CPI T04CO User manual

INSTALLATION
&
OPERATION
MANUAL
MPA Hub Mount
For Use With Model Numbers . . .
T04CO
T04UO
Service Center Headquarters and Design Center
West Coast Operations
811 Hansen Way
Palo Alto, CA 94303
Manufacturing
East Coast Operations
45 River Drive
Georgetown, Ontario
Canada L7G 2J4
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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 © 2001 by Communications & Power Industries. All rights reserved.

MPA HUB MOUNT
Table of Contents
SAFETY
Introduction ...................................................................................... S-1
High Voltage Equipment .................................................................. S-1
Personnel Operating Guidelines ................................................ S-1
When is Voltage "High"?............................................................ S-2
General Guidelines .................................................................... S-2
Microwave Radiation ....................................................................... S-7
Personnel Operating Guidelines ................................................ S-7
Microwave Discussion ............................................................... S-7
General Microwave Guidelines .................................................. S-8
CHAPTER 1 INTRODUCTION
1.1 Overview...................................................................................1-1
1.2 Optional Features .....................................................................1-3
1.3 About This Manual....................................................................1-4
1.4 Conventions..............................................................................1-5
Notes and Cautions ....................................................................1-5
Warnings ..................................................................................1-5
Text Conventions ........................................................................1-6
CHAPTER 2 UNPACKING AND INSTALLATION
2.1 Overview...................................................................................2-1
2.2 Pre-Inspection ..........................................................................2-1
2.3 Unpacking.................................................................................2-1
2.4 Installation ................................................................................2-2
2.4.1 Amplifier Installation .........................................................2-2
2.4.2 Cooling Considerations ....................................................2-3
2.4.3 Electrical Power Connections...........................................2-4
2.4.3.1 Prime Power...........................................................2-4
2.4.3.2 Grounding...............................................................2-4
2.4.4 Remote Control Interface .................................................2-5
2.4.5 Switch Interface Connector (J5) .......................................2-7
2.4.6 RF Coaxial Cable Connections (J3, J4) ...........................2-7
2.4.7 RF Output Waveguide Flange Connection (J8) ...............2-8
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TABLE OF CONTENTS
CHAPTER 3 INITIAL POWER ON AND CHECKOUT
3.1 Overview...................................................................................3-1
3.2 Front Panel Controls and Indicators......................................... 3-2
3.3 Optional RCU Controls and Indicators .....................................3-4
3.3.1 Remote Control Multi - Drop Operation ...........................3-4
3.3.2 Control Keys.....................................................................3-6
3.3.3 Display and LED Group ...................................................3-8
3.4 Operation with PC Computer, Setup & remote software ........ 3-10
3.5 First Time Pre-Power Procedure............................................. 310
3.6 Power On Sequence ..............................................................3-11
3.6.1 Initial Check, High Voltage OFF..................................... 3-11
3.6.1.1 Check Factory Set Values via a Computer……….3-12
3.6.1.2 Check Factory Set Values via RCU………………3-12
3.6.2 Initial Check, High-Voltage ON ......................................3-14
3.7 Verify RF Output..................................................................... 3-16
3.8 Setup For Operational Service ............................................... 3-17
CHAPTER 4 EXTERNAL INTERFACES
4.1 Overview...................................................................................4-1
4.1.1 Control Mode Hierarchy .................................................. 4-1
4.2 Serial Interface ......................................................................... 4-2
4.2.1 Interface Configuration.....................................................4-2
4.3 RF Switch Interface (J5)........................................................... 4-2
4.3.1 Relay Definitions .............................................................. 4-3
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MPA HUB MOUNT
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CHAPTER 5 NORMAL OPERATION
5.1 General.....................................................................................5-1
5.2 Overview of Operation..............................................................5-2
5.3 Normal Operating Procedures..................................................5-3
5.3.1 LOCAL Mode Operation...................................................5-3
5.3.2 Remote Control Mode, Computer Control ........................5-4
5.4 Shutdown..................................................................................5-4
5.4.1 Normal Shutdown.............................................................5-4
5.4.2 Prime Power Interrupts.....................................................5-4
5.5 Making Routine Safety Checks ................................................5-5
5.6 Description of Amplifier States .................................................5-5
5.6.1 POST................................................................................5-6
5.6.2 Heater Time Delay (HTD).................................................5-6
5.6.3 Standby State...................................................................5-7
5.6.4 Beam On Sequence .........................................................5-7
5.6.5 Transmit State ..................................................................5-7
5.6.6 Beam Off Sequence .........................................................5-7
5.6.7 Fault State ........................................................................5-8
5.6.7.1 Auto Fault Recycle Mode Rules .............................5-8
5.6.7.2 Fault Log ................................................................5-9
CHAPTER 6 OPERATOR MAINTENANCE
6.1 Introduction...............................................................................6-1
6.2 Preventive Maintenance Tasks ................................................6-1
6.2.1 Visual Inspection ..............................................................6-2
6.2.2 Air System Maintenance ..................................................6-3
6.3 Other Preventive Maintenance Tasks ......................................6-4
6.4 Customer Service .....................................................................6-4
CHAPTER 7 DRAWINGS
List of Included Drawings..................................................................7-1

TABLE OF CONTENTS
vi Installation and Operation Manual
APPENDICES
Appendix A Warranty and Support Information .............................A-1
Customer Service .......................................................................A-1
Telephone Directory ...................................................................A-1
Return Procedure .......................................................................A-2
Appendix B Operation Setup & Remote software...........................B-1
Appendix C Replaceable parts ...................................................... C-1
Appendix D Optional Linearizer operation..................................... D-1
Appendix E Optional L-band BUC operation ..................................E-1
Appendix F Optional Internal 1:1 switch controller operation .........F-1
Appendix G Optional Hybrid switch controller operation ............... G-1
LIST OF FIGURES
Figure 1-1. MPA Hub Mount ............................................................1-2
Figure 1-2. MPA Hub Mount RF Diagram........................................1-3
Figure 2-1. MPA Connector Locations..............................................2-5
Figure 2-2. RS-232 Cables..............................................................2-6
Figure 2-3. MPA Hub Mount Rear Panel ......................................... 2-8
Figure 3-1. Amplifier Front Panel Controls and Indicators............... 3-2
Figure 3-2. Remote Control Unit Front Panel ..................................3-4
Figure 3-3. Remote Control Unit Control Keys ................................3-7
Figure 3-4. Display and LED Group................................................. 3-8
Figure 3-5. Remote Control Unit Menu Tree ...................................3-9
Figure B-1. Startup Screen .............................................................B-1
Figure B-2. Meters screen (in HTD) ................................................B-2
Figure B-3. No Communication fault ...............................................B-2
Figure B-4. Communication settings................................................B-3
Figure B-5. RF Control Screen .......................................................B-4
Figure B-6. Power supply settings...................................................B-4
Figure B-7. Miscellaneous screen ...................................................B-5
Figure B-8. RF Inhibit state .............................................................B-6
Figure B-9. Changing parameters ...................................................B-6
Figure B-10. Meters screen .............................................................B-7
Figure B-11. Fault reporting .............................................................B-8
Figure B-12. Fault log .....................................................................B-9
Figure B-13. Optional Linearizer settings .....................................B-10

MPA HUB MOUNT
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Figure B-14. WG switch (F3) is active ......................................... B-10
Figure B-15. Switch system with separate input........................... B-11
Figure B-16. Switch system with switched (ganged) input............ B-11
Figure B-17. Switch system type setup......................................... B-12
Figure F-1. Interconnect Diagram (Optional SW Controller) …… ...F-2
Figure G-1. Front view of the Sub System Front Panel ................. G-2
Figure G-2. Top view of the Switch Sub System ...........................G-2
Figure G-3. RF Block Diagram........................................................ G-3
Figure G-4. Switching and Combining State Diagram ................. G-11
Figure G-5. Switching and Combining State Diagram .................. G-11
LIST OF TABLES
Table 1-1. MPA Hub Mount Amplifiers.............................................1-1
Table 3-1. Hub-Mount MPA Front Panel Controls and Indicators....3-3
Table 3-2. Helix and RF Settings Fault and Alarm Ranges ...........3-13
Table 4-1. RF Switch Pin Assignment (J5) ......................................4-6
Table 6-1. Preventative Maintenance - Operator.............................6-2
Table 6-2. Preventative Maintenance - Technician .........................6-2
Table F-1. Drawings ........................................................................F-2
Table G-1. Pin-out Specifications for RS-485................................. G-6
Table G-2. Pin-out Specifications for M&C Interface .....................G-6
Table G-3. Cable Connections ...................................................... G-9
Table G-4. Four Combiner States ................................................G-12
Table G-5. Serial Commands and Arguments .............................G-13
Table G-6. Drawings ....................................................................G-13

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viii Installation and Operation Manual
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MPA HUB MOUNT
SAFETY
Introduction
In addition to the High Voltage Equipment Personnel Operating
Guidelines and the Microwave Radiation 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. Many high voltage
circuits are like loaded guns. In general, you cannot see a high
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SAFETY
voltage hazard. You can learn to recognize situations that present a
threat and how to avoid them.
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.
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.
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MPA HUB MOUNT
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
measurement with respect to ground. If you float an
instrument, you may forget and 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
been miswired. Each and every time you go to work on a
piece of high voltage equipment, use a grounding rod 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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SAFETY
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 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 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 fore-
knowledge 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.
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MPA HUB MOUNT
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.
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
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SAFETY
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 is defective,
you would still have the high voltage 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 the 30-second rule. Wait 30 seconds after you have shut
off the equipment before you work on a unit. Part of the
reason for the 30-second 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, the 30-second rule provides an additional margin
of safety.
z. Maintain a healthy respect for any kind of live circuits.
Complacency can hurt or kill you. Your continued
wariness is your best insurance against injury or death.
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MPA HUB MOUNT
Microwave Radiation
Personnel Operating Guidelines
This guideline section presents operating practices appropriate for
operators and technicians who work with equipment involving
microwave radiation. Keep in mind that levels of microwave
radiation that do not induce immediate physical discomfort in most
individuals can be sufficiently high to induce longer term effects.
CPI Satcom 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.
ELECTRICAL HAZARD! 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.
Currently the permissible level has been reduced to 1mw/cm. sq.
in the United States, as has been the case for several European
countries.
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SAFETY
S-8 Installation and Operation Manual
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 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
with 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. 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.

MPA HUB MOUNT
Chapter 1
INTRODUCTION
1.1 Overview
The CPI MPA (Medium Power Amplifier) Hub Mounts are
designed for satellite communication earth stations, satellite news
gathering vehicles, and flyaway applications. The key feature of
these amplifiers permits direct mounting to antenna structures,
thereby eliminating transmission line losses encountered in
conventional remotely mounted arrangements. For this reason,
these amplifiers are referred to as “MPA Hub Mount Amplifiers.”
Table 1-1 shows the model numbers, frequency ranges, and power
outputs of these amplifiers. Figure 1-1 is a photograph of an MPA.
All models have the same appearance.
Table 1-1. MPA Hub Mount Amplifiers
Model Number Frequency Range
(GHz)
Rated Power
(Watts)
T04UO 12.75 to 14.5 GHz 400 W
T04CO 5.85 to 7.1 GHz 400W
By industry convention, the rated power of an amplifier is the
output power of the high power-amplifying component, a traveling
wave tube (TWT). The output power available to the user at the
amplifier output flange is lower.
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INTRODUCTION
Figure 1-1. MPA Hub Mount (Front View)
The MPAs operate with AC input (line) voltages of 100 - 240 ± 10%
VAC at any frequency between 47 and 63 Hz.
All of the MPAs are the same size and nearly the same weight. The
typical model weighs 51 pounds (23.2 kg.), the overall dimensions,
excluding switches, connectors, and mounting brackets, are 10.25
by 10.4 by 20.5 inches.
These amplifiers are air-cooled. The cooling air enters the bottom
of the unit and exits the front end. (See Chapter 2 for more details.)
MPAs can operate in direct sunlight at ambient temperatures
ranging from –40 to +50°C.
Detailed specifications for the MPA Hub Mount are provided in
Chapter 7, "Drawings”.
The MPAs can be operated in either local or remote mode, the latter
being the primary mode of operation. Remote operation is
performed using either a CPI Remote Control Unit or a user-
supplied IBM compatible computer.
The RF Block diagram is shown in Figure 1-2.
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MPA HUB MOUNT
Figure 1-2. MPA Hub Mount RF Diagram
1.2 Optional Features
The MPA Hub Mount has seven main internal optional features:
A SSIPA Option (with optional pin diode attenuator)
A Linearizer option
Forward power detection over CIF option.
An L-band block up-converter option. (Ku Band Only)
An internal 1:1 switch controller with drive option.
An internal hybrid switch controller with drive option.
A separate MPA Hub Mount Remote Control Unit is also available.
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INTRODUCTION
1.3 About This Manual
This manual describes the MPA Hub Mount installation and
operation procedures.
The Safety section that precedes Chapter 1 provides practical
guidelines regarding High Voltage and Microwave Radiation
operating practices.
Chapter 2, “Unpacking and installation”, contains procedures for
unpacking and installing MPA Hub Mount.
Chapter 3, “Initial Power ON and Checkout”, describes the controls
and indicators on the front panel of the amplifier, the CPI Remote
Control Unit controls and indicators, and the procedures to use for
initial checkout after the amplifier has been installed.
Chapter 4, “Interfaces”, describes:
•
•
The Hub Mount Medium Power Amplifier external interfaces
and external connector pinouts.
The commands used to setup the serial interface hardware
characteristics.
Chapter 5, “Operation”, describes the procedures for normal start-
up and shutdown, and describes the operational modes of the
amplifier.
Chapter 6, “Maintenance”, describes the procedures for scheduled
maintenance and the procedures for return of equipment to CPI.
Chapter 7, “Drawings”, contains relevant engineering drawings
and specifications of the Hub Mount Low Power Amplifier.
The Appendices, “A” through “G”, contain additional topics such
as “Service and Warranty” information and optional features.
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