CPI S5CIA User manual

INSTALLATION, OPERATION, AND
PREVENTATIVE MAINTENANCE
MANUAL
INDOOR SSPA
P/N 01040244R7
For Use With Model Numbers...
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
S5CI
S4UI
S5XI

INDOOR SSPA
II DOC.01040042 REV.6
PROPRIETARY INFORMATION
The design and other information contained in this document are provided solely for the
purposes of operating and maintaining 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 @ 2009 by Communications & Power Industries. All rights reserved.

INDOOR SSPA
DOC.01040042 REV.6 III
TABLE OF CONTENTS
Operational Warnings
Safety Section 0103274800
0104002200 Rev.2
Rev.1
Chapter 1
Introduction 0104004300 Rev.6
Chapter 2
Unpacking & Installation 0104004400 Rev.6
Chapter 3
External Interfaces 0104004500 Rev.6
Chapter 4
Initial Power-On and
Checkout
0104005300 Rev.6
Chapter 5
Operation 0104008600 Rev.7
Chapter 6
Maintenance 0104008700 Rev.6
Chapter 7
Functional Tree 0104008900 Rev.4
Chapter 8
Redundant Switch Option 0104001900 Rev.3
Chapter 9
Drawings 0104008800 Rev.5
Appendix A
Customer Support
Warranty Information
0104002500
0103098900
SC4133
Rev.1
Rev.5
Rev.-
Appendix B
Optional L-Band BUC 0104002400 Rev.3

INDOOR SSPA
IV DOC.01040042 REV.6
This page is intentionally left blank.

INTRODUCTION
DOC.01040043 REV.6 1-1
1-1
Chapter 1
Introduction
Table of Contents
CHAPTER 1 INTRODUCTION............................................................................................................1-1
1.1 OVERVIEW.................................................................................................................................1-3
1.2 GENERAL DESCRIPTION.......................................................................................................1-4
1.3 STANDARD FEATURES...........................................................................................................1-4
1.3.1 COMPACT RACK HEIGHT ................................................................................................1-5
1.3.2 FORWARD AND REFLECTED RF POWER METERING................................................1-5
1.3.3 REAL TIME CLOCK............................................................................................................1-5
1.3.4 LOCAL OR REMOTE M&C................................................................................................1-5
1.3.5 GRAPHICAL DISPLAY.......................................................................................................1-5
1.3.6 FRONT PANEL LED’S ........................................................................................................1-6
1.3.7 EVENT LOG .........................................................................................................................1-6
1.3.8 FAULT LOG .........................................................................................................................1-6
1.3.9 HISTOGRAM LOG...............................................................................................................1-6
1.3.10 AUTO FAULT RECYCLE ...................................................................................................1-6
1.3.11 INTERNAL TEST POINTS..................................................................................................1-6
1.3.12 QUICK REPLACEMENT OF POWER SUPPLY, BRICK, OR FAN .................................1-6
1.3.13 RS-232/422/485 REMOTE CIF PROTOCOL.......................................................................1-6
1.3.14 4 PROGRAMMABLE DISCRETE RELAY OUTPUTS......................................................1-6
1.3.15 AUTOMATIC POWER COMPENSATION ........................................................................1-7
1.3.16 VARIABLE GAIN ATTENUATION...................................................................................1-7
1.3.17 VARIABLE OR AUTOMATIC FAN SPEED......................................................................1-7
1.3.18 TRANSPORTABLE MEMORY...........................................................................................1-7
1.4 OPTIONS......................................................................................................................................1-7
1.4.1 REMOTE CONTROL PANEL (1RU) ..................................................................................1-8

INTRODUCTION
1-2 DOC.01040043 REV.6
1.4.2 BLOCK-UP CONVERTER (BUC).......................................................................................1-8
1.4.3 BUC BYPASS .......................................................................................................................1-8
1.4.4 REDUNDANT POWER SUPPLIES.....................................................................................1-8
1.4.5 TRANSIENT SURGE SUPPRESSION................................................................................1-9
1.4.6 ETHERNET LAN INTERFACE.........................................................................................1-10
1.4.7 REDUNDANT/PHASE COMBINED SWITCH SYSTEM................................................1-10
1.4.8 INPUT AND OUTPUT POWER SAMPLING PORTS......................................................1-10
1.4.9 EXHAUST DUCT...............................................................................................................1-10
1.5 ABOUT THIS MANUAL..........................................................................................................1-10
1.6 CONVENTIONS........................................................................................................................1-11
1.6.1 NOTES AND CAUTIONS..................................................................................................1-11
1.6.2 ELECTRICAL OR RF WARNINGS ..................................................................................1-11
1.6.3 TEXT CONVENTIONS......................................................................................................1-12
List of Figures
Figure 1-1. Indoor SSPA (Front View) ................................................................................................1-3
List of Tables
Table 1-1. Indoor SSPA Amplifiers......................................................................................................1-3
Table 1-2. Weight and Dimensions......................................................................................................1-4
Table 1-3. Redundant Power Supply Parts and Quantity Supplied ...............................................1-9

INTRODUCTION
DOC.01040043 REV.6 1-3
1.1 Overview
This manual describes the installation and operation (I&O) procedures of CPI’s Indoor Units
(IDU) 100W, 125W, and 225W SSPA (Solid State Power Amplifier) for service in satellite earth
stations.
Technical maintenance for repair and troubleshooting is covered in the Service Manual.
The IDU SSPA is designed specifically for indoor operation, providing uplink service in fixed
satellite terminals, “fly-away” earth stations and digital satellite newsgathering vehicles.
Table 1-1 shows the model numbers, frequency ranges, and power outputs of these amplifiers.
Figure 1-1 is a photograph of an IDU SSPA.
Table 1-1. Indoor SSPA Amplifiers
Model Number Frequency Range
(GHz) Rated Saturated Power (Watts) Rated Saturated Power (dBm)
S5CIA 5.850 – 6.425 125 51
S5CIB 5.850 – 6.425 225 53.5
S5CIC 5.850 – 6.725 100 50
S5CID 5.850 – 6.725 200 53
S5XI 7.900 – 8.400 200 53
S4UIA 13.750 – 14.500 100 50
S4UIB 14.000 – 14.500 100 50
Figure 1-1. Indoor SSPA (Front View)

INTRODUCTION
1-4 DOC.01040043 REV.6
1.2 General Description
The Indoor SSPA is a self-contained unit consisting of a power supply, a solid state brick
containing an array of Gallium Arsenide (GaAs) FET devices, a microprocessor driven
controller, and cooling system. Typical model weight and dimensions are shown in table 1-2.
Table 1-2. Weight and Dimensions
Frequency Band Dimensions (WxHxD) Weight
C Band 19.00x5.25x26.00 in. or 483.0x133.0x660.0 mm. 80 lbs or 36.3 kg
Ku Band 19.00x5.25x26.00 in. or 483.0x133.0x660.0 mm. 72 lbs or 32.7 kg
X Band 18.36x6.99x25.94 in. or 466.3x177.6x659.0 mm. 76 lbs or 36.0 kg
The overall dimensions for C or Ku Band models, excluding switches, connectors, and
mounting brackets is (WxHxD) inches or 483X133X660 mm. For X Band the overall dimensions,
excluding switches, connectors, and mounting brackets are (WxHxD) inches or
The SSPA’s power supply operates with an AC input line voltage of 100–240 ± 10% VAC at any
frequency between 47 and 63 Hz. The state of the art power supply regulates power to the solid
state brick, microprocessor driven controller, and cooling system.
The SSPA’s solid state brick produces a linear output power of 100W, 125W, or 225W. The
microprocessor driven controller simplifies the local and remote interfaces for monitor and
control functions. The front panel display is easily navigated using the arrow and menu keys.
The SSPA is forced-air cooled with integral fans. The cooling air enters the front of the unit and
exits the rear panel. A minimum of 4 inches is required for the air intake and exhaust clearance.
Special attention has been given to SSPA’s ability dissipate thermal energy. The SSPA uses a
heatsink, variable speed fans, and over temperature switches to regulate heat produced by the
amplifier during operation. These protective features minimize damage to the electrical
components, thereby prolonging the SSPA’s operating life.
1.3 Standard Features
Standard features include:
•Compact rack height
•Forward and reflected RF power metering
•Real Time Clock
•Local or remote M&C
•Graphical display

INTRODUCTION
DOC.01040043 REV.6 1-5
•Front panel LED’s
•Event log
•Fault log
•Histogram log
•Automatic fault recycle
•Internal test points
•Quick power supply, brick, or fan replacement
•RS-232/422/485 remote CIF protocol
•4 programmable discrete relay outputs
•Automatic power compensation
•Variable gain attenuation
•Variable or automatic fan speed
•Transportable memory
1.3.1 Compact Rack Height
This feature allows more amplifiers to fit into a rack assembly.
1.3.2 Forward and Reflected RF Power Metering
The forward and reflected RF power metering allows the operator to read how much RF power
is being transmitted from the SSPA and how much of that power is reflected back to the SSPA.
1.3.3 Real Time Clock
The real time clock can be updated and set by the operator using the network time protocol
(NTP) or using the front panel display menu key.
1.3.4 Local or Remote M&C
The SSPA can be operated locally using the front panel display in local mode only. It can also be
operated remotely using an RS-422/232 cable to a computer interface.
1.3.5 Graphical Display
The graphical display is located on the front panel and includes RF metering, power supply unit
(PSU) display, and fan speed display.

INTRODUCTION
1-6 DOC.01040043 REV.6
1.3.6 Front Panel LED’s
Front panel LED’s display amplifier status’s such as transmit, standby, fault, on-line, and
remote.
1.3.7 Event log
This feature captures events at preset time interval or when there is a change in status. The
entry event log puts a time and date stamp on every entry. After 2000 entries the next entry will
overwrite the oldest one.
1.3.8 Fault Log
The fault log is used to capture in-depth information and can capture 5 separate faults. The
most recent faults are kept in memory, discarding the oldest fault as a new fault occurs.
1.3.9 Histogram Log
The histogram log keeps a record of the amplifier operating conditions over time.
1.3.10 Auto Fault Recycle
If the amplifier fails it will automatically recycle the fault and try to return to its previous state.
This feature allows quick recovery after minor faults.
1.3.11 Internal Test Points
Internal test points have been built into the SSPA allowing for easy measurement and
troubleshooting.
1.3.12 Quick Replacement of Power Supply, Brick,
or Fan
Replacement of the power supply, brick, or fan can be done in less than 1 hour.
1.3.13 RS-232/422/485 Remote CIF Protocol
The SSPA is equipped with a remote CIF protocol that can handle RS-232/422/485.
1.3.14 4 Programmable Discrete Relay Outputs
The D-Type connector J6 at the back of the SSPA has 4 discrete programmable relay outputs.
The outputs can be programmed for any fault or alarm.

INTRODUCTION
DOC.01040043 REV.6 1-7
1.3.15 Automatic Power Compensation
The amplifier can be set to achieve a constant output power using the variable gain attenuator
automatically. The attenuator will compensate for input drive level changes as well as
temperature changes.
1.3.16 Variable Gain Attenuation
The SSPA overall gain can be adjusted up to 23dB in 0.1dB steps.
1.3.17 Variable or Automatic Fan Speed
Fan speed can be adjusted manually or automatically as required by the operator. The fans will
automatically operate at full power if there is any over temperature alarm.
1.3.18 Transportable Memory
The SSPA has built in transportable memory that holds serial numbers and calibration data.
1.4 Options
Optional equipment aids in the amplifiers performance, user friendliness, and reliability.
Options include the following:
•Remote control panel
•Block-up converter (BUC)
•BUC bypass
•Redundant power supplies
•Transient surge suppression
•Ethernet LAN interface
•Redundant or phase combined switch system
•Input and output sample ports
•Exhaust duct

INTRODUCTION
1-8 DOC.01040043 REV.6
1.4.1 Remote Control Panel (1RU)
The remote control panel is rack-mountable, 19 inches wide, 1.75 inches high, 9 inches deep and
weighs 5 lbs.
The remote control panel duplicates most of the controls and indicators of the front control
panel. It communicates to the amplifier via a RS-485 serial interface. The panel requires a
source of AC power and includes the connectors for the interconnect cable from the amplifier. A
specific length of the interconnect cable can be provided (Option). The remote panel can itself be
controlled over a LAN.
1.4.2 Block-Up Converter (BUC)
A L-band BUC can be integrated into the amplifier’s enclosure. This allows the user to operate
the SSPA with an L-Band input frequency of 950 to 1825 MHz. The BUC converts the L-Band
input frequency to the output frequency of the SSPA.
CPI’s BUCs use DRO (Dielectric Resonant Oscillators) that can operate independently or be
phase locked to a high-stability reference. The reference signal is brought into the amplifier by
multiplexing the reference onto the cable carrying the input signals, so that no extra cables are
required.
This simplifies the end-user's system design. Options are available for internal or multiplexed
reference signals. For more information about BUCs, refer to Appendix C in this manual.
When operating a SSPA with a BUC, the operator may select the BUC’s frequency lock fault
output to either trigger the amplifier with an alarm (notification, but no action) or a fault (in
which case the amplifier would cease transmitting upon becoming unlocked). This selection is
made via the front panel menu setup screen.
1.4.3 BUC Bypass
The BUC Bypass allows the amplifier to be used both with the carrier frequency or L-Band I/F.
The operator can choose to bypass the BUC L-Band input and directly input the carrier
frequency into the SSPA at J2 (RF input), or the operator is able to use the BUC L-Band input at
J16 by connecting the RF coaxial jumper cable (provided) from J17 (BUC output) to J2 (RF
input).
1.4.4 Redundant Power Supplies
The redundant power supply option provides an external 1RU rack that mounts in the rack
beneath the amplifier. This rack can contain up to 4 hot-swappable power supply modules.
Each module is capable on its own, of running the amplifier. Any additional modules share the
total load, operate cooler, and extend the life of each module.

INTRODUCTION
DOC.01040043 REV.6 1-9
The main RF voltage will be supplied using all available modules to a maximum of four total.
The extra power supplies are hot swappable (able to be changed while the unit is operating). At
least one module is required to operate the amplifier. The operator can observe the status of the
power supply using the front panel display, which will update with each module
insertion/extraction. Table 1-3 provides a list of parts provided for each configuration of
redundant power supply.
Table 1-3. Redundant Power Supply Parts and Quantity Supplied
Parts List N+0 (Qty) N+1 (Qty) N+2 (Qty) N+3 (Qty)
Screw 10-32 x ½
1290050100 4 4 4 4
Connector Lock and Entry
5350002870 1 2 3 4
Power Supply Module
7850111370 1 2 3 4
Power Supply Rack
7850111770 1 1 1 1
Blank Panel
7850111800 3 2 1 0
DC Power Harness
0104466500 1 1 1 1
Redundancy Alarm Harness
0104466700 1 1 1 1
Note: Do not disconnect the DC Power Harness on the Power Supply Rack.
Reversing the polarity while reconnecting the DC Power Harness will cause
permanent damage and void the warranty.
Note: Do not remove all redundant power supplies while Indoor SSPA is in
operation.
1.4.5 Transient Surge Suppression
The transient surge suppression module allows the SSPA to handle 6KV surges without
effecting operation. The TVSS module is rated for 10,000 Amps and 300 Joules. This option
allows the amplifier to be compliant with EN61000-4-5, 6kV voltage surges: both common mode
and differential mode power line voltage surges.

INTRODUCTION
1-10 DOC.01040043 REV.6
1.4.6 Ethernet LAN Interface
The Ethernet port allows the SSPA to be monitored and controlled from anywhere that the local
area network (LAN) can reach.
1.4.7 Redundant/Phase Combined Switch System
The redundant switch system is detailed in the dedicated manual that accompanies the switch.
The available switch systems include redundant configurations as well as power/phase
combined systems. All switch systems are displayed graphically on the front panel display.
1.4.8 Input and Output Power Sampling Ports
The power sampling ports provide a coupled sample of the input or output power signals.
Either a RF signal analyzer or a RF power meter can be connected at these ports, to monitor the
input or output signals.
1.4.9 Exhaust Duct
Use of the exhaust duct allows the evacuation of the hot exhaust air to an exterior location,
helping to prevent heat build-up in the amplifiers indoor location. The exhaust duct should
transition to an 8” duct within 1m of the output, or provide slightly negative pressure to
prevent amplifier over heating due to excessive backpressure.
1.5 About This Manual
This manual describes the installation, operation, maintenance, and troubleshooting procedures
for the Indoor SSPA. Because specialized training is required for some phases of installation and
repair, parts of this manual are directed only to trained personnel. Where appropriate, warnings
appear to caution the operators or technicians of potential RF and high voltage hazards.
Each chapter begins with a clearly marked tab that allows rapid access to a particular section.
The “Table of Contents”, “List of Figures”, and “List of Tables” are included at the beginning of
this volume.
Chapter 1, “Introduction”, provides a brief overview of the amplifier and this manual.
Chapter 2, “Unpacking and Installation”, provides instructions on preparing the site for
installation, how to uncrate, and make necessary electrical connections.
Chapter 3, “External Interfaces”, describes built-in interfaces to external devices and gives
detailed descriptions for each connection.
Chapter 4, “Initial Power-On and Check Out”, describes pre-power procedures on how to use the
control panel for start up and control.

INTRODUCTION
DOC.01040043 REV.6 1-11
Chapter 5, “Operation”, provides procedures for operation, and turn off.
Chapter 6, “Maintenance”, contains procedures for routine maintenance. Troubleshooting and
repair information is contained in the “Indoor SSPA Service Manual”.
Chapter 7, “Functional Tree”, contains a functional tree of the front panel screens.
Chapter 8, “Redundant Switch Option”, contains information on installing and operating a
redundant switch system.
Chapter 9, “Drawings and Schematics”, contains drawings of significant parts of the Indoor
SSPA. It includes detailed schematics for the AC subsystems, DC subsystems, RF subsystems,
interconnections, and over all architecture of the system.
Appendices, contains supplementary data.
1.6 Conventions
Symbols and conventions used throughout this manual are described in the following sections.
1.6.1 Notes and Cautions
General notes, cautions, or warnings, provide additional commentary or technical information.
They identify conditions, operations, or procedures that could potentially damage the
equipment, induce physical strain, maim, or kill people. This includes heavy weights, sharp
edges or protrusions, and chemical hazards. They are identified by the following symbol:
1.6.2 Electrical or RF Warnings
Electrical warnings identify conditions, operations, or procedures that expose the operator to
potentially lethal high voltages and are identified by the following symbol:
Microwave radiation warnings identify conditions, operations, or procedures that expose
people to microwave radiation sources that could cause serious injuries, particularly to the eyes
and are identified by the following symbol:

INTRODUCTION
1-12 DOC.01040043 REV.6
1.6.3 Text Conventions
When operator action is required for software entries, the action required is capitalized and the
action object is capitalized and may be bold for emphasis. For example, PRESS ENTER.
Labels for Front Panel controls and indicators are capitalized. For example, RESET.
Sometimes the actual labels are abbreviated. For Example, TWT TEMP.
Italics are used in references to other manuals and other parts of this manual, such as: See
Service Manual.

UNPACKING & INSTALLATION
DOC.01040044 REV.6 2-1
2-1
Chapter 2
Unpacking & Installation
Table of Contents
CHAPTER 2 UNPACKING & INSTALLATION................................................................................2-1
2.1 OVERVIEW.................................................................................................................................2-3
2.2 PRE-INSPECTION .....................................................................................................................2-3
2.3 UNPACKING...............................................................................................................................2-3
2.3.1 EQUIPMENT AND ACCESSORIES ...................................................................................2-3
2.3.2 CHECK PACKING SLIPS....................................................................................................2-3
2.3.3 POST UNPACKING INSPECTION.....................................................................................2-3
2.4 LOCATION OF INSTALLATION............................................................................................2-4
2.5 PREPARING FOR INSTALLATION.......................................................................................2-4
2.6 INSTALLATION.........................................................................................................................2-4
2.6.1 MECHANICAL INSTALLATION.......................................................................................2-4
2.6.2 GROUNDING .......................................................................................................................2-5
2.6.3 COOLING CONSIDERATIONS..........................................................................................2-5
2.6.4 ELECTRICAL POWER CONNECTIONS...........................................................................2-5
2.6.4.1 PRIME POWER.................................................................................................................2-6
2.6.5 WAVEGUIDE CONNECTIONS..........................................................................................2-8
2.6.6 RF COAXIAL CONNECTIONS...........................................................................................2-9
2.6.6.1 RF INPUT (J2)...................................................................................................................2-9
2.6.6.2 RF OUTPUT MONITOR (J4) (OPTIONAL) .....................................................................2-9
2.6.6.3 RF INPUT MONITOR (J5) (OPTIONAL) .......................................................................2-10
2.6.6.4 BUC INPUT WITH BUC BYPASS (J16) (OPTIONAL)...................................................2-10
2.6.6.5 BUC BYPASS (J17) (OPTIONAL)...................................................................................2-10

UNPACKING & INSTALLATION
2-2 DOC.01040044 REV.6
List of Figures
FIGURE 2-1. CONNECTOR LOCATIONS (C BAND SHOWN) .........................................................................2-7
FIGURE 2-2A.TIGHTENING SEQUENCE (C-BAND) ....................................................................................2-8
List of Tables
TABLE 2-1. PRIMARY POWER CABLE CONNECTIONS................................................................................2-6
TABLE 2-2. WAVEGUIDE FLANGE SCREW TORQUE ..................................................................................2-9

UNPACKING & INSTALLATION
DOC.01040044 REV.6 2-3
2.1 Overview
This section contains instructions on preparing the site for installation, how to unpack, and
make necessary electrical connections for the Indoor SSPA.
2.2 Pre-inspection
Before unpacking the equipment, inspect the exterior and the interior of the shipping containers
for evidence of damage in shipment. If damage is 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
Note: Save all packing material until inspections and installation are
complete. It is recommended that any factory returns be shipped in their
original shipping container. See Appendix A for Return information.
2.3.1 Equipment and Accessories
Carefully unpack and remove the following items from the shipping container(s):
•The SSPA •Cables and accessories •The packing slips
•Manual •Optional accessories
2.3.2 Check Packing Slips
After unpacking the Indoor SSPA verify all items on the packing slips have been received.
2.3.3 Post Unpacking Inspection
Inspect all items for evidence of damage in shipment. If damage is evident, immediately contact
the carrier that delivered the equipment to file a claim. Failure to do so could invalidate future
claims. Save the packing boxes for inspection by the carrier’s agent to validate damage claims. Take
photos of marks on boxes and crates. Check the equipment thoroughly for damaged or loose parts.

UNPACKING & INSTALLATION
2-4 DOC.01040044 REV.6
2.4 Location of Installation
This amplifier is an IDU (Indoor Unit). It is only intended for installation in an indoor location
that provides reasonable temperature control and shielding against direct sunlight. Further, the
location chosen must be clean and dry.
WARNING! ELECTRICAL WARNINGS IDENTIFY CONDITIONS, OPERATIONS, OR
PROCEDURES THAT EXPOSE THE OPERATOR TO POTENTIALLY LETHAL HIGH
VOLTAGES.
2.5 Preparing For Installation
It is recommended that an electrical inspection for verification of customer interface connections
be performed before and after the installation of the equipment in its final operational location;
the following basic steps must be completed:
•Verify that the Indoor SSPA RF input and output are properly terminated.
•Verify that all Indoor SSPA user interface connectors that to be used match the pin-out data
provided in this section.
•Verify the prime power connection to the Indoor SSPA is the correct line voltage.
Warning: Operating the Indoor SSPA amplifier without proper terminations
is a safety hazard and will void the warranty. See specifications in the
“drawings” chapter.
The amplifier is air-cooled. The intake and exhaust areas must not be blocked. For further
information, refer to the respective outline drawing in the “Drawings” chapter and the yellow
Operational Warning document located at the front of this manual.
2.6 Installation
Installation of the IDU SSPA is detailed in the following sections.
2.6.1 Mechanical Installation
Caution: Due to the weight of the Indoor SSPA, two persons are required
for installation into the final cabinet assembly.
The IDU SSPA is designed for rack slide mounting in a standard 19-inch (48.3 cm) wide cabinet.
Use the following procedure for this installation:
1. Determine the required front panel arrangement and exact panel locations for the IDU SSPA
on the rack cabinet.