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INSTALLATION, OPERATION, AND

PREVENTATIVE MAINTENANCE

M A N U A L
COMPACT HIGH POWER OUTDOOR UNIT
0104700500r2
For Use With Model Numbers...

T07DO
T07CO

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

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TOC

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 © 2010 by Communications & Power Industries, Inc. All rights reserved.

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TOC

TABLE OF CONTENTS
Operational Warnings 0103910900
Safety Section 0104002200
Chapter 1 0104720100 Rev.2
Introduction
Chapter 2 0104720200 Rev.2
Unpacking and Installation
Chapter 3 0104720300 Rev.2
Operation
Chapter 4 0104720400 Rev.1
Preventative Maintenance
Chapter 5 0104720500 Rev.2
Drawings
Appendix A 0104002500 Rev.2
Support Information 0103098900
Product Warranty SC4133
TWT Warranty PUB5370
Warranty Return Form MF-1024
Appendix B 0104002400 Rev.4
Optional L-Band BUC
Appendix C 0104682700 Rev.1
Messages

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INTRODUCTION

1-1

Chapter 1
Introduction
Table of Contents
CHAPTER 1 INTRODUCTION ...........................................................................................................1-1

1.1 OVERVIEW.................................................................................................................................1-3

1.2 EQUIPMENT DESCRIPTION ..................................................................................................1-3

1.3 STANDARD FEATURES ...........................................................................................................1-4


1.3.1 ETHERNET INTERFACE.......................................................................................................1-4
1.3.2 CONTROL AND STATUS PANEL........................................................................................1-5
1.3.3 LEGACY SWITCH CONTROLLER INTERFACE ...............................................................1-5
1.3.4 WEATHERPROOF COMPACT DESIGN..............................................................................1-5
1.3.5 STRAIGHTFORWARD OPERATION...................................................................................1-5
1.3.6 DIRECT ANTENNA MOUNTING.........................................................................................1-5
1.3.7 EASY TO MAINTAIN ............................................................................................................1-5
1.3.8 ENERGY EFFICIENT .............................................................................................................1-5
1.3.9 AUTOMATIC FAULT RECYCLING ....................................................................................1-6

1.4 OPTIONAL FEATURES ............................................................................................................1-6


1.4.1 REMOTE CONTROL UNIT (RCU) .......................................................................................1-6
1.4.2 SWITCH INTERFACE MODULE (SIM) ...............................................................................1-6
1.4.3 SOLID STATE INTEGRAL POWER AMPLIFIER (SSIPA).................................................1-6
1.4.4 LINEARIZER...........................................................................................................................1-6
1.4.5 BLOCK-UP CONVERTER (BUC) .........................................................................................1-7
1.4.6 SERIAL INTERFACE .............................................................................................................1-7

1.5 ABOUT THIS MANUAL............................................................................................................1-7

1.6 CONVENTIONS..........................................................................................................................1-8
1.6.1 NOTES AND CAUTIONS ......................................................................................................1-8

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INTRODUCTION

1.6.2 ELECTRICAL OR RF WARNINGS.......................................................................................1-8


1.6.3 TEXT CONVENTIONS...........................................................................................................1-8

List of Figures
Figure 1-1. Front View............................................................................................................................1-4

List of Tables
Table 1-1. Model, Frequency Range, and Rated Output Power ......................................................1-3

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INTRODUCTION

1.1 Overview
The CPI Compact High Power Outdoor Unit (Compact HPA ODU) is designed for satellite
communication earth stations, satellite newsgathering 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. Table 1-1 shows the model numbers, frequency ranges, and power output of
these amplifiers. Figure 1-1 is a photograph of a standard Compact HPA ODU as all models are
similar in appearance.

Table 1-1. Model, Frequency Range, and Rated Output Power

Rated Output Power at the


Model Number Frequency Range (GHz)
TWT | O/P Flange (Watts)
T07CO-A 5.850 - 7.100 750 | 630
T07CO-B 5.850 - 6.650 750 | 630
T07CO-C 5.850 - 6.725 750 | 630
T07CO-D 5.850 - 6.750 750 | 630
T07DO-A 17.300 - 18.400 750 | 630
T07DO-B 17.300 - 18.400 750 | 630
T07DO-C 17.300 - 18.400 750 | 630

By industry convention, amplifiers are classified by the rated power level of the internal
traveling wave tubes (TWT). In actuality, the TWT's rated power is attenuated by the output
component thus decreasing the overall rated power of the amplifier at the output flange. Refer
to the "Drawings" chapter for specifications and a detailed outline.

1.2 Equipment Description


The power supply and RF components are housed in a rugged and compact weatherproof
enclosure. The overall dimensions are 11.25Hx12.75Wx22.25D inches, excluding the connectors
and mounting brackets. It weights 75lbs without options. It is digital ready for wideband,
single or multiple-carrier satellite service in the DBS or Ku frequency bands dependant on
model. Cool air is taken in from the bottom and exhausting it at the front. The amplifier can
operate at ambient temperature ranging from -40 to +55 C.
The power supply section includes the power factor correction, power processor, and high
voltage regulation circuitry. RF components include the TWT, I/O isolation circuits, RF
detectors, and output harmonic filter. Monitor and control circuits are included to permit safe,
efficient, and reliable operation.

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INTRODUCTION

All base models are equipped with an Ethernet jack and are TCP/IP enabled. This allows a
remote PC within the same network as the amplifier running a web browser application the
ability to control and monitor the amplifier.
An outline drawing can be found in the “Drawings” chapter. Detailed dimensions and the
interface connector locations can be found on the outline drawing.

Figure 1-1. Front View

1.3 Standard Features


This section provides details on the standard features included on all base models. The
standard features described in this section include the Ethernet interface, control status panel,
Legacy switch interface, weatherproof compact design, straightforward operation, direct
antenna mounting, easy to maintain, energy efficient, and automatic fault recycling.

1.3.1 Ethernet Interface


The built-in Ethernet interface provides the communication port through which the amplifier
can be monitored and controlled. The industry-standard 10 Base-T interface supports the
TCP/IP, FTP, and NTP protocols. Due to the Ethernet port’s high speed, communication with
the amplifier is much faster then legacy serial interfaces. The FTP protocol allows the operator
to download logs from, and upload firmware to, the amplifier. The NTP protocol allows the
operator to automatically synchronize the time and date with that of a host computer.

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INTRODUCTION

1.3.2 Control and Status Panel


The control and status panel shows the current state of the amplifier through the use of labeled
LEDs indicators. Three weatherized push buttons labeled transmit/standby, reset, and
local/remote are provided to perform basic control. The control and status panel functionality
is detailed in the "Operation" chapter.

1.3.3 Legacy Switch Controller Interface


The Legacy switch controller interface is used when the amplifier is optionally installed in a 1:N
RF switch, power combine, frequency multiplexed, or safety interlock system. A interlock
jumper plug is provided and must be connected to the Legacy switch controller interface when
it is not in use. This interface is explained in detail in the "Unpacking and Installation" chapter.

1.3.4 Weatherproof Compact Design


This amplifier is designed to be weatherproof and compact. It is digital ready, for wideband,
single- and multi-carrier satellite service in the DBS frequency band. It is ideal for transportable
and fixed earth station applications as its small size allows for direct mounting to antenna
structures or installation in mobile broadcasting vehicles.

1.3.5 Straightforward Operation


This amplifier utilized microprocessor controlled logic translated through a web browser
interface. Point and click navigation provides intuitive operation. The operator has access to
digital meters, pin diode attenuation (optional), meter logs, and limit setting adjustments.

1.3.6 Direct Antenna Mounting


The amplifiers lightweight design allows it to be directly mounted to an antenna structure
minimizing cable losses and costly system designs. Threaded mounting holes, located on both
sides of the amplifier, can support the full weight of the amplifier.

1.3.7 Easy to Maintain


The modular design and built in diagnostic capability allow the operator to quickly determine
maintenance requirements. Refer to the "Preventative Maintenance" chapter for details.

1.3.8 Energy Efficient


The amplifier employs a high efficiency, dual-depressed collector helix travelling wave tube, for
reducing operating costs. A minimum of 30% energy penalty is paid when using a high power
solid state amplifier when compared to a TWTA. Better efficiency extends the operating life of
the amplifier. With a low operating cost and a longer operating life, customers can expect a
great return on investment (ROI.)

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INTRODUCTION

1.3.9 Automatic Fault Recycling


Minor faults that occur will be non-latching initially as the built in software attempts to recycle
the fault three times before becoming latched into the fault state. If the cause of the fault is
removed while the amplifier is recycling it will not become latched into the fault state.

1.4 Optional Features


This section provides details on optional features available for the amplifier. Optional features
are installed and tested at the factory to ascertain they function properly. The optional features
described in this section include the remote control unit, switch interface module, solid state
integral power amplifier, linearizer, block up converter, and serial interface.

1.4.1 Remote Control Unit (RCU)


The Remote Control Unit is rack-mountable and is able to duplicate all amplifier controls and
monitors. The RCU communicates with the amplifier via serial or Ethernet interface. The panel
requires a source of AC power, and includes the connectors to build an interconnect cable for
the amplifier, but not normally the cable.

1.4.2 Switch Interface Module (SIM)


This interface uses a controller area network (CAN) to provide switch system monitor and
control. Each amplifier and waveguide switch is daisy chained together within the redundant
or power/frequency combining switch system. These interface ports should remain terminated
with the weatherized connectors provided when not in use.

1.4.3 Solid State Integral Power Amplifier (SSIPA)


The solid state integral power amplifier (SSIPA) provides additional signal gain which is
used to drive the TWT. The SSIPA has an internal pin diode attenuator with a step size of
0.1dB and a range of 0dB to 30dB. It is also equipped with a built in mute or RF inhibit.

1.4.4 Linearizer
A linearizer is used to improve the AM/PM, third order intermodulation products, spectral
regrowth, and NPR performance. An amplifier with a linearizer operating at 4 dB total
output backoff and an amplifier without a linearizer operating at 7 dB total output backoff
would have similar performance. The linearizer is tuned at the factory to provide linear
power across the entire frequency band of the amplifier.
This option may include a built in SSIPA in addition to the linearizer. This feature is
referred to as a LIPA and functions both as a linearizer and SSIPA.

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INTRODUCTION

1.4.5 Block-Up Converter (BUC)


The block-up converter (BUC) allows the amplifier to operate with an L-Band input frequency.
The BUC converts an L-Band input frequency to the frequency required by the TWT. All BUC's
require a high-stability 10MHz reference to operate. The reference frequency can be provided
in one of three ways; multiplexing the RF input signal with the 10MHz reference, applying an
external 10MHz reference, or internal 10MHz reference. Refer to the "Optional L-Band BUC"
appendix for details.
This option may include a built in SSIPA in addition to the BUC. This feature is referred to
as a BIPA and functions both as a BUC and SSIPA.

1.4.6 Serial Interface


This interface allows for RS-232/422/485 remote communication. Control and monitor
software must be written when using this interface. The CIF protocol document in the
drawings chapter is provided for this purpose. Refer to the "Unpacking and Installation" chapter
for connector details

1.5 About This Manual


This manual describes the installation, operation, and preventative maintenance procedures for
the Compact HPA ODU.
The Operational Warnings and Safety Section that precedes Chapter 1 contains practical
guidelines regarding safe High Voltage and Microwave Radiation operating practices.
Chapter 1, “Introduction,” provides a brief overview of the amplifier and this manual.
Chapter 2, “Unpacking and installation,” contains procedures for unpacking and installing. This
chapter also contains external interface information and pin designations.
Chapter 3, “Operation,” describes the procedures for normal start-up, shutdown, and
operational modes. It also describes the controls, indicators, and procedures for initial checkout
after the amplifier has been installed.
Chapter 4, “Preventative Maintenance,” describes the procedures for scheduled maintenance and
return of equipment to CPI.
Chapter 5, “Drawings,” contains relevant engineering amplifier drawings and specifications.
The Appendices contain additional topics such as “Service and Warranty” information,
supplementary data, and other general information.

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INTRODUCTION

1.6 Conventions
Symbols and conventions used throughout this manual are described in the sections that follow.

1.6.1 Notes and Cautions


General notes, cautions, or warnings, provide additional commentary or technical information.
They identify conditions, operations, or procedures that could potentially damage the
equipment, induce physical strain, maim, or kill people. This includes heavy weights, sharp
edges or protrusions, and chemical hazards. They are identified by the following symbol:

1.6.2 Electrical or RF Warnings


Electrical warnings identify conditions, operations, or procedures that expose the operator to
potentially lethal high voltages and are identified by the following symbol:

Microwave radiation warnings identify conditions, operations, or procedures that expose


people to microwave radiation sources that could cause serious injuries, particularly to the eyes
and are identified by the following symbol:

1.6.3 Text Conventions


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

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UNPACKING AND INSTALLATION

2-1

Chapter 2
Unpacking and Installation
Table of Contents
CHAPTER 2 UNPACKING AND INSTALLATION .........................................................................2-1

2.1 OVERVIEW.................................................................................................................................2-3

2.2 PRE-INSPECTION .....................................................................................................................2-3

2.3 UNPACKING...............................................................................................................................2-3

2.4 INSTALLATION AND INTERFACING ..................................................................................2-3


2.4.1 MECHANICAL INSTALLATION .......................................................................................2-3
2.4.1.1 COOLING CONSIDERATIONS ........................................................................................2-4
2.4.2 ELECTRICAL POWER CONNECTIONS ...........................................................................2-4
2.4.2.1 J1, PRIME POWER ...........................................................................................................2-5
2.4.2.2 GROUNDING ....................................................................................................................2-5
2.4.3 J2, ETHERNET INTERFACE ..............................................................................................2-5
2.4.4 J3 & J4, COAXIAL CONNECTIONS ..................................................................................2-5
2.4.5 J8, RF OUTPUT FLANGE CONNECTION.........................................................................2-6
2.4.6 J5, LEGACY SWITCH INTERFACE...................................................................................2-7
2.4.6.1 PROGRAMMABLE RELAY DEFINITION ........................................................................2-8
2.4.7 J5 & J6, SIM SWITCH INTERFACE (OPTION).................................................................2-9
2.4.8 J10, SERIAL INTERFACE (OPTIONAL)..........................................................................2-10

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UNPACKING AND INSTALLATION

List of Figures
Figure 2-1. External Interface Locations .............................................................................................2-4
Figure 2-2. J8, Tightening Sequence and Location ............................................................................2-7
Figure 2-3. Programmable Relay Schematic.......................................................................................2-8
Figure 2-4. J10, Serial Remote Pin Designation Diagram ...............................................................2-10

List of Tables
Table 2-1. Recommended Torque ........................................................................................................2-6
Table 2-2. J5 Pin Designations ..............................................................................................................2-8

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UNPACKING AND INSTALLATION

2.1 Overview
This chapter contains instructions for unpacking and installing the amplifier. Read all
instructions to become familiar before proceeding. All external interfaces are detailed in this
chapter as well.

2.2 Pre-Inspection
Inspect the exterior of the shipping container(s) for evidence of damage in shipment. If damage
is evident, immediately contact the carrier that delivered the equipment and submit a damage
report. Failure to do so could invalidate future claims.

2.3 Unpacking
Carefully unpack and remove all items from the shipping container(s). Inspect the interior of
the container for damage. Save all packing material until all inspections are complete. It is
recommended that all packing material be saved for potential future use. Verify that all items
listed on the packing slips have been received.
Inspect all items for evidence of damage in shipment. If damage seems evident, immediately
contact the carrier that delivered the equipment and file a claim. Failure to do so could
invalidate future claims.

2.4 Installation and Interfacing


This section includes mechanical installation, electrical power connections, the Ethernet
interface, coaxial connections, RF output connection, legacy switch interface, SIM switch
interface (optional), and serial interface (optional). Refer to the outline drawing in the
“Drawings” chapter for dimensions and mounting information. Become familiar with operating
hazards by reading the “Operational Warnings” document found at the front of this manual.

2.4.1 Mechanical Installation


The amplifier may be mounted using the four threaded holes located on each side of the chassis,
eight holes total. Refer to the outline drawing provided in the "Drawings" chapter of this
manual. These holes are 1/4-20 and 0.38 inch deep. In order to provide secure mounting, each
bolt must be dressed with both a lock washer and flat washer. This hardware can be found in
the ship kit. CPI recommends that all eight holes are used in the installation. If the amplifier is
mounted to an antenna, the structure must be capable of supporting the additional load of the
amplifier plus any wind loading effects, which may occur.

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UNPACKING AND INSTALLATION

It is recommended that locations subject to electrical interference, such as that from motor
contactors, be avoided.
Heat produced during operation is conducted through heatsink fins which are cooled by a
central blower. The intake and exhaust areas must not be blocked. The air intake must be given
a minimum clearance of two inches and the air exhaust must be given a minimum clearance of
four inches. The hot air should be exhausted away from the air intake. For further information
see the outline drawing located in the "Drawings" chapter.

2.4.1.1 Cooling Considerations


The internal fan air cools the amplifier drawing air in from the bottom of the unit and
exhausting it through the duct located at the front.
To insure proper operation of the amplifier, the following guidelines must be observed:
1. There must be at least two inches of clearance on the bottom of the unit (air intake).
2. There must be at least four inches of clearance behind the unit that has the exhaust ducts
(the end with the visible cooling fins).
3. The hot exhaust air must be directed away from the air intake.
4. The area below the air intake must be free of foreign material, loose dirt, debris, and any
other material that may be drawn toward the unit that may block the air intake area.

2.4.2 Electrical Power Connections


Electrical power connections include the prime power connector and the chassis ground.
Connector locations are located on the front panel and displayed in figure 2-1.

Figure 2-1. External Interface Locations

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2.4.2.1 J1, Prime Power


WARNING! DO NOT APPLY PRIME POWER TO THE AMPLIFIER UNTIL DIRECTED TO
DO SO.

Prime power is applied to connector J1 (AC IN) located on the front panel. Prime power is 200 -
240VAC ± 10%, 47-63 Hz. The proper voltage is indicated on a label located on exhaust end of
unit. A prime power mating connector is supplied in the ship kit with the unit. The pins of the
prime power connector should be wired as follows:
Pin 1 - line (or Phase A) Pin 3 - Neutral (or Phase B)
Pin 2 - No connection Pin PE - Protective Earth

Prepare the prime power cable but do not connect the cable to the amplifier at this time.

2.4.2.2 Grounding
Proper grounding of the amplifier to the station protective earth bus is necessary for personnel
and equipment safety. The 6-32 UNC-2B threaded ground stud on the front panel is used for
grounding. #14AWG wire or larger is recommended for the grounding cable. The amplifier
should be protected against direct lightning strikes.

2.4.3 J2, Ethernet Interface


This port is a standard RJ-45, 10BaseTx jack. A shielded weatherized mating plug for the
system installers Ethernet cable is provided in the ship kit. A mating connector for this interface
must be built using shielded twisted pair RJ-45 plug and cable.
The operator uses a web browser and TCP/IP protocol to interface with the amplifier.
Instructions on connecting to the amplifier can be found in the "Operation" chapter.
Warning: The Ethernet port is only weatherized when connected to a
properly assembled Ethernet cable built with the weatherized mating
connector provided in the ship kit. Failure to use the weatherized mating
connector will allow moisture into the amplifier and void the warranty.

Note: The baud rate is fixed at 9600 and cannot be changed. This ensures
both Ethernet and serial communications can be established.

2.4.4 J3 & J4, Coaxial Connections


The RF input and sample port is located on the front panel. Both ports are sma-type female (for
DBS-Band) or N-type female (for Ku/C-Band) connections. Terminate these connections when
they are not being used. The system installer is responsible for providing the male mating
coaxial sma-type (for DBS-Band) or N-type female (for Ku/C-Band) cables. While tightening
coaxial connectors, do not over torque them and ensure they are not cross-threaded.

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2.4.5 J8, RF Output Flange Connection


The RF output flange size will be WR-62G (DBS-Band), WR-75G (Ku-Band), or CPR137G (C-
Band) with threaded holes. The threaded holes allow mating waveguide of the same size to be
connected. Refer to the “Outline” drawing provided in the “Drawings” chapter for An RF gasket
is provided in the ship kit. It must be used in the installation so a proper seal is made. This
minimizes the risk a harmful RF radiation leak will occur.
To install mating waveguide to the output flange, proceed as follows:
1. Place the RF gasket into the grooved portion of the waveguide flange.
Warning: Do not allow dirt and debris to enter the output waveguide flange
of the amplifier or mating waveguide. This will result in high VSWR and
may cause damage to the amplifier. Damage to the amplifier caused this
way shall void the warranty.
2. Position the mating waveguide so that it aligns precisely with the output waveguide flange
of the amplifier (J8.)
Caution: If flange alignment is not precise or if the installation is subject to
motion or vibration; flexible waveguide can be used.

3. After alignment is verified in all planes, loosely attach the mating waveguide to the output
waveguide flange of the amplifier with the 6-32 inch bolts (WR-62/WR-75) or 10-32 inch
bolts (CPR-137), flat-washers, and lock-washers provided in the ship kit. Each bolt should
be dressed with a lock washer and then a flat washer before being used. Start all bolts by
hand and verify alignment.
4. A progressive tightening procedure is recommended. Tighten each bolt until the lock
washer starts to compress before proceeding to the next one. Repeat until all bolts have
been partially tightened.
5. Starting with the first bolt, fully tighten them to the recommended torque per table 2-1.
Over-tighten can strip threads or distort the mating flange. Refer to figure 2-2 for the
tightening sequence.

Table 2-1. Recommended Torque

Frequency Band Waveguide Screw Qty. Screw Size Screw Torque (in/lbs)
Ku Band WR-75 4 6-32 in. 8.5
DBS Band WR-62 4 6-32 in. 8.5
C Band CPR-137 8 10-32 in. 32

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UNPACKING AND INSTALLATION

Figure 2-2. J8, Tightening Sequence and Location

2.4.6 J5, Legacy Switch Interface


Connector J5 is a DB 9-pin female (socket) weatherized connector. It is commonly used when
the amplifier is a part of a Legacy redundant RF switching system or is to be connected to an
external interlock device.
Caution: A jumper plug is supplied with the amplifier. In a standalone
configuration, the jumper plug must be connected to J5 for normal
operation. The amplifier will indicate an interlocks open fault and/or
interlock inhibit if this connector is removed or not securely fastened. The
jumper plug is wired as follows:
-Jumper pin 8 to pin 9
-Jumper pin 6 to pin 7
The Legacy Switch Interface provides the relay-reported amplifier status required by an
external waveguide switch controller or safety interlock device. The status relay can be
programmed for several states, as described in the "Relay Definition" section. The RF inhibit and
external interlock relays are active at all times and are not subject to the control mode hierarchy.

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Table 2-2. J5 Pin Designations

Pin # Signal Name


1 I/F Panel
2 I/F Panel Return
3 Relay NC
4 Relay NO
5 Relay Common
6 External Interlock
7 External Interlock Return
8 RF Inhibit
9 RF Inhibit Return
Table 2-2 Notes:
1. Outputs are dry-circuit relay contacts rated up to 50 VDC, 50 mA.
2. External interlocks and RF Inhibit inputs are optically isolated. Maximum open circuit voltage present is 16 VDC. Typical
operating current is 3 mA.
3. The RF Inhibit and External Interlock require a maintained closed-contact with RF Inhibit return and External Interlock return
respectively for normal operation.
4. An open RF Inhibit or External Interlock will cause an RF Inhibit or Fault respectively.

2.4.6.1 Programmable Relay Definition


One programmable relay is provided indicate one of several conditions. The condition
configured to this relay is setup through the Ethernet interface port. The figure below shows a
schematic of the programmable relay in a de-energized state.

Figure 2-3. Programmable Relay Schematic

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Configuration definitions are provided below.


Fault Anytime the amplifier enters the fault state the relay will be triggered.
Low RF The Low RF status indicates that the Low RF Alarm or the Low RF Fault state is engaged.
The Low RF status has two modes, Flexible and Rigid.
In Rigid mode the Low RF status will indicate the RF output is below the Low RF Alarm
level when this condition occurs, except during an RF Switch RF Inhibit command. The
Rigid mode can be thought of as the strictest operation of the Low RF status.
In Flexible mode the Low RF status will indicate the RF output is below the Low RF Alarm
level any time this condition occurs during the Transmit state, except during an RF Inhibit.
If RF Inhibit is activated while the Low RF Relay indicates a low RF condition, the Low RF
Relay will not change state. (It will continue to indicate Low RF.) Once the RF Inhibit
disappears, the Low RF Relay will report existing conditions. The Flexible mode allows the
amplifier to operate in any normal operating state without effecting switch controller in
automated switching mode.
Note: The Low RF status will not assert during a Fault state.
Sum Fault Indicates the amplifier latched into the fault state. When latched into the Fault state, the
operator must clear the fault source and issue a Reset command to return it to a normal
operating condition.
Transmit Transmit indicates that the Beam is turned on and the RF is not inhibited. This is the
normal operating state of the amplifier. The amplifier will cease transmitting (and the
Transmit indication will be negated) if the interlock circuit opens.
Beam On Indicates the Beam On state. (HV applied to TWT)

2.4.7 J5 & J6, SIM Switch Interface (Option)


The Switch Interface Module (SIM) switch system is designed to simplify the interface between
microwave waveguide switches (WGS) and CPI products. This option replaces the Legacy
switch interface.
The SIM circuitry consists of a power supply, microcontroller, and WGS motor drive. All
switch system monitor and control functionality is located on the SIM. A ribbon cable or off-
the-shelf shielded cable with D-sub connectors is required to interface with the SIM. This
allows multiple SIMs to be easily daisy chained together and no patch panels are required.
A SIM switch system consists of up to sixteen SIMs and up to sixteen amplifiers. The SIMs and
amplifiers communicate with each other over a CAN (Controller Area Network) bus operating
at 100K baud. In addition to the CAN bus there is also a RS-232 serial interface which is used to
automatically identify the location of each SIM eliminating the need for DIP switches and
jumpers. CAN bus termination is required at the first amplifier and the last SIM.
The first SIM (SIM 1) which plugs into the amplifier chain is considered the “Master SIM” and
all other SIMs are slaves. Switch system configuration, status, amplifier priority, along with
other information is stored in SIM 1. SIM 1 monitors the status of the amplifiers and determines
what WGSs need to change position in order to backup a failed amplifier. When a WGS is
rotated its SIM broadcasts the WGS position to all devices connected to the CAN bus. Each
amplifier monitors the position of all WGSs and will inhibit RF should a rotating WGS be
within that amplifiers signal path. Detailed information can be found in the switch system
manual provided.

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2.4.8 J10, Serial Interface (Optional)


The operator can use either a PC or the optional CPI Remote Control Unit connected to J10
(“REMOTE”) to remotely monitor and control the amplifier. J10 is a 10-pin MS type connector,
ITT Canon KPSE06F-12-10P. A mating connector is supplied in the ship kit when this option is
purchased. The PC can use either RS-232 or RS-422/485 communication standards, while the
CPI Remote Control Panel uses only RS-422.
Default settings are as follows:
Protocol: STX/ETX
Baud Rate: 9600
Parity: EVEN
There are seven (7) data bits, with one (1) start bit and one (1) stop bit. The operator may
change these settings. Refer to the "Drawings" chapter for the computer interface protocol
document.
Interconnect cables should be wired for either RS-232 or RS-422/485, but not both. A pin
designation diagram is provided in the figure below.

Figure 2-4. J10, Serial Remote Pin Designation Diagram

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3-1

Chapter 3
Operation
Table of Contents
CHAPTER 3 OPERATION...................................................................................................................3-1

3.1 OVERVIEW.................................................................................................................................3-4

3.2 OPERATIONAL OVERVIEW ..................................................................................................3-4

3.3 PC INTERFACING.....................................................................................................................3-4
3.3.1 FINDING THE IP ADDRESS .................................................................................................3-5

3.4 PRE-POWER ON PROCEDURE ..............................................................................................3-6

3.5 NAVIGATING THE INTERFACE ...........................................................................................3-7


3.5.1 DATA ORGANIZATION........................................................................................................3-7
3.5.2 NAVIGATION AND DATA ENTRY.....................................................................................3-7
3.5.3 OPERATIONAL STATES AND INDICATORS....................................................................3-7
3.5.3.1 STANDBY.........................................................................................................................3-7
3.5.3.2 TRANSMIT.......................................................................................................................3-8
3.5.3.3 RF INHIBIT .....................................................................................................................3-8
3.5.3.4 FAULT .............................................................................................................................3-8
3.5.3.5 ALARM ............................................................................................................................3-9

3.6 INITIAL POWER-ON ................................................................................................................3-9


3.6.1 INITIAL CHECK, STANDBY ................................................................................................3-9
3.6.2 PREFERENCE SETTINGS ...................................................................................................3-11
3.6.3 VERIFY FACTORY SETTINGS ..........................................................................................3-11
3.6.3.1 TEMPERATURE LIMIT SETTINGS..............................................................................3-12
3.6.4 CHANGING THE AMPLIFIER IP ADDRESS ....................................................................3-13
3.6.5 INITIAL CHECK, BEAM ON (TRANSMIT).......................................................................3-13

3.7 BROWSER SCREENS..............................................................................................................3-14


3.7.1 AMP STATUS SCREEN .......................................................................................................3-14
3.7.2 AMP INFO SCREEN.............................................................................................................3-15

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3.7.3 METER LOG SCREEN .........................................................................................................3-16


3.7.3.1 LOG SETTINGS.............................................................................................................3-17
3.7.4 SETPOINTS SCREEN...........................................................................................................3-18
3.7.5 CONFIG SCREEN .................................................................................................................3-19
3.7.6 TIMERS .................................................................................................................................3-20
3.7.7 IP SETTINGS SCREEN ........................................................................................................3-20
3.7.8 EMAIL SCREEN ...................................................................................................................3-21
3.7.9 SET LOGIN SCREEN ...........................................................................................................3-21
3.7.10 CLOCK SCREEN..............................................................................................................3-22
3.7.11 OPTIONS SCREEN...........................................................................................................3-22

3.8 FRONT PANEL CONTROLS AND INDICATORS..............................................................3-24


3.8.1 COMMUNICATION PORT MANUAL RESET ..................................................................3-25

3.9 SHUTDOWN AND RECOVERY ............................................................................................3-25


3.9.1 AC POWER INTERRUPTION..............................................................................................3-26
3.9.2 FAULT RECOVERY.............................................................................................................3-26
3.9.2.1 HIGH/LOW RF OUTPUT FAULTS ..............................................................................3-26
3.9.2.2 HIGH REFLECTED RF FAULTS .................................................................................3-26

List of Figures
Figure 3-1. Local Area Connection Properties ...................................................................................3-5
Figure 3-2. TCP/IP Properties Example .............................................................................................3-6
Figure 3-3. Login Screen......................................................................................................................3-10
Figure 3-4. Amp Status Screen and Menu ........................................................................................3-10
Figure 3-5. Amp Status Screen ...........................................................................................................3-14
Figure 3-6. Amp Info Screen...............................................................................................................3-16
Figure 3-7. Meter log screen ...............................................................................................................3-17
Figure 3-8. Log Setting Screen ............................................................................................................3-17
Figure 3-9. Setpoints screen ................................................................................................................3-18
Figure 3-10. Config Screen ..................................................................................................................3-19
Figure 3-11. Timers screen ..................................................................................................................3-20
Figure 3-12. IP settings screen ............................................................................................................3-20
Figure 3-13. Email screen ....................................................................................................................3-21
Figure 3-14. Set login screen ...............................................................................................................3-21

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Figure 3-15. Clock Screen ....................................................................................................................3-22


Figure 3-16. Options screen ................................................................................................................3-22
Figure 3-17. Front Panel Push Button and LED Display ................................................................3-24

List of Tables
Table 3-1. User-configurable Preference Settings. ...........................................................................3-11
Table 3-2. Factory Settings ..................................................................................................................3-11
Table 3-2. Factory Settings (continued).............................................................................................3-12
Table 3-3. Temperature Limit Settings ..............................................................................................3-12
Table 3-4. Amp Status Button Definition..........................................................................................3-15
Table 3-5. Front Panel Controls and Indicators ...............................................................................3-24
Table 3-5. Front Panel Controls and Indicators (continued)..........................................................3-25
Table 3-6. Parameter and Manual Reset Default Setting................................................................3-25

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3.1 Overview
The amplifier is operated remotely using a web browser application. Each amplifier is
configured and thoroughly tested at the factory. Once installed, the amplifier should be
monitored at initial power on to ascertain that it functions properly. The following sections
describe procedures for PC interfacing, pre-power on, navigating the control panel, initial
power on with checkout, browser screens, front panel controls, and shutdown.

3.2 Operational Overview


Note: Before applying power ensure all initial power-on and checkout
procedures have been completed. See the “Initial Power-On and Checkout”
chapter for instructions.
An initial self-test will be conducted by the amplifier when prime power is applied. When
initializing has completed the operator switches from STANDBY state to TRANSMIT state, sets
the desired output level, and applies the RF input. The input signal is amplified and output to
the antenna.
During operation, the 'Amp Status' screen is used to control the amplifier. Transmit, standby,
RF inhibit, automatic level control (ALC), and manual mode are the control parameters that can
be accessed from the 'Amp Status' screen. The amp status screen is discussed in a later section.
When the amplifier is ready to be shutdown, the operator clicks on the STANDBY button and
confirms the selection by clicking “yes” in the command confirmation screen. With the RF
input drive disabled the operator allows a few minutes for the fans to cool the TWT before
removing power.

3.3 PC Interfacing
The operator can use a PC, connected to the J2 on the amplifier, using an Ethernet cable. The
mating connector for J2 on the amplifier is provided in the ship kit and should already be
available for this step. The IP settings are set at the factory and should be changed. A
controlling PC should be used to setup the Ethernet address of the amplifier.

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3.3.1 Finding the IP address


The Default IP address should be 192.168.000.254. This may not be the address if the unit was
used previously or the address was modified. If the address is unknown a program called
"Amp Search" has been provided with this manual in a ZIP file.
The Amp Search program will detect all CPI amplifiers within the same TCP/IP network as the
host PC. It is executable and does not require installation. After un-zipping the program run it
and initiate an IP address scan. All CPI amplifiers on the same TCP/IP network will be
detected. Write down the IP address, subnet mask, and default gateway of the amplifier. CPI
amplifiers do not currently support dynamic host configuration protocol (DHCP) so the address
must be setup manually to be in the same subnet as the controlling PC. The following
instructions can be used:
Configure the PC to communicate with the amplifier using the following steps:
1. On the controlling PC open the network connections location.
2. Right click on the LAN connection.
3. Click properties.
4. Select Internet protocol (TCP/IP).
5. Click properties.

Figure 3-1. Local Area Connection Properties

6. The Internet protocol properties screen should appear. See figure 3-2.
7. Fill in the subnet mask field with 255.255.255.0.
8. Fill in the default gateway field with the same default gateway as the amplifier.
9. Fill in the IP address with the address provided on the front panel label of the amplifier
changing only the last number in the IP address from 1-255 so it is different from the
amplifiers IP address. ***All devices on a network must have a unique IP address***
The controlling PC workstation is setup for connection with the amplifier.

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Figure 3-2. TCP/IP Properties Example

Note: When using a remote control unit (RCU), refer to the RCU installation
and operation manual for connection details and setup.

3.4 Pre-Power On Procedure


Before applying prime power, verify that the following conditions have been met:
1. AC prime power is 200 - 240 VAC ± 10%, 47-63 Hz, as indicated by the label located on
exhaust end of unit, and single phase.
2. With prime power locked out, connect the power cord to J1.
3. A ground strap is connected from the installation sites’ ground bus to the ¼ - 20 UNC 2B
ground screw-mounting hole located on the amplifier’s front panel.
4. The RF output waveguide flange is connected to proper matched waveguide which has
been securely tightened.
5. The waveguide load used should be rated for twice the rated output power of the amplifier.
6. Check all input sources and verify they are off.
7. There is at least 2 inches of clearance at the air intake and 4 inches of clearance at the
exhaust.

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8. The exhaust/intake areas are not blocked.


9. Use a power meter to set the RF input drive to a level equal to or below –40dBm. Verify the
operation in the proper frequency range.
10. Turn on the controlling PC and launch the browser.
Warning: Failure to verify these pre-power conditions may cause damage or
malfunction. Operating the equipment before verifying these items may void the
warranty.

3.5 Navigating the Interface


The amplifier is monitored and controlled via a web browser. The software loaded on the
amplifier transforms a typical web browser into an operator interface. This section describes
data organization and navigation of the operators interface.

3.5.1 Data Organization


During normal operation, the "Amp Status" screen displays the control mode, state of operation,
any fault or alarm conditions, the RF output level, and power mode. The side panel of the web
interface displays the other accessible screens. The other screens contain amplifier information,
settable parameters, and operating preferences.

3.5.2 Navigation and Data Entry


Navigation is performed using the controlling PC's mouse to select a system screen. Multiple
browser windows can be opened at a time allowing the operator to view different screens
simultaneously. Data input is performed by either selecting a value from a drop down menu or
keying the data into the operator settable field using the keyboard. Settings are saved by
clicking the APPLY button or pressing the ENTER key in the absence of an apply button

3.5.3 Operational States and Indicators


Operational states are displayed on most screens. The operational states include standby,
transmit, RF inhibit, fault, and alarm. This section describes these states. In addition to the
operational states the control type, RF output power, and power mode are displayed.
Note: The amplifiers state can only be changed in the "Amp Status"
screen. This includes resetting faults, transitioning from standby to
transmit, and vice versa.

3.5.3.1 Standby
When the amplifier is in the standby state, it is indicated within the state box. When the
amplifier is in this state the TWT's heater is kept hot while helix voltage is removed.
Transmission is not possible during this state.

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3.5.3.2 Transmit
When the amplifier is in the transmit state, it is indicated within the state box. During this state
the TWT's helix voltage is applied allowing amplification of an RF input signal. This is
considered normal operation.

3.5.3.3 RF Inhibit
The RF inhibit state is indicated by a flashing blue background within the state box. The RF
inhibit can be enabled during in either the standby or transmit state. When RF inhibit is
enabled, power to the SSIPA is removed. The RF input signal is isolated from reaching the TWT
and RF becomes inhibited.

3.5.3.4 Fault
When the amplifier is in the fault state, it will be indicated by a flashing red background within
the state box. The type of fault and fault code is displayed below the state box. There are two
types of faults; non-latching, and latching. Faults which are not critical to the amplifiers
operation will be non-latching. The amplifier will attempt to recycle these faults three times
before becoming latched into the fault state. If the fault state is cleared during while recycling
the amplifier will resume normal operation and a log entry will be generated. If the fault
remains after three recycle attempts, the amplifier will become latched into the fault state and
operator intervention is required. All faults should be investigated before manually resetting as
they may indicate maintenance required or the end of life which can save in costly down time.

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3.5.3.5 Alarm
When the amplifier is in the alarm state, it will be indicated by a flashing yellow background
within the state box and is usually an early indication a fault may occur. Some alarm settings
are operator settable within the 'Setpoints' screen and others have been setup at the factory.
Alarms should always be set lower then the fault trip limit.

3.6 Initial Power-On


Caution: A qualified technician should perform this task. Initial power on
is not a normal power on sequence.

Initial power on should not be performed unless all procedures in the “Unpacking and
Installation” chapter have been completed. Should maladjustments be discovered during initial
power on, proceed to the “Troubleshooting” chapter in the service manual or contact CPI
customer support. Refer to the “Customer Support and Warranty Information” appendix for
contact information.

3.6.1 Initial Check, Standby


Each time power is switched on the microprocessor performs a series of self-test to ensure the
ability to control and monitor the amplifier. Once the power on self test (POST) is successfully
completed, the amplifier will enter a heater time delay (HTD) state. After the HTD the
amplifier will assume its previous state of operation; either transmit or standby. The amplifier
should be in a standby state after the HTD countdown.
WARNING! BEFORE CONTINUING WITH THIS PROCEDURE VERIFY THE RF
INPUT DRIVE IS OFF AND ALL THE PROCEDURES IN THE “UNPACKING AND
INSTALLATION” CHAPTER HAVE BEEN COMPLETED. FAILURE TO VERIFY
THESE CONDITIONS MAY DAMAGE THE AMPLIFIER OR CAUSE PERSONAL
INJURY.
Proceed as follows:
1. Turn on the prime power distribution system so that AC power is applied at J1.
2. Verify that the cooling fan comes on after AC power is applied.
Caution: If the XMT LED is flashing on the front panel controls press the HV ON
button located on the front panel of the amplifier or the amplifier will go directly
into transmit once the HTD cycle is completed.

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Note: The amplifier should be in the STANDBY mode at this time. If the amplifier
is not in standby mode click on the standby icon in the Amp Status screen and
confirm the selection.
3. Enter the default IP address found on the front panel label in the web browser application of
the controlling PC.
4. A login screen will appear as shown in the figure below.

Figure 3-3. Login Screen

5. Enter the default user name and password (lower case.) It is recommended that the default
user name and password are changed from the factory default.
User Name: cpi Password: cpi
6. The amp status screen will be shown. Refer to the figure below.

Figure 3-4. Amp Status Screen and Menu

7. The first three minutes during turn on is the heater time delay (HTD). After the countdown
the amplifier will indicate the STANDBY state.

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3.6.2 Preference Settings


Before operation at the installation site, the operator configurable preference settings can be adjusted
to meet requirements. Table 3-1 shows user-configurable preference settings.

Table 3-1. User-configurable Preference Settings.

Name Setting System Screen


ALC Set PT Automatic Level Control Setpoints
Manual RF Set PT Manual RF Level Setpoints
Attenuation Set PT Attenuation Level Setpoints
Confirm Transmit Selection Prompts user to confirm transmit Options
Confirm Standby Selection Prompts user to confirm standby Options
Confirm Inhibit Selection Prompts user to confirm inhibit Options

3.6.3 Verify Factory Settings


To verify the factory settings click on the setpoint menu on the left panel of the web browser
labeled “Setpoint” and use the table below as a guide.

Table 3-2. Factory Settings

Setting Name Min. Setting Factory Setting Default Setting Max. Setting
Low RF Output Alarm 0W 0W 0W 750W
Low RF Output Fault 0W 0W 0W 750W
High RF Output Alarm 0W 700W 700W 800W
High RF Output Fault 0W 710W 710W 800W
High Reflected RF Alarm 0W 50W 35W 65W
(NOTE1)
High Reflected RF Fault 0W 60W 50W 75W
High RF Drive Alarm 1.0mW 3.0mW 10.0mW 50.0mW
High RF Drive Fault 1.0mW 8.0mW 31.6mW 100.0mW
ALC Disable RF 0W 5W 5W 10W
ALC Setpoint 0W 0W 0W 800W
Attenuation Setpoint 0dB 30dB 30dB 30dB
Helix Over Voltage Fault(NOTE2&3) 11.0kV NPV +300V 12.8kV 13.8kV
Helix Under Voltage Fault(NOTE2&3) 0.0kV NVP -300V 10.7kV 13.2kV
Helix Over Current Fault(NOTE3) 0.0mA 12.0mA 12.0mA 15.0mA

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Table 3-2. Factory Settings (continued)

Helix Voltage in Standby Fault(NOTE3) 0.0kV 3.0kV 3.0kV 3.0kV


(NOTE3)
Heater Over Current Fault 1.0A 1.5A 1.5A 2.0A
(NOTE3)
Heater Over Voltage Fault 6.1V 6.6V 6.6V 6.7V
Heater Under Voltage Fault(NOTE3) 5.8V 6.1V 6.1V 6.4V
Heater Over Current Flt (HTD)(NOTE3) 2.5A 3.0A 3.0A 4.5A
Blower Under Speed Fault(NOTE3) 10RPM 10RPM 10RPM 10RPM
Manual Blower Voltage 0.0V 10.0V 10.0V 10.0V
Table 3-2 Notes:
1. Factory Set. Do not change.
2. Use the TWT's name plate voltage (NPV) to determine the setting.
3. This fault setting is not displayed and is not operator settable. Contact CPI customer support if this fault occurs.

3.6.3.1 Temperature Limit Settings


Temperature limit settings can only be changed by CPI trained service personnel and are not
operator accessible. The following table lists these settings:

Table 3-3. Temperature Limit Settings

Setting Name Minimum Setting Default Setting Maximum Setting


Cabinet Over Temperature Alarm 80 80 85
Cabinet Over Temperature Fault 80 85 85
TWT Over Temperature Alarm 75 115 115
TWT Over Temperature Fault 85 120 120
Fan Off Temperature 25 25 25
Fan On Temperature 40 40 40
Blower High Temperature 75 85 85
Blower Low Temperature 40 40 40
Blower Off Temperature 35 35 35

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3.6.4 Changing the Amplifier IP Address


The IP address of the amplifier should be changed to suit the network the amplifier will become
a part of. Changing the IP address requires that after applying the changes the amplifier must
be shutdown (powered off) and restarted. Use the following instructions to change the IP
address of the amplifier:
1. When connected to the amplifier click on the 'IP Settings' screen.
2. Enter a new IP address, subnet mask, and default gateway following the standards set by
the TCP/IP networking philosophy. These setting should be provided by your network
administrator.
3. Click the Apply button.
4. If the amplifier was in operation allow a cool down period before the next instruction.
5. Remove AC power from the amplifier and wait three minutes.
6. Apply AC power to the amplifier.
Note: If done correctly communication between the amplifier and the PC should
be lost. To reestablish communication follow the instructions in the 'PC
Interfacing' section at the beginning of this chapter using the new IP settings.

3.6.5 Initial Check, Beam On (Transmit)


With the amplifier in the standby state proceed as follows:
1. Verify all the pre-power on procedures have been completed before continuing with the
initial check, beam on.
2. Verify that the amplifier is in standby state by viewing the amp status screen. There should
be no faults or alarms. Any faults or alarms must be evaluated and cleared before
proceeding.
3. Verify that the drive to the amplifier is at -40dbm and that an external power meter and
sensor is connected to the RF monitor port on the amplifier.
4. Determine the attenuation setting by going to the Setpoints tab in the Web control page.
Adjust the attenuation to at least 10db.
5. Click the TRANSMIT button and confirm the selection.
6. After a couple of seconds, the Beam On Sequence (BONS) should complete.
7. Select a drive frequency at mid band of the operating range of the ODU. Starting at –40
dBm, slowly increase the RF drive until rated output is achieved. Adjust the attenuation
control if necessary.
8. If the factory test data is available compare the data in the final test data with the readings in
the WEB page and the gain of the amplifier (input / output power).
Warning: Do not exceed a RF drive of -14dBm Max.

9. Click the STANDBY icon to end the initial check H.V. on.

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3.7 Browser Screens


The operational screens available are shown on the side panel. Access a screen by clicking on
its title in the side panel. Screens are detailed in this section.
Note: All screen shots shown are subject to change without notice and
may not reflect all amplifier configurations or options which can be
purchased. All technical data presented in the screen shots shown is for
aesthetic purposes only.

3.7.1 Amp Status Screen


The amp status screen allows the operator to change the operating state of the amplifier, set RF
unit preferences, and displays the monitored parameters. This screen governs the main control
over the amplifier and includes the STANDBY, TRANSMIT, RF INHIBIT, RESET, ALC, and
MANUAL buttons. The unit of the RF display can be changed using the "RF Units" section.
Caution: Resetting faults or changing states can only be executed while in
the 'Amp Status' screen or through local control. Press RESET in the 'Amp
Status' screen to recycle faults. Refer to the “Front Panel Controls”
section to reset a fault locally.
Beneath each monitored parameter, a three colored bar is in place to indicate if the current value
is within normal operation (green), alarm (yellow), or fault (red). The level of the monitored
parameter is also displayed adjacent to the parameter.

Figure 3-5. Amp Status Screen

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Table 3-4. Amp Status Button Definition

Button Definition
TRANSMIT Applies helix voltage to the TWT. This is the normal operating mode for the amplifier.
STANDBY Removes helix voltage from the TWT. Used to cool the TWT during shutdown.
RF INHIBIT Removes power to the SSIPA inhibiting the RF input signal from reaching the TWT.
RESET Recycles faults. The fault condition must be cleared before using the RESET button.
The amplifier will attempt to recover from most faults three times before becoming
latched in a fault state. A latched fault must be manually reset.
ALC(NOTE1) The amplifier will adjust the attenuator to sustain the automatic level control (ALC)
setpoint value. The attenuator will continually change to keep output power constant.
Adjusting the attenuator will disable ALC.
Manual(NOTE1) The amplifier will adjust the attenuator initially to the manual setpoint value. Manual
mode will not continually adjust the attenuator to keep power constant.
Table 3-4 Notes:
1. The range of power adjustment is relative to the range of the attenuator.

3.7.2 Amp Info Screen


The amp info screen displays the amplifier type, and serial number. The version of the main,
PS, BIPA, and RF software loaded on the amplifier is displayed as well. From this screen the
amplifier can be given a name by typing it in the “Amp Name” box and clicking APPLY.
• Clicking on the Download Manual button will retrieve the manual from the amplifiers
memory.
• Clicking on the Download Factory Data button will retrieve an Excel file containing the
amplifiers test data, and an as built record.
• Clicking on the Download Settings button will retrieve a text file containing the amplifiers
current settings.
• Clicking on the Download Snapshot File button will retrieve a .csnp file that can be opened
using Snapshot Viewer program.
• Clicking on the Download Log button will retrieve the meter log file. This file can be saved
as either a text file and imported into a spread sheet for viewing.
• Clicking on the Download Database button will save all the amplifiers settings in a file.
This file can then be used to “clone” another amp with the same settings using the “Upload
Database” field.
To update the firmware select the firmware file location using the “Browse” feature. Click
“Upload” to load the new firmware.

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Figure 3-6. Amp Info Screen

3.7.3 Meter Log Screen


The meter log screen displays twenty entries at any given time however can be set to display
anywhere from 1 to 1000 entries. The previous and next button will move the displayed entries
in blocks of ten. It is recommended the factory settings remain unchanged.
Special events, such as service or related activities can be entered in the meter log manually by
typing text in the Event Detail box and clicking the Submit button. The meter log is
downloadable for device history purposes by clicking the Download Log button and saving the
text file. The event text entry in the meter log cannot be modified.

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Figure 3-7. Meter log screen

3.7.3.1 Log Settings


The 'Log Settings' screen is used to change the limits which will generate log entries. The log
setting value for each parameter determines when a log entry is generated when exceeded.

Figure 3-8. Log Setting Screen

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3.7.4 Setpoints Screen


The amplifier fault and alarm trip-points can be entered from the set point screen. Fault trip-
limits are factory-set and should NOT be adjusted. Fault and alarm trip points protect the
amplifier from damage by disabling RF or fore warning the operator of upcoming fault
conditions.

Figure 3-9. Setpoints screen

Caution: Factory settings can be found in the "Verify Factory Settings"


section of this chapter. Settings shown in the figure should not be used.

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3.7.5 Config Screen


The ‘Config’ screen displays standard and optional features configured on the amplifier.
Interface ports and optional equipment can be modified or adjusted through the software
granting the ability to setup the amplifier for a specific application. If an option with
configurable settings is included in the amplifier it will be shown in the ‘Config’ screen.

Figure 3-10. Config Screen

The linearizer configuration will only be shown if a linearizer is installed. The three linearizer
settings gain, phase, and magnitude can be adjusted between the ranges of 0 to 255 for each
tube channel. Adjustments can only be made if the correct password has been entered. This
password will be provided by CPI if needed. The linearizer is tuned at the factory for the entire
frequency band of the amplifier to meet specification.
Tube channels can be changed using the “Tube Channel” field below the linearizer settings.
There can be a maximum of 8 tube channel presets.

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The CIF Protocol field is operator selectable between binary computer interface protocol (BCIP)
or ASCII computer interface protocol (ACIP). The address field sets the CIF address of the
amplifier. No two amplifiers in a system can have the same address. The BCIP the address
range is 17-255 and the ACIP address range is 48-111.
The ‘BUC Unlock Type’ field is operator selectable to FAULT or ALARM. If the reference signal
of the BUC either drifts or is removed either a fault or alarm will be generated by the amplifier.
The Legacy WGS I/F will only be shown if the legacy WGS I/F option is installed. The
‘Interlock Type’ field selects if the external interlock generates an ALARM or a FAULT and is
operator settable.
The ‘Relay Control’ is used to select the conditions which will activate the WGS I/F relay.
The ‘Remote Control Point’ is used to determine which interface the amplifier will be controlled
through. It can be set to either “Ethernet CIF”, “Serial CIF”, “WEB Browser” or ”Remote”. All
interfaces have the ability to control the amplifier.

3.7.6 Timers
The ‘Timers’ screen shows unit on time, heater on time, heater off time, transmit time, and HTD.

Figure 3-11. Timers screen

3.7.7 IP Settings Screen


The default IP address can be found on the front of the amplifier. The user may reset the IP
address through the 'IP Settings' screen. For the new settings to take place the unit must be
powered off and back on again.

Figure 3-12. IP settings screen

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3.7.8 Email Screen


The email screen can be set up to send the alarm/fault and the meter log to an assigned e-mail
address. The HOLD OFF period can be set to a user specified time in minutes, which the
amplifier will not send the same fault/alarm message. Alarm/fault events and meter logs will
be sent when the check box is marked and the SUBMIT button is clicked. RESET will clear all
entries on the email screen.

Figure 3-13. Email screen

3.7.9 Set Login Screen


The 'Set Login' screen is used to change the user name and password. All fields must be filled
out. Click the Apply button to save the changes.

Figure 3-14. Set login screen

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3.7.10 Clock Screen


The time screen is used to set either automatically or manual the current time and date. The
operator can type in the hour, minute, second, month, day, and year and click Apply button for
the new settings to be loaded. Alternately the amplifier can be given a network time protocol
(NTP) server address to automatically retrieve the time and date.

Figure 3-15. Clock Screen

3.7.11 Options Screen


The options screen is used to set operator preferences during amplifier operation. It helps avoid
mis-clicks through confirmation prompts and allows the operator to save the current operating
state in the memory of the amplifier.

Figure 3-16. Options screen

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The ‘Confirm Transmit Selection’ when enabled, will prompt the operator with an "Are You
Sure" message box in the browser whenever the TRANSMIT button is pushed from the “Amp
Status” screen.
The ‘Confirm Standby Selection’ when enabled, will prompt the operator with an "Are You
Sure" message box in the browser whenever the STANDBY button is pushed from the “Amp
Status” screen.
The ‘Confirm Inhibit Selection’ when enabled, will prompt the operator with an "Are You Sure"
message box in the browser whenever the RF INHIBIT button is pushed from the “Amp
Status” screen.
The ‘Save Transmit State’ when enabled, will allow an amplifier which was powered off in
transmit state to automatically return to the transmit state when powered on again.
The ‘Enable Fault Alarm Sound’ when enabled, will play an audible alarm in the web-browser
whenever the amplifier has faulted. When using this feature remember to check all sound
settings of the PC to ascertain they are working properly.
The ‘BIPA Installed’ shows whether a BIPA is installed (checkmark) or not (unchecked). This is
determined at the factory and cannot be disabled by the operator.
The ‘SEM Installed’ shows whether the switch expansion module (SEM) is installed
(checkmark) or not (unchecked). This field is operator selectable and should not be enabled if
the amplifier is not in a SIM switch system. A resulting “Switch Interlock Fault” will result
when this field is enabled and the amplifier is not used in a SIM switch system.
When the ‘SEM Installed’ is enabled, a “Switch Ctrl” screen will be available to the operator.
The “Switch Ctrl” screen is used to set parameters and provide control of the switch system.
Detailed operation of the “Switch Ctrl” screen is provided in the switch system manual.
The ‘Ext Interlock Enable’ selects of the external interlock is enabled (checked) or not
(unchecked). The external interlock pin must be connected to the common pin on the J5
connector when Legacy is installed as a standard feature. This interlock should not be enabled
when the SIM switch option is purchased.
The Save User Settings button will save all the current settings to non volatile (NV) amplifier
memory.
The Load User Settings button will load the saved setting in the NV amplifier memory.
The Load Factory Settings will load the factory configured settings.

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3.8 Front Panel Controls and Indicators


The front panel push button and LED display is shown in the figure below. Table 3-5 lists the
front panel controls and indicators and defines the function of each listed item.

Figure 3-17. Front Panel Push Button and LED Display

Table 3-5. Front Panel Controls and Indicators

Label Type Function


RESET(NOTE 1) Push Button When pressed, will remove the latched fault state. The fault LED will
Switch be off and the standby LED will become lit.
If pressed when the amplifier is not in a latched fault state; toggles
the RF inhibit ON or OFF.
HV ON(NOTE 1) Push Button When pressed, toggles between the transmit state (HV ON) and
Switch standby state (HV OFF). The XMIT LED will be lit when the amplifier
is in the transmit state and off when in the standby state.
LCL/RMT Push Button When pressed, toggles between LOCAL and REMOTE control.
Switch A lit RMT LED indicates REMOTE mode and the operator can set
and monitor system parameters remotely. All local control is
disabled in this state except for the LCL/RMT push button.
An unlit RMT LED indicates LOCAL mode and the operator can only
change the operating state of the amplifier or reset faults.
PWR LED (green) Is lit when power on self test has completed.
STBY (Standby) LED (amber) Is lit when there are no faults, and HV is OFF.
XMT (Transmit) LED (green) Will blink during beam on sequence (BONS).
Will blink during transmit heater time delay (XHTD).
Is lit when in the amplifier is in transmit state (HV ON).

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Table 3-5. Front Panel Controls and Indicators (continued)

Label Type Function


FLT LED (red) Will blink when the amplifier is latched in a fault state. Pressing the
RESET push button will clear the fault.
RMT LED (amber) Is lit when the amplifier is set for remote operation.
Is off when the amplifier is set for local operation.
Table 3-5 Notes:
1. This switch is active in LOCAL mode only.

3.8.1 Communication Port Manual Reset


If the communication port settings are unknown, a manual communication port reset is
required. To perform the reset use the following instructions:
1. With the power off hold down both the RESET and LCL/RMT front panel buttons.
2. Apply prime power.
3. When the internal blower initiates a self check release the RESET and LCL/RMT front panel
buttons. The default communication port settings are shown in table 3-6.

Table 3-6. Parameter and Manual Reset Default Setting

Parameter Manual Reset Default Setting


ACIP Amp Address 48
BCIP Amp Address 48
IP Address 192.168.000.254
IP Gateway 192.168.000.001
IP Mask 255.255.255.000
NTP Server Address 192.043.244.018
SMTP IP Address 192.168.000.010

3.9 Shutdown and Recovery


The following procedures describe normal shutdown.
1. Press STANDBY button. Verify the amplifier is in a standby state and wait 5 minutes.
2. When the amplifier has cooled, remove main power from the amplifier.

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3.9.1 AC Power Interruption


In the event of a power interruption, when power is reapplied, the amplifier will automatically
return to its state prior to the interruption. Emergency shutdown can be performed in one of
the following two ways:
1. At the source, turn off the mains.
2. Unplug connector J1.

3.9.2 Fault Recovery


Before resetting a latched fault determine the nature of the fault. If the fault is caused by one of
the user settable limits then determine if the cause is the limit setting, the RF drive level, or the
output load. If any of the faults that are not user settable occur call CPI or get a trained local
technical consultant. Refer to the fault messages in the “Messages” appendix of this manual for
detail. Once the cause of the fault is identified and cleared recover from a fault by using the
following instructions:
1. Click on the 'Amp Status' screen.
2. Click on the RESET button.
If the fault persists and it is not critical try to determine the cause of the fault. If trip limits must
be changed make a record of the changes in the meter log screen using a text entry. If the fault
persists call CPI or get a trained local technical consultant.

3.9.2.1 High/Low RF Output Faults


This high RF output fault is commonly caused by too much gain or RF input power or an
incorrect setting of the high RF output fault. This fault can also be caused by RF leakage. RF
leakage may cause the amplifier to oscillate, increasing the RF output power to a point that trips
this fault. Confirm the RF input power is not too high and the internal attenuator is working
properly.
If these conditions are okay, the amplifier should be checked for RF leakage or possible loose RF
connections. Only a trained service person or system installer should make adjustments to the
amplifier.
The low RF output fault is commonly caused by a faulty input source or broken input cables or
an incorrect setting of the low RF output fault. Have a trained service person check the input
source and input cables to ascertain they are working properly. Check that the low RF output
fault setting on the amplifier is not set too high.

3.9.2.2 High Reflected RF Faults


This fault is commonly caused by a bad output waveguide match or the incorrect setting of the
high reflected RF fault. CPI recommends that the high reflected RF fault setting be set to 10% of
rated power. If waveguide mismatch is suspected contact a trained service person or system
installer to fix the problem.

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PREVENTATIVE MAINTENANCE

4-1

Chapter 4
Preventative Maintenance
Table of Contents
CHAPTER 4 PREVENTATIVE MAINTENANCE............................................................................4-1

4.1 OVERVIEW.................................................................................................................................4-3

4.2 SCHEDULED PREVENTIVE MAINTENANCE ....................................................................4-3

4.3 OPERATOR’S PREVENTATIVE MAINTENANCE .............................................................4-5


4.3.1 CHECK METER LOG FOR FAULTS AND ALARMS.........................................................4-5
4.3.2 VISUAL INSPECTION ...........................................................................................................4-5
4.3.3 FAN INSPECTION..................................................................................................................4-6
4.3.4 EXTERNAL CLEANING........................................................................................................4-6

4.4 TECHNICIAN’S PREVENTATIVE MAINTENANCE..........................................................4-6


4.4.1 INITIAL POWER-ON CHECK ...............................................................................................4-6
4.4.2 AIR SYSTEM MAINTENANCE ............................................................................................4-6
4.4.3 FAN REPLACEMENT ............................................................................................................4-7
4.4.4 CONDITION SPARE TWT'S OR AMPLIFIERS ...................................................................4-7
4.4.5 PERFORMANCE TESTING ...................................................................................................4-7
4.4.5.1 POWER AND GAIN PERFORMANCE TEST .................................................................4-8
4.4.5.2 RF RADIATION MEASUREMENT ...............................................................................4-10

4.5 TWT GENERAL OPERATIONAL GUIDELINES...............................................................4-10

4.6 PROTECTING PARTS FROM ELECTROSTATIC DISCHARGE ...................................4-11


4.6.1 PRECAUTIONS.....................................................................................................................4-11
4.6.2 WORKSTATION PRACTICES ............................................................................................4-11
4.6.3 WORKSTATION UPKEEP...................................................................................................4-12
4.6.4 PACKAGING.........................................................................................................................4-13

4.7 CUSTOMER SERVICE............................................................................................................4-13

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List of Figures
Figure 4-1. Performance Test Setup.....................................................................................................4-8

List of Tables
Table 4-1. Preventive Maintenance Performed by Operators..........................................................4-3
Table 4-2. Preventive Maintenance Performed by Technician ........................................................4-4
Table 4-3. Recommended Test Equipment.........................................................................................4-4
Table 4-4. Power and Gain Test Data Sheet........................................................................................4-9

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4.1 Overview
This chapter provides instructions for routine maintenance of the amplifier. It includes
procedures and test equipment for scheduled maintenance tasks and amplifier performance
testing. Guidelines for protecting parts from electrostatic discharge are also included in this
chapter.

Caution: Improper maintenance of the amplifier may void the warranty. For
additional information, see Appendix A, “Warranty & Support Information”

The amplifier’s internal memory contains a an alarm or fault log which can be used to easily
understand the long term operating conditions that the amplifier has experienced. This log can
be downloaded, and e-mailed which can be helpful in identifying trends or potential problems.

4.2 Scheduled Preventive Maintenance


Note: There are additional preventive maintenance tasks that require a service
technician who has attended a formal training program for servicing the
amplifier. (See Table 4-2).
To function safely and effectively, the amplifier requires periodic maintenance by the operator.
No maintenance is required for the electrical components inside the amplifier.
Refer to Table 4-1 for the Preventive Maintenance tasks to be performed by operators. Table 4-2
outlines preventive maintenance tasks to be performed by a service technician.
Operator Preventive maintenance includes visual inspection and cleaning. Some of these tasks
require the AC power removed. Details are listed in the following sections.

Table 4-1. Preventive Maintenance Performed by Operators

Tasks Daily 1 Mo. 3 Mo. 6 Mo. 1 Yr.


Check Meter Log for Faults and Alarms X
Perform Visual Inspection X
¹Cooling Fan Inspection X
Perform External Cleaning X
Table 4-1 Notes:
1. Cleaning may be required more or less frequently than shown, depending on the environment of operation.

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Table 4-2. Preventive Maintenance Performed by Technician

Tasks Daily 1 Mo. 3 Mo. 6 Mo. 1 Yr.


Perform Initial Power ON Check X
Air System Maintenance X
¹Fan Replacement A/R
Condition Spare TWT's or Amplifiers X
Run Performance Tests X
Table 4-2 Notes:
1. Replace fan after 50,000 hours of operation.
NOTE! PERSONS PERFORMING MAINTENANCE PER TABLE 4-2 MUST BE SERVICE
PERSONNEL WHO HAVE ATTENDED FORMAL TRAINING FOR SERVICE OF THE
AMPLIFIER.

Table 4-3. Recommended Test Equipment

Example
Item Description
(Equivalent may be substituted)
1 Analog Swept Signal generator, capable of CW and HP 8757D / E8257D
swept operation, compatible with Scalar Analyzer. Scalar
Network Analyzer, complete with dual detector probes.
2 Vector Network Analyzer HP E5071C; N5230C
3 Second CW signal source HP E8257D
4 CPI HV Test Set (includes HV Breakout Box, Heater CPI 0103531900
Load and adapter cables. Also contains a heater
breakout box.
5 RF pads, adapter, 10db coaxial coupler, Type N / SMA / HP / WINCHEL / Narda
2.9 / 2.4
6 RF Power Meter complete with power sensors, power HP E4418 meter HP 8481, ECP-
measurement range -30 to +20 dBm E18A sensor
7 High quality, low loss RF test cables as required for test
set ups
8 RF Radiation Detector Narda 8718 meter with 8621 probe
9 Calibrated Waveguide Directional Coupler, 50 dB APOLLO, MITEC, etc.
10 Dummy Load for rated power +20% APOLLO, MITEC etc.
11 Spectrum Analyzer HP N9010EXA ; E4446A PSA series
12 PC (Computer) with USB; ETHERNET; 232 SERIAL and HP / Dell
cables

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4.3 Operator’s Preventative Maintenance


WARNING! OPERATORS SHOULD NOT REMOVE COVERS WITH ELECTRICAL
HAZARD INDICATORS. ONLY SERVICE TECHNICIANS SHOULD REPAIR, REPLACE,
OR PLUG IN PARTS

Warning: before attempting any cleaning, remove all power. When using
solvents, provide adequate ventilation and avoid breathing fumes. When
cleaning with air, wear safety goggles and use clean, dry compressed air not
exceeding 25 psi (1.75 kg/cm).

4.3.1 Check Meter Log for Faults and Alarms


The meter log should be checked daily for faults and alarms that may have occurred. All faults
and alarms should be investigated as they may identify a future maintenance requirement or
potential system failure. The meter log should be downloaded periodically as only 1000 entries
will be held in the amplifiers available memory.

4.3.2 Visual Inspection


At one-month intervals, the amplifier should be visually inspected for physical defects. If the
equipment is subject to severe environmental conditions, inspections should be performed more
frequently.
The event log is a good source for clues that could indicate an intermittent or marginal
condition. Any increase in reflected power, temperature or unexplained fault conditions could
point to a deteriorating condition.
The circuit breaker must be off while the following general inspection is performed.
Perform the following visual inspection:
1. Check that all connector plugs are properly seated in their mating connectors and have not
been damaged. Only have a service technician replace any bad connector plugs and reseat
any that are dislodged.
2. Inspect cables for signs of discoloration, broken, and bad insulation. A service technician
should repair or replace cables as needed.
3. Inspect all waveguide for discoloration, cracks, loose connectors, and proper sealing.
Contact a qualified service technician for waveguide repairs.
4. Check for other defects. These include, but are not limited to, wear, breakage, deterioration,
fungus, excess moisture, and mounting integrity. Contact a qualified service technician for
repairs.
5. Inspect the air intake and clean it if necessary.

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4.3.3 Fan Inspection


Contact a local service technician for fan replacement parts. Feel the amplifier for abnormal
vibration indicating a fan balance or bearing problem. Listening for unusual or atypical sounds
can indicate a problem and should be investigated. Examination of the log files for
inconsistencies may indicate degraded fan performance. A trained technician can perform
replacements as covered in the CPI service manual, or contact the CPI service center.

Caution: Observation may be required more or less frequently than shown,


depending on the installation site environment.

4.3.4 External Cleaning


Look for signs of dirt or moisture contamination, which can cause short-circuiting, arcing,
corrosion, or overheating. Use a lint-free cloth, a small vacuum cleaner, or a compressed-air
blower at low pressure to clean contaminated areas.

Warning: When using compressed air wear proper eye protection. Do not use
pressure blowers to clean debris from your person.

4.4 Technician’s Preventative Maintenance


NOTE! SERVICE TECHNICIANS MUST BE SERVICE PERSONNEL WHO HAVE
ATTENDED FORMAL TRAINING FOR SERVICE OF THE AMPLIFIER.

WARNING! REMOVE ALL POWER TO THE UNIT BEFORE TOUCHING ANY


COMPONENTS.

4.4.1 Initial Power-On Check


Every three months the initial power-on and checkout procedure in the “Initial Power-On and
Checkout” chapter should be performed.

4.4.2 Air System Maintenance


The amplifier must be checked for airflow to insure proper transfer of heat away from the
internal heatsink. The measurement of airflow temperature, the inspection, and elimination of
any contaminants restricting the airflow must be performed periodically. The recommended
cycle is three months, but may be required more often if conditions warrant it.

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4.4.3 Fan Replacement


After 50,000 hours of operation or if the fans have problems, the fan should be replaced.
Contact CPI service for instructions.

Caution: Fan Replacement may be required more or less frequently than


shown, depending on the site environment.

4.4.4 Condition Spare TWT's or Amplifiers


The procedure below is applicable for amplifiers that are used on occasion or are turned off for
prolonged periods of time (several weeks or months).
Use the following procedure when conditioning a spare amplifier:
1. All steps in the "Unpacking and Installation" chapter should be completed before attempting
this procedure.
2. Turn the amplifier on with NO RF DRIVE applied.
3. Allow 5 minutes but not longer than 15 minutes before clicking the TRANSMIT button
from the 'Amp Status' screen.
4. If the amplifier is able to operate in transmit without a limit trip, continue this procedure. If
not refer to service manual.
5. The amplifier should be run without RF until the helix current has stabilized (this should be
at least 5 minutes).
6. Apply RF slowly up to the point of rated power. Follow the instructions in the 'RF
Radiation Measurement' section.
7. Run with and without RF input for a minimum of 30 minutes after the Helix current has
stabilized. The time required to stabilize varies with the age of the tube, storage time, and
storage conditions.
8. Put the amplifier in Standby for 2 minutes to cool the TWT prior to shutdown.
Follow the instructions in the 'Performance Testing' section.

4.4.5 Performance Testing


Once a year perform the tests for power and gain, radiation levels, and record their results. If
the results change dramatically consult the service manual for troubleshooting and repair.

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4.4.5.1 Power and Gain Performance Test


Follow these steps to test the amplifier for power and gain. Record the results on the “Power
and Gain Test Data Sheet” provided in table 4-4.
1. Connect equipment as shown in figure 4-1 “Performance Test Setup”.
2. Turn off the synthesizers RF output. Set the input drive level to minimum and the amplifier
attenuation to maximum.
3. Set the synthesizer to center wave (CW). The same frequencies should be used every time
preventative maintenance is performed so that a trend chart can be developed.
4. Turn on the synthesizer’s RF output.
5. Slowly decrease the amplifier’s attenuation until it reaches 0 or the amplifier has reached
rated power. If rated power is reached and there is still attenuation place a 10 dB fixed
attenuator and perform steps 1 through 5 again.
6. Increase the drive level until the amplifier has reached rated power.
7. Calculate the gain at rated power and record on the test data sheet.
Gain = Pout (dBm) – Pin (dBm)
8. Reduce the drive level until the amplifier is at rated power –10dB. It may be necessary to use
a 10dB fixed attenuator at the input to achieve a reliable input power measurement.
Remember to inhibit or put the amplifier in standby when physically breaking the RF input
chain.
9. Calculate the small signal gain, and record the result on the test data sheet.
10. Repeat for the all frequencies shown on the “Test Data Sheet” table 4-4.

Figure 4-1. Performance Test Setup

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Table 4-4. Power and Gain Test Data Sheet

Amplifier Model
Number:
Amplifier Serial Number:

Frequency Small Signal Gain Gain @ Rated Power


(10dB backoff rated power)
Low:

Center-Low:

Center:

Center-High:

High:

Notes:

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4.4.5.2 RF Radiation Measurement


To measure radiation levels:
1. Adjust for rated power.
2. Using a radiation probe, measure the highest level of RF leakage around the amplifier, at
less then 12 inches away from any point source.
3. Record the measured value(s). Measured levels should be less then 1mW/cm². If this value
is exceeded. Shut down the amplifier and tighten the joints or install grounding or gaskets
to eliminate leakage.

Note: If any RF radiation levels are to be measured, it is a good idea to check


for RF leakage as above.

4.5 TWT General Operational Guidelines


Once the amplifier is in service, it is important that the operation is preformed correctly. The
three guidelines to TWT amplifier operation are as follows:
1. When an amplifier is the standby amplifier in a redundant switch system (1:N), it should be
left in transmit. Leaving the TWT amplifier in standby with the heater on for several hours
can cause the cathode to age quickly reducing the TWT's life. Gas build up will poison the
cathode and reduce the emission.
2. The heatsink fins must be kept clean. If the heatsink fins become clogged, the collector can
overheat and over a long period can produce gas. This can poison the cathode and affect
the performance.
3. The heater must be operated at the nameplate voltage for the particular TWT. A voltage
setting too high or too low can cause premature failure. However, when the TWT is old and
the beam current drops due to cathode depletion, the heater voltage can be raised 5 percent
without causing any harm. Refer to the service manual for the procedure on raising the
heater voltage.

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4.6 Protecting Parts from Electrostatic


Discharge
Static electricity is a familiar phenomenon; except for an occasional mild shock or annoying
“static cling,” it does not seem very serious to most personnel handling integrated circuit (IC)
parts or assemblies. Unfortunately, many electronic components can be damaged or destroyed
by electrostatic discharge (ESD) at potentials well below a person’s range of feeling. This
damage can occur before, during, or after the part is installed.
People often carry 1000 to 5000 volts of static charge and do not feel any discharge of less than
3500 to 4000 V. Components mounted on a printed circuit board face increased risk of ESD
damage because each printed conductor (wire) is a path connecting several devices. A discharge
to that conductor stresses several devices at once.
Passive as well as active components are susceptible, and the damage ranges from a slight
degradation of a parameter to catastrophic failures, such as short circuits. In many cases, a
damaged part exhibits little or no visible physical damage, even under microscopic
examination.

4.6.1 Precautions
ESD damage can be prevented for the most part by following these precautions:
1. Treat all electronic parts and assemblies as static sensitive.
2. Do not touch leads, pins, or traces while handling parts.
3. Keep parts in original containers until ready for use.
4. Discharge static before handling devices by touching a grounded metallic surface such as a
cabinet. For personal grounding, use a wrist strap grounded through a 1-megohm resistor.
5. Do not slide static-sensitive devices over any surface.

4.6.2 Workstation Practices


Handle all sensitive parts or assemblies at static-safe workstations. A static-safe workstation
provides the following features:
• A conductive tablemat grounded through a 1-megohm resistor.
• A conductive wrist strap wired to a swivel connector on the mat through a 1-megohm
resistor.
• A common ground point at each workstation.
• A work area free of nonconductors, including all common plastics, “polybags,” cardboard,
cigarette packages, candy wrappers, work envelopes, synthetic mats, and ungrounded
metal plates. Carpeting should not be used on floors, work surfaces, or shelving.

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• Do not allow clothing to come in contact with components or assemblies. Sleeves should be
rolled high enough to keep them away from sensitive parts. Antistatic smocks should be
worn.
• Gloves, if used, should be made of cotton or antistatic materials only.
• Brushes, if needed, should have natural, not synthetic, bristles.
• If walking is necessary and wrist straps cannot be worn, use a conductive floor mat in
conjunction with conductive shoe heels.
• Transport and store electrostatic-sensitive devices only in static-protective containers. No
paper or cards should be placed inside the containers. A label attached to each container
should warn personnel to observe proper handling precautions.
• Transportation carts should have carrying surfaces covered by conductive mats and should
have at least two conductive wheels. Verify that carts, wheels, casters, frames, and shelves
are conductive. Do not transport sensitive electronic equipment on a rubber-wheeled cart
being pushed by a person wearing crepe- or heavy-rubber-soled shoes; this promotes very
high levels of electrostatic charge.

4.6.3 Workstation Upkeep


Perform the following checks at the static-safe workstation on a weekly basis:
1. Monitor each workstation for proper grounding, safe procedures, and possible static
hazards.
2. Check electrical grounds and wrist-strap continuity with an ohmmeter.
3. Check workstations, including materials and containers, with a static meter.
4. Spray a commonly available antistatic solution on a clean cotton cloth and wipe the surfaces
of workbenches, hand tools, and chairs.
5. Clean conductive mats with mild detergent and water or with antistatic solution. This
removes dirt and wax, which can insulate the surface and render it nonconductive.

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4.6.4 Packaging
Package parts properly for storage or transportation in the following manner:
Attach a static warning label on the outside of each applicable envelope and container. (A
JEDEC/EIA ESDS symbol is preferred.) Pack parts for storage or transportation in antistatic
packaging; pack the parts tightly to prevent motion that could generate static.
Note: The best protective enclosure is a Faraday cage, which shunts any
inductive charges around the part, providing complete protection. Metal,
metalized plastic, and carbon-loaded plastic bags are all examples of
Faraday cages. Metalized plastic has the advantage that it is
semitransparent and its contents can be seen without opening it. The often-
used “pink poly” bags afford less protection.

4.7 Customer Service


Refer to the “Warranty and Support Information” appendix, for CPI Satcom contact, service,
and return information.

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DRAWINGS

5-1

Chapter 5
Drawings
This chapter contains the drawings for the Compact HPA ODU.

Table 5-1. Compact HPA ODU Drawings

Drawing Name Number


TECHNICAL DESCRIPTION, 750W DBS-BAND ODU TD187
TECHNICAL DESCRIPTION,, 750W C-BAND ODU TD188
(NOTE1)
AMP SEARCH, (ZIP file) 0101401500
CIF PROTOCOL, BINARY 0104161100
ASSEMBLY, RF, 750W DBS-BAND ODU(NOTE2) 0104700000
OUTLINE, 750W ODU 0104700100
RF DIAGRAM, 750W DBS-BAND ODU 0104700200
INTERCONNECT DIAGRAM, 750W ODU 0104700300
SHIP KIT, 750W DBS-BAND ODU (LM ONLY) 0104709400
SHIP KIT, 750W C-BAND ODU (LM ONLY) 0104709402
ASSEMBLY, RF, 750W C-BAND ODU(NOTE2) 0104840000
RF DIAGRAM, 750W C-BAND ODU 0104840300
Table 5-1 Notes:
1. This software is provided with the manual on CD. The software is a ZIP file and must be extracted before use.
2. Refer to service manual for respective LM.

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DRAWINGS

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CUSTOMER SUPPORT AND WARRANTY INFORMATION

Appendix A
Customer Support and Warranty
Information
For details, refer to separate supplements included following this page.

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L-BAND BUC OPTION

B-1

Appendix B
L-Band BUC Option

B.1 Overview
The L-Band RF input signal is converted by the Block Up-Converter (BUC) to the frequency
band of the amplifier.
Each amplifier is provided with a label indicating the correct L-Band input frequencies accepted
by the BUC. This label is shown in figure B-1. The bandwidth of the L-Band input frequency is
typically the same bandwidth as the amplifier's output frequency bandwidth.
Warning: Ensure that the proper L-band frequency range is not exceeded
or damage may result. Damage due to an improper frequency input may
not be covered in the warranty of the amplifier.
This appendix provides information on BUC operation and explains the three types of
frequency references which can be used.

Figure B-1. RF Warning Label

Note: Refer to the amplifier specifications in the "Drawings" chapter for


performance of the amplifier with a BUC.

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L-BAND BUC OPTION

B.2 General Operation


The BUC converts the L-Band input frequency to the frequency required by the TWT through
adding the frequency of local oscillation (FLO) to the L-Band input frequency.
All BUC's require a reference signal to operate properly. This reference signal is typically
10MHz, however can be a different value. If the BUC FLO reference fails or drifts outside of the
capture range, a "BUC alarm" or "BUC fault" signal will be reported by the amplifier.
In the event that the BUC F becomes unlocked and a fault signal is reported the amplifier will
LO

inhibit RF and shutdown HV to the TWT. A reset command will restore the amplifier to normal
operation once the fault has cleared.
The FLO reference can be supplied in one of the following three ways:
• Multiplexed - FLO reference is multiplexed with the L-Band input signal.
• Internal - FLO reference is generated internal to the BUC.
• External - FLO reference through a dedicated reference port.
Caution: For multiplexed and external FLO reference BUC's, the L-band
input signal must be free of the spurious signals that can cause poor
performance. Spurious signals may also cause the amplifier to fail.

B.2.1 Multiplexed Reference


Most L-band modems now have a built-in 10 MHz reference. A multiplexed reference BUC is
configured to accept this reference multiplexed with the L-band input signal on the same
connector. This is CPI’s standard configuration and is recommended for most applications.
The level of the FLO reference should be +5 to -5 dBm at the amplifiers input.
Caution: A multiplexer should be used rather than a combiner. In case of
using a combiner, band pass filters should be added to modems’ output or
a 10 dB fixed attenuator can be added to each combiner’s input.

B.2.2 Internal Reference


An internal FLO reference signal with ±1 ppm stability is included in the BUC. The oscillator
performance is not as precise as a GPS reference, but it is adequate for many applications.

B.2.3 External Reference


This allows the user to connect a system 10 MHz reference through a separate amplifier input.
The external reference is used for systems that need to slave all amplifiers to a common timing
reference, such as the GPS signal. The FLO reference level required is +5 to -5 dBm.

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MESSAGES

C-1

Appendix C
Messages

C.1 Messages from the Amplifier


The amplifier will indicate alarm and fault events in a flashing text box which appears in the
web browser. Alarm text messages will flash yellow and fault messages will flash red. There
are many limits that are not operator adjustable. When these limits are exceeded, they can
cause a variety of alarms and faults. Never reset the amplifier on a non-operator settable fault
or alarm. Have anything that is not high power limit, low power limit, reflected power limit
faults investigated by a qualified technical person. The amplifier setup should be verified in the
“Pre-Power On Procedure” section located in the “Operation” chapter.
The following two tables indicate whether a fault or alarm is operator settable, factory settable,
or a status indicator.

Table C-1. Fault Messages

Section Limit – Status Indicator Operator Settable Factory Setting Status Indicator
BIPA BUC LOCK X
EEPROM X
WGSIF INTERLOCK X
HIGH RF DRIVE X
RF HIGH POWER LIMIT X
LOW POWER LIMIT X
REFLECTED POWER LIMIT X
MAIN BBRAM X
BIPA COMM X
BIPA RESTARTED X
CAN BUS X
CAN LEVEL KEY X
EEPROM X

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MESSAGES

Table C-1. Fault Messages (continued)

Section Limit – Status Indicator Operator Settable Factory Setting Status Indicator
MAIN PS COMM X
(con’t)
PS RESTARTED X
RF COMM X
RF RESTARTED X
SEM COMM X
SEM RESTARTED X
SYSTEM X
POWER CABINET TEMPERATURE
X
SUPPLY LIMIT
EEPROM X
HEATER CURRENT LIMIT X
HEATER OVER VOLTAGE X
HEATER UNDER VOLTAGE X
HELIX CURRENT LIMIT X
HELIX OVER VOLTAGE X
HELIX UNDER VOLTAGE X
HELIX VOLTAGE
X
DETECTED
TUBE BLOWER UNDER
X
SPEED
TUBE OVER TEMP X
TUBE OVER TEMP SWITCH X

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MESSAGES

Table C-2. Alarm Messages

Section Limit – Status Indicator Operator Settable Factory Setting Status Indicator
BIPA BUC LOCK X
I2C TIMEOUT
HIGH RF DRIVE X
POWER CABINET OVER
X
SUPPLY TEMPERATURE
I2C TIMEOUT X
TUBE BLOWER OVER
X
SPEED
TUBE OVER
X
TEMPERATURE
MAIN LOW BATTERY X
RTC FAILURE X
RF ALC LIMIT X
HIGH REFLECTED RF X
HIGH RF OUT X
LOW RF OUT X
SWITCH AMP IDENT CONFLICT X
SIM X X

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MESSAGES

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