CPI Satcom Division VZU-6997 Series User manual

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INSTALLATION, OPERATION, AND
PREVENTATIVE MAINTENANCE
MANUAL
CHPA (COMPACT HIGH POWER AMPLIFIER)
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
VZU-6997 Series
VZU-6996 Series
VZU-6995 Series
VZC-6967 Series

CHPA SERIES
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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.

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Table of Contents
SAFETY................................................................................................................................................... S-1
INTRODUCTION................................................................................................................................... S-1
HIGH VOLTAGE EQUIPMENT......................................................................................................... S-1
PERSONNEL OPERATING GUIDELINES....................................................................................... S-1
WHEN IS VOLTAGE "HIGH"?.......................................................................................................... S-1
GENERAL GUIDELINES................................................................................................................... S-2
MICROWAVE RADIATION................................................................................................................ S-4
PERSONNEL OPERATING GUIDELINES....................................................................................... S-4
MICROWAVE DISCUSSION............................................................................................................. S-5
GENERAL MICROWAVE GUIDELINES......................................................................................... S-5
PHYSICAL SAFETY........................................................................................................................... S-6
LIFTING HEAVY OBJECTS..............................................................................................................S-6
EXTENDING RACK SLIDES.............................................................................................................S-6
CHAPTER 1 INTRODUCTION...........................................................................................................1-1
1.1 OVERVIEW.................................................................................................................................1-1
1.2 ABOUT THIS MANUAL............................................................................................................1-3
1.3 MAJOR SUBSYSTEMS AND THEIR FUNCTIONS..............................................................1-4
1.4 TECHNICAL DESCRIPTION...................................................................................................1-4
1.4.1 RF SUBSYSTEM..................................................................................................................1-4
1.4.2 POWER SUPPLY SUBSYSTEM .........................................................................................1-6
1.4.3 POWER FACTOR CORRECTION MODULE ....................................................................1-7
1.4.4 POWER PROCESSOR MODULE........................................................................................1-7
1.4.5 HIGH-VOLTAGE MODULE ...............................................................................................1-7
1.4.6 RF POWER MONITOR MODULE......................................................................................1-7
1.4.7 CONTROL AND DISPLAY MODULES.............................................................................1-8
1.5 LRU PHILOSOPHY ...................................................................................................................1-8
1.6 OPTIONAL FEATURES............................................................................................................1-9
CHAPTER 2 UNPACKING AND INSTALLATION.........................................................................2-1

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2.1 OVERVIEW.................................................................................................................................2-1
2.2 PRE-INSPECTION .....................................................................................................................2-1
2.3 UNPACKING...............................................................................................................................2-1
2.4 PREPARING FOR INSTALLATION.......................................................................................2-2
2.5 INSTALLATION.........................................................................................................................2-2
2.5.1 MECHANICAL INSTALLATION.......................................................................................2-2
2.5.2 ELECTRICAL CONNECTIONS..........................................................................................2-3
2.5.3 PRIME POWER ....................................................................................................................2-3
2.5.4 GROUNDING .......................................................................................................................2-4
2.5.5 I/O INTERFACES.................................................................................................................2-4
2.5.6 RF CONNECTIONS .............................................................................................................2-4
2.5.7 RF OUTPUT (WAVEGUIDE CONNECTION)(J3).............................................................2-5
2.5.8 COOLING CONSIDERATIONS..........................................................................................2-5
CHAPTER 3 INTERFACES .................................................................................................................3-1
3.1 OVERVIEW.................................................................................................................................3-1
3.2 CHPA CONTROL MODE HIERARCHY................................................................................3-1
3.3 SERIAL REMOTE INTERFACE .............................................................................................3-2
3.4 RF SWITCH SYSTEM INTERFACE.......................................................................................3-4
3.4.1 RELAY DEFINITIONS ........................................................................................................3-4
3.5 EXTERNAL INTERLOCKS INTERFACE .............................................................................3-6
3.6 COMPUTER INTERFACE........................................................................................................3-8
3.6.1 CIF HARDWARE CONFIGURATION ...............................................................................3-8
3.7 COMPUTER INTERFACE (CIF) PROTOCOL .....................................................................3-9
3.8 PROTOCOL MESSAGE STRUCTURE...................................................................................3-9
3.9 COMMAND AND RESPONSE FORMAT.............................................................................3-10
3.9.1 HEADER AND ENDING BYTES......................................................................................3-10
3.9.2 ADDRESS BYTE................................................................................................................3-11
3.9.3 COMMAND BYTE.............................................................................................................3-11
3.9.4 RESPONSE BYTE(S) .........................................................................................................3-11

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3.9.5 REJECT BYTE(S)...............................................................................................................3-11
3.9.6 CHECK BYTE.....................................................................................................................3-12
3.9.7 CARRIAGE RETURNS AND LINE FEEDS.....................................................................3-13
3.10 COMMANDS.............................................................................................................................3-13
3.10.1 SLOW COMMANDS..........................................................................................................3-16
3.11 STATUS BYTE DEFINITIONS...............................................................................................3-17
3.12 ID/VERSION MESSAGE .........................................................................................................3-21
CHAPTER 4 INITIAL POWER ON AND CHECKOUT ..................................................................4-1
4.1 OVERVIEW.................................................................................................................................4-1
4.2 PRE-POWER PROCEDURES...................................................................................................4-1
4.3 USING THE FRONT PANEL....................................................................................................4-2
4.4 INITIAL POWER-ON PROCEDURES....................................................................................4-3
4.4.1 POWER-ON SELF-TEST AND HEATER TIME DELAY..................................................4-3
4.5 VERIFYING OPERATIONAL SETTINGS.............................................................................4-4
4.6 SETTING THE FAULT AND ALARM TRIP POINTS..........................................................4-4
4.7 SETTING SERIAL REMOTE AND CIF PORT PARAMETERS.........................................4-6
4.8 VERIFYING RF OUTPUT LEVEL ..........................................................................................4-7
4.9 VERIFYING RF ALARM AND RF FAULT TRIP POINTS..................................................4-8
4.10 TESTING THE CHPA VIA COMPUTER CONTROL ..........................................................4-9
4.11 TESTING OPTIONAL EQUIPMENT......................................................................................4-9
4.11.1 REMOTE CONTROL INTERFACE ....................................................................................4-9
CHAPTER 5 OPERATION...................................................................................................................5-1
5.1 OVERVIEW.................................................................................................................................5-1
5.2 ESSENTIAL CHPA OPERATING PROCEDURES...............................................................5-2
5.2.1 TRANSMIT...........................................................................................................................5-2
5.3 NORMAL SHUTOFF .................................................................................................................5-3
5.4 BASIC CHPA OPERATION......................................................................................................5-3

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5.5 CHPA STATES AND DESCRIPTION......................................................................................5-4
5.6 INITIALIZATION AND POWER-ON SELF-TEST (POST) STATE...................................5-4
5.7 HEATER TIME DELAY (HTD) STATE..................................................................................5-5
5.8 STANDBY STATE ......................................................................................................................5-6
5.9 TRANSMIT STATE....................................................................................................................5-7
5.10 FAULT STATE............................................................................................................................5-7
5.11 CHPA CONTROL MODES AND HIERARCHY....................................................................5-8
5.12 RF CONTROL MODES .............................................................................................................5-9
5.13 SPECIAL CHPA FUNCTIONS ...............................................................................................5-10
5.13.1 FACTORY AUTHORIZED ACCESS MODE ...................................................................5-10
5.14 TERMINOLOGY......................................................................................................................5-10
5.15 EXITING A MENU...................................................................................................................5-11
5.16 DATA ENTRY RULES.............................................................................................................5-11
5.17 QUICK ACCESS CODES.........................................................................................................5-13
CHAPTER 6 MAINTENANCE ............................................................................................................6-1
6.1 OVERVIEW.................................................................................................................................6-1
6.2 SCHEDULED PREVENTIVE MAINTENANCE....................................................................6-1
6.3 MECHANICAL PREVENTIVE MAINTENANCE.................................................................6-2
6.4 VISUAL INSPECTION...............................................................................................................6-4
6.4.1 INSPECTING AND CLEANING AIR FILTERS.................................................................6-5
6.4.2 CHECKING A3 LEDS AND DISPLAY...............................................................................6-5
6.4.3 COLLECTOR AIR SYSTEM MAINTENANCE .................................................................6-5
6.4.4 CHECKING B1 COLLECTOR BLOWER...........................................................................6-6
6.4.5 MISCELLANEOUS CLEANING.........................................................................................6-6
6.5 ELECTRICAL PREVENTIVE MAINTENANCE ..................................................................6-6
6.6 SPARE TWT MAINTENANCE AND PERIODIC OPERATION OF THE AMPLIFIER.6-6
6.7 PERFORMANCE TESTING .....................................................................................................6-8

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6.8 POWER AND GAIN ...................................................................................................................6-8
CHAPTER 7 DRAWINGS AND SCHEMATICS...............................................................................7-1
CHAPTER 8 SUPPLEMENTARY DATA...........................................................................................8-1
APPENDIX A SPECIFICATIONS......................................................................................................A-1
APPENDIX B CONTROL APPEARANCE AND CONTENT.........................................................B-1
B.1 OVERVIEW................................................................................................................................B-1
B.2 BUTTONS ...................................................................................................................................B-1
B.3 LEDS............................................................................................................................................B-2
B.4 BEEPER.......................................................................................................................................B-3
B.5 ALPHANUMERIC DISPLAY DEFINITION .........................................................................B-3
B.6 METERS......................................................................................................................................B-5
B.6.1 HVPS METER DISPLAY LIST: .........................................................................................B-5
B.6.2 RF METERS.........................................................................................................................B-5
B.6.3 METER ORDER ..................................................................................................................B-5
B.6.4 METER LIST........................................................................................................................B-6
B.7 FAULT MESSAGES THAT CORRESPOND TO DIGITAL STATUS LINES...................B-6
B.8 FAULT MESSAGES GENERATED BY LIMIT COMPARISONS .....................................B-7
B.9 ALARMS.....................................................................................................................................B-8
B.10 CONTROL MENU.................................................................................................................B-9
B.11 DATA ENTRY RULES..........................................................................................................B-9
B.11.1 CATEGORIES....................................................................................................................B-13
B.11.2 RF CONTROL....................................................................................................................B-13
B.11.3 LINEARIZER CONTROL (OPTIONAL)..........................................................................B-14
B.12 LINEARIZER ADJUSTMENT...........................................................................................B-15
B.13 RF TRIP LIMITS/SWITCH PORT RELAY SETTINGS................................................B-16
B.13.1 FAULT LOG ......................................................................................................................B-17
B.13.2 FACTORY AUTHORIZED ACCESS CODE (FAAC).....................................................B-18
B.13.3 FAULT TRIP SETTING ....................................................................................................B-19

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B.13.4 FACTORY TESTS.............................................................................................................B-19
B.13.5 RESET ELAPSED TIME METERS ..................................................................................B-19
B.13.6 RESET TO FACTORY DEFAULTS.................................................................................B-20
B.13.7 CHPA HVPS TEST MODE ...............................................................................................B-20
B.13.8 USER TESTS......................................................................................................................B-21
B.13.9 TIME/DATE SET...............................................................................................................B-22
B.13.10 REMOTE/COMPUTER INTERFACE PARAMETERS...............................................B-23
B.13.11 SOFTWARE VERSIONS...............................................................................................B-26
B.13.12 ELAPSED HOURS INFORMATION............................................................................B-26
B.14 QUICK ACCESS CODES....................................................................................................B-27
B.15 POST FAULTS .....................................................................................................................B-29
B.16 SOFTWARE ERROR CODES............................................................................................B-29
B.16.1 FLASH RAM - OPERATION AND PROGRAMMING...................................................B-30
B.16.2 TO FORCE THE CHPA TO USE EPROM CONTENTS..................................................B-30
B.16.3 REPROGRAMMING THE FLASH RAM.........................................................................B-30
B.16.4 ERROR MESSAGES ASSOCIATED WITH THE FLASH RAM....................................B-32
APPENDIX C REPLACEABLE PARTS............................................................................................C-1
APPENDIX D WARRANTY AND SUPPORT INFORMATION....................................................D-1
APPENDIX E OPTIONS AND FEATURES ......................................................................................E-1
APPENDIX F OPTIONAL L-BAND BUC .........................................................................................F-1
F.1 OVERVIEW................................................................................................................................F-1
F.2 PRECAUTIONS .........................................................................................................................F-2

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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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Table 3-12. Secondary Status Bytes....................................................................................................3-18
Table 3-13. Fault and Miscellaneous Status......................................................................................3-19
Table 3-13. Fault and Miscellaneous Status (continued)................................................................3-20
Table 3-14. Information/Error Messages..........................................................................................3-20
Table 3-14. Information/Error Messages (continued)....................................................................3-21
Table 4-1. Helix and RF Settings Ranges ............................................................................................4-5
Table 4-1. Helix and RF Settings Ranges (continued).......................................................................4-6
Table 5-1. Front Panel Categories......................................................................................................5-11
Table 5-1. Front Panel Categories (continued).................................................................................5-12
Table 5-1. Front Panel Categories (continued).................................................................................5-13
Table 6-1. Preventive Maintenance Schedule CHPA........................................................................6-2
Table 6-1. Preventive Maintenance Schedule CHPA (continued)...................................................6-3
Table 6-2. Recommended Test and Service Equipment Description..............................................6-3
Table 6-2. Recommended Test and Service Equipment Description (continued) ........................6-4
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-10
Table B-3. Front Panel Categories (continued) ...............................................................................B-11
Table B-4. Default Values For User Features...................................................................................B-12
Table B-5. RF Display Preferences....................................................................................................B-13
Table B-6. RF Alarms and Faults.......................................................................................................B-16
Table B-7. User Tests and Results.....................................................................................................B-21
Table B-8. Time/Date Settings..........................................................................................................B-22
Table B-9. Computer Interface Parameters......................................................................................B-23
Table B-9. Computer Interface Parameters (continued)................................................................B-24
Table B-10. Computer Interface Parameters....................................................................................B-24
Table B-10. Computer Interface Parameters (continued)..............................................................B-25
Table B-11. Software Versions...........................................................................................................B-26
Table B-12. Elapsed Hours Feature...................................................................................................B-26
Table B-13. POST Faults.....................................................................................................................B-29