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

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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

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Table B-14. Software Error Codes.....................................................................................................B-29
Table C-1. Replaceable Parts Listing..................................................................................................C-1
Table C-1. Replaceable Parts Listing (continued).............................................................................C-2

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S-1
Safety
Introduction
In addition to the High Voltage Equipment Personnel Operating Guidelines given in this chapter,
included by reference are the following pertinent sections of the International Standard EN60215,
Safety Requirements for Radio Transmitting Equipment:
•Appendix D, Guidance on Assessing the Competence of Personnel for Designation as
Skilled, and also Sub-clause 3.1 of the Standard.
•Appendix E, Guidance on Safety Precautions to be Observed by Personnel Working on
Radio Transmitting Equipment, and also Sub-clauses 3.2, 3.7, and 22.1 of the Standard.
High Voltage Equipment
Personnel Operating Guidelines
This guideline document presents operating practices for operators and technicians who work
with high voltage equipment. In the context of this discussion any voltage that is lethal is viewed
as "high voltage." Therefore, even prime power (115 to 440VAC) is dangerous because prime
power potentials have been known to cause death or injury.
Electrical circuits operate quickly and do not allow a careless individual a second chance. When
dealing with high voltage, the results are very consistent and predictable and hazards associated
with high voltage are always present. The fact that the control switch says OFF does not mean
you are safe.
Note: 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.
When is Voltage "High"?
As stated earlier, any voltage that can kill you should be treated as high voltage. Voltages
associated with prime power generally do not jump the air gap between people and the
equipment. Usually exposed circuit elements such as a terminal, bare piece of wire, or some non-
insulated surface must be touched.

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One of the problems associated with prime power is some equipment can be "floating" above
ground. In this case, if you place one hand on the equipment chassis and the other on earth
ground, you can be jolted, injured, or killed. 440VAC can stimulate an involuntary muscle
response that will either literally throw you across a room or seize and hold you across the voltage
terminals. 600 or more volts can hold you indefinitely. If the potential is sufficient to drive 200
milliamps through your body you will be held indefinitely. Some people consider the 200 to 600
volt range to be worse than potentials of thousands of volts.
General Guidelines
In addition to the above, the following practices have proven effective for personnel who deal
with high voltage equipment.
a. Hands off. Avoid contact with any potential source of high voltage. Keep hands out
of the equipment when it is operating.
b. Avoid accidental contact. Make sure that some other part of your body does not come
in contact with the high voltage circuits. It is easy to forget the hazards when you are
concentrating on a frustrating or interesting task. Pens and badges in shirt pockets
could contact the equipment.
c. Never work on high voltage circuits when you are alone. If anything should happen
to you, your only chance may be prompt action by some other person. Be sure
someone else is present and knows what to do in any emergency (e.g., how to shut
equipment off, first aid, who to call, etc.)
d. Use one hand when working with high voltage circuits. Many people recommend
that you put one hand in your pocket when you use a probe or other piece of
equipment inside a high voltage section.
e. Do not float measuring equipment above ground. Make all measurements with
respect to ground. If you float an instrument, do not reach inside the equipment.
Although it is more difficult to get the right setup, it is well worth the effort.
f. Do not assume that the level of risk is a function of size. Some large high power
voltage equipment looks docile. One reason the equipment is so big is to get the
proper separation between high voltage points. On the other hand, just because the
equipment is small is no assurance of safety. Dense packaging results in more difficult
access and increases the chance that you will accidentally hit the wrong point.
g. Always discharge high voltage capacitors. High voltage capacitors store a lot of
energy for long periods of time. High voltage capacitors also exhibit a "memory" in
that they can recover after discharge and reach lethal levels. In addition to the
"memory" problem, there have been instances where the built-in safety features have
failed or have been miswired. Each and every time you go to work on a piece of high
voltage equipment, use a discharge device with a long handle to discharge every
high voltage capacitor.
h. Do not depend on the automatic features of the equipment to save you. You never
know when someone has left a circuit disabled, if there has been a wiring error, or if a
component has failed.

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i. Take personal responsibility to assure that no one can turn on the high voltage
circuits when you are working on the equipment. Precautions would include taping
down (or installing a keeper) on controls/circuit breakers and/or disconnecting the
power source to the high voltage circuits, activating interlocks that prevent high
voltage turn on, etc. Know where the power disconnects are and use them. Do NOT
rely on anyone not to turn on the high voltage.
j. Set up your test equipment with the power off. Conduct the power-on operations
when you have your hands out of the equipment.
k. Do not use short probes for high voltage measurements. A short probe does not
allow any margin for error. If your hand slips you could accidentally come into contact
with a danger point. A long probe avoids the whole problem.
l. Read the instruction manual. The best insurance is foreknowledge of hazards.
m. Create a favorable environment for safe operations. This means that if people are
crowding you, stop the operation if it involves high voltage. Pressure can lead to
carelessness. In the same way, fatigue is also an enemy. STAY ALERT AT ALL TIMES
WHEN WORKING WITH HIGH VOLTAGE.
n. Do not become over-confident. Maintain a healthy respect for high voltage.
o. A good operating practice is to check the potential between the equipment chassis
and earth ground before you complete the circuit with your body. As voltage levels
increase, the protection you get from insulation and air gap diminishes. For example,
in a piece of equipment that involves beam voltages of about 16kV, the beam
transformers look very safe with massive insulation on the outside of the coils.
Physical contact with the beam coil when the system is operating can be fatal.
Although the equipment is placard to warn people of the presence of high voltage, it is
virtually impossible to placard every point of danger in a system.
p. If you do not know how the equipment works and what the hazards associated with
the equipment are in specific terms, do NOT handle the equipment. The greatest
protection you can have when dealing with high voltage equipment is specific detailed
knowledge on that particular piece of equipment.
q. Avoid "haywire" test setups. It is easy to get in trouble if the setup you are using has a
jumble of wires.
r. Make sure your connections are secure. Do NOT allow leads to slip off and move
about in an uncontrolled fashion. Even if it is not one of the high voltage leads, a free
lead could (and generally does) move exactly to where you do not want it. The only
safe connection is a mechanically secure one.
s. Watch out for unterminated high voltage leads. Some connectors depend on circuit
loading to avoid arcing between closely spaced terminals. Unloaded high voltage lines
or plugs can lead to arcing situations.

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t. Shut off the high voltage when you are making low voltage measurements. It does
not make sense to increase danger needlessly. While there may be times when you
cannot shut off the high voltage during a low voltage measurement, this is generally
not the case.
u. Remove the test equipment when you have finished a measurement program. There
have been many instruments destroyed or damaged because a test program was
conducted in a haphazard manner, rather than in an orderly progression from start to
finish. Experience has shown in many instances when a little order would have
prevented a tragedy or avoided an expensive mistake.
v. Be extremely wary when making filament voltage measurements. The cathode of
tubes is elevated above (or below) ground and the filament voltages usually cannot be
measured with reference to ground. Do everything you can to assure that the high
voltage cannot be turned on when you are making your measurements. This includes
disconnecting the high voltage drive source, shorting out appropriate leads, taping
down switches, and anything else you can think of to protect yourself.
w. When troubleshooting a unit, assume that the switches and components are
defective. You may shut off the high-voltage switch in some systems, but if the switch
were defective, the high voltage would still be on. Returned units are potential booby
traps.
x. Make sure that your workstation is stable. Flimsy work surfaces or supports for the
equipment or the test instruments represent a real threat. Do NOT use a setup that you
know is unstable and/or dangerous.
y. Use a 1-minute rule. Wait 1 minute or more after you have shut off the equipment
before you work on a unit. Part of the reason for a 1-minute rule is that some of the
dielectrics (insulators) used for high voltage circuits can store a charge. While the
amount of charge stored is a function of the size of the object, a 1-minute rule provides
an additional margin of safety.
z. Maintain a healthy respect for any kind of live circuit. Complacency can hurt or kill
you. Your continued wariness is your best insurance against injury or death.
Microwave Radiation
Personnel Operating Guidelines
This guideline presents operating practices appropriate for operators and technicians who work
with equipment involving microwave radiation. Keep in mind that levels of microwave radiation
that do not induce immediate physical discomfort in most individuals can be sufficiently high to
induce longer-term effects.

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CPI Satcom Division equipment usually is related to amplification of a RF signal from an external
source. Even if a source is not connected to the amplifier you are working with, there are
situations where the amplifier can go into a self-induced mode and generate high levels of RF
energy. This condition can exist if the unit is operated with high voltage ON and without proper
termination on the input and output of the amplifier.
CAUTION! PROTECT YOURSELF AND THOSE AROUND YOU FROM UNWANTED RF
EXPOSURE. ALWAYS TERMINATE THE AMPLIFIER INPUT AND OUTPUT WITH A
RF DUMMY LOAD BEFORE YOU TURN THE HIGH VOLTAGE ON. THIS WILL
REDUCE THE CHANCES OF OSCILLATION DUE TO INTERNAL AMPLIFIER NOISE.
Microwave Discussion
Limit exposure to microwave radiation to prevent unwanted biological effects. There are other
effects that can lead to problems if you are careless in operating or servicing microwave
equipment. The permissible levels are quite low in comparison to the power levels of the
amplifiers built by CPI (e.g., less than 10 milliwatts vs. 20 to 10,000 Watts delivered by different
units)
Local radiation levels can be detected with the proper equipment. The permissible levels are
currently being studied by a number of organizations. In the past the U.S. Safety Codes
established a dosage rate of 10mw/cm. Sq. Recently the permissible level has been reduced to
1mw/cm. sq. in the United States, as has been the case in several European countries.
General Microwave Guidelines
The purpose of these guidelines is to provide practical approaches to control unwanted
microwave energy associated with the operation and servicing of CPI Satcom Division equipment.
The following approaches are effective in both laboratory or field environments:
a. Always terminate the output waveguide or coaxial connector with a dummy RF load
(capable of dissipating full CW RF power). Similarly, terminate the input to avoid the
possibility of the amplifier being driven by stray leakage signals. Incorporate the
terminations prior to applying prime power to the amplifier. This procedure prevents self-
oscillation and irradiation of the local equipment.
b. Do not look into the output port of the powered RF amplifier. Treat the powered amplifier
as though it is a loaded gun. Your eyes are particularly vulnerable parts of your body.
c. Shut off the unit if you are trying to locate a RF leak. As noted earlier, the levels of concern
are very low. Examine the physical unit with the high voltage OFF. If you have to survey the
RF runs with the power ON to find the leaky joint or component, start by testing the system
with low RF input and a radiation meter.
If the microwave radiation exceeds 0.5mw/cm. sq., shut OFF the high power voltage and consult
your supervisor. Work quickly (not at a panic pace) to minimize the dose level. The dose you get
is directly proportional to the power level and the time you are exposed. Exposure to microwave
radiation can induce both thermal and non-thermal biological effects, especially with the eyes.

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If you damage the lens of your eyes by exposure to microwave radiation, cataracts can result.
Consider that small microwave ovens are very effective in cooking foods. If you follow these
guidelines you can minimize exposure of yourself and other people in the operations that you
control.
Physical Safety
Lifting Heavy Objects
Back and other injuries can result from one person trying to lift too much weight.
Use extreme caution when lifting klystrons. Klystrons weigh up to 100 pounds (45 kg) and
require two persons to lift them.
Due to the weight of the drawers, at least two persons are required for installation of the drawers
to the final rack assembly. At least two people are also required for removal of the drawers from
the rack assembly.
Extending Rack Slides
a. Serious injuries can result from heavily loaded racks or drawers falling forward.
b. Due to the weight of the drawers, the rack must be securely bolted to the floor in all four
corners to prevent tipping when the drawer slides are extended.
c. Verify that all slides are securely mounted and that all latches and stops are functioning
properly.
d. Serious injuries can also result from hands, fingers, or clothing getting caught in slides and
drawers when extended drawers are being pushed back into a rack.
e. Exercise extreme caution when sliding extended drawers back into a rack.

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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 5.715 - 6.425 602
VZC-6967AB 5.850 - 6.650 602
VZC-6967AG 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 12.75 - 14.50 501
VZU-6997AB 12.75 - 14.50 650
VZU-6997AC 13.75 - 14.50 602
VZU-6996AC 13.75 - 14.50 501
VZU-6997AE 14.00 - 14.80 602
VZU-6997AG 14.70 - 15.32 602
(549 above 15GHz)

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Table 1-1. CHPA Model Number and Frequency Ranges (continued)
Model No. Frequency Range (GHz) Rated Power (Watts)
VZU-6997AA 13.00 - 13.25 602
VZU-6997AD 13.75 - 14.50 650
VZU-6997AJ 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