
d. Shut off the amplifier if RF radiation is detected. The operator should put the amplifier in
standby or shut off the breaker if RF radiation is detected. Consult management if the
microwave radiation exceeds 1mw/ cm². Examine the physical unit with the high voltage
OFF for visible cracks in the output waveguide.
CHPA SERIES
DOC.01023245 REV.R THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS &POWER INDUSTRIES.
REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED S-5
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.
f. Work quickly to minimize RF radiation exposure. RF radiation exposure is directly
proportional to power level and time exposed. Exposure to RF radiation can cause both
thermal and non-thermal biological effects.
Physical Safety
General Lifting Guidelines
One person can typically lift a maximum weight of 40 lbs safely. However, the actual weight
that can safely be lifted will depend on the fitness level of the person doing the lifting and on
the lifting technique used.
Extending Rack Slides
Serious injuries may result from heavily loaded rack assemblies. Racks must be securely
bolted to the floor in all four corners to prevent tipping when slides are extended to accept
units. Verify all slides are securely mounted and all latches and stops are functioning properly.
Serious injury can occur to hands, fingers, or clothing becoming caught in slides. Exercise
caution when sliding units into and out of a rack paying close attention to hands, fingers and
clothing.
CHPA SERIES
S-6 THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS &POWER INDUSTRIES.
REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED DOC.01023245 REV.R
This page is intentionally left blank.
CHPA SERIES
DOC.01023245 REV.R THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS &POWER INDUSTRIES.
REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED 1-1
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:
Table 1-1. CHPA Model Number and Frequency Ranges
Model No. Frequency Range (GHz) Rated Power (Watts)
VZC-6967AM 5.850 - 6.725 650
VZC-6967AN 5.850 - 7.075 650
VZC-6967AT 5.850 - 6.650 650
VZC-6967AD (obsolete) 5.715 - 6.425 602
VZC-6967AB (obsolete) 5.850 - 6.650 602
VZC-6967AG (obsolete) 5.850 - 7.075 602
VZC-6967AJ 5.725 - 6.725 602
VZC-6967AH 6.425 - 7.100 650
VZC-6967AF 5.725 - 6.725 650
VZU-6996AB (obsolete) 12.75 - 14.50 501
VZU-6997AB/ABL 12.75 - 14.50 650/325 (SuperLinear® Version)
VZU-6997AC 13.75 - 14.50 602
VZU-6996AC (obsolete) 13.75 - 14.50 501
VZU-6997AE 14.00 - 14.80 602
VZU-6997AF 13.00 - 14.80 650
VZU-6997AG 14.70 - 15.32 602 (549 above 15GHz)
CHPA SERIES
1-2 THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS &POWER INDUSTRIES.
REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED DOC.01023245 REV.R
Table 1-1. CHPA Model Number and Frequency Ranges (continued)
Model No. Frequency Range (GHz) Rated Power (Watts)
VZU-6997AA (obsolete) 13.00 - 13.25 602
VZU-6997AD 13.75 - 14.50 650
VZU-6997AJ (obsolete) 12.75 - 13.25 650
VZU-6995AY 17.30 - 18.40 407
VZU-6996AY 17.30 - 17.80 501
VZU-6997CY 17.30 - 18.40 650
VZU-6997AX 17.30 - 18.40 624
VZU-6997AY 17.30 - 18.10 624
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.
Figure 1-1. The CHPA
CHPA SERIES
DOC.01023245 REV.R THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS &POWER INDUSTRIES.
REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED 1-3
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. Warnings appear at the appropriate points to caution all users of
potential RF or high-voltage hazards.
Each chapter begins with a clearly marked tab; this allows the reader to have rapid access to a
particular section. A “Contents,” “List of Figures,” and “List of Tables” are included at the
beginning of the manual for reference to each section.
Chapter 1, “Introduction,” contains a brief overall description and a detailed technical
description of the CHPA. The design philosophy and a brief description of the optional features
are also included in this chapter.
Chapter 2, “Unpacking and Installation,” contains procedures for preparing the site for
installation and unpacking the CHPA. It also describes the steps required to make the
necessary power connections.
Chapter 3, “Interfaces,” describes the CHPA’s built-in interfaces to external devices; also listed
are detailed descriptions for each connection. The communication protocol and command set
used for computer control of the CHPA are also included in this chapter.
Chapter 4, “Initial Power-On and Checkout,” describes the TWT (traveling wave tube)
preconditioning procedures, use of the Front Panel to start up and check out the CHPA, and
instructions for configuring the CHPA for the particular site installation; this includes setting
serial port parameters.
Chapter 5, “Operation,” contains procedures for normal start-up, shutdown, and detailed
operational modes of the CHPA.
Chapter 6, “Preventative Maintenance,” contains procedures for scheduled maintenance; also
explained are fault and alarm conditions.
Chapter 7, “Drawings and Schematics,” contains drawings of the various frequency band
CHPAs. It also includes detailed RF schematics and an overall system interconnect drawing.
The Appendices contain additional topics such as “Control Appearance and Content”,
“Replaceable Parts”, “Warranty and Support Information”, “Options and Features”, and
“Optional L-Band BUC” information.
CHPA SERIES
1-4 THIS DOCUMENT IS THE PROPERTY OF COMMUNICATIONS &POWER INDUSTRIES.
REPRODUCTION OR RELEASE WITHOUT EXPRESS PERMISSION IS STRICTLY PROHIBITED DOC.01023245 REV.R
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.
The RF section includes the TWT (traveling wave tube), SSIPA (solid-state intermediate power
amplifier) with integrated PIN diode attenuator, input/output isolation circuits, RF detectors,
and output filter.
The power supply section includes the power factor correction, power processor, and high-
voltage regulation circuitry as well as monitor and control circuitry.
Microprocessor circuits provide automatic sequencing to control both CHPA operation and
continuous monitoring of critical parameters.
The front panel of the unit serves as the primary user interface housing all monitor and control
functions including a type “N” RF connector to sample and measure output RF power.
Protection circuits are included to permit safe, efficient, and reliable operation of the CHPA.
Detailed specifications for the CHPA are provided in Chapter 7, “Drawings.”
1.4 Technical Description
1.4.1 RF Subsystem
A conservative, field-proven approach is used in the CHPA RF subsystem. The RF block
diagram (Figure 1-2) identifies all major circuit elements for this technical description.
Figure 1-2. CHPA RF Diagram
Table of contents
Other CPI Amplifier manuals
