CPI T04CO, Installation & Operation Manual

Page 1: ...nt For Use With Model Numbers T04CO T04UO Service Center Headquarters and Design Center West Coast Operations 811 Hansen Way Palo Alto CA 94303 Manufacturing East Coast Operations 45 River Drive Georgetown Ontario Canada L7G 2J4 Doc 01031254 Rev 1 ...

Page 2: ...ing and maintaining CPI equipment Except for rights expressly granted by contract all such information is the exclusive property of CPI Satcom Division This document may not be duplicated in whole or in part or be used for manufacture without written permission of CPI Satcom Division Copyright 2001 by Communications Power Industries All rights reserved ...

Page 3: ...3 About This Manual 1 4 1 4 Conventions 1 5 Notes and Cautions 1 5 Warnings 1 5 Text Conventions 1 6 CHAPTER 2 UNPACKING AND INSTALLATION 2 1 Overview 2 1 2 2 Pre Inspection 2 1 2 3 Unpacking 2 1 2 4 Installation 2 2 2 4 1 Amplifier Installation 2 2 2 4 2 Cooling Considerations 2 3 2 4 3 Electrical Power Connections 2 4 2 4 3 1 Prime Power 2 4 2 4 3 2 Grounding 2 4 2 4 4 Remote Control Interface 2...

Page 4: ...irst Time Pre Power Procedure 310 3 6 Power On Sequence 3 11 3 6 1 Initial Check High Voltage OFF 3 11 3 6 1 1 Check Factory Set Values via a Computer 3 12 3 6 1 2 Check Factory Set Values via RCU 3 12 3 6 2 Initial Check High Voltage ON 3 14 3 7 Verify RF Output 3 16 3 8 Setup For Operational Service 3 17 CHAPTER 4 EXTERNAL INTERFACES 4 1 Overview 4 1 4 1 1 Control Mode Hierarchy 4 1 4 2 Serial I...

Page 5: ... 5 6 Description of Amplifier States 5 5 5 6 1 POST 5 6 5 6 2 Heater Time Delay HTD 5 6 5 6 3 Standby State 5 7 5 6 4 Beam On Sequence 5 7 5 6 5 Transmit State 5 7 5 6 6 Beam Off Sequence 5 7 5 6 7 Fault State 5 8 5 6 7 1 Auto Fault Recycle Mode Rules 5 8 5 6 7 2 Fault Log 5 9 CHAPTER 6 OPERATOR MAINTENANCE 6 1 Introduction 6 1 6 2 Preventive Maintenance Tasks 6 1 6 2 1 Visual Inspection 6 2 6 2 2...

Page 6: ...MPA Connector Locations 2 5 Figure 2 2 RS 232 Cables 2 6 Figure 2 3 MPA Hub Mount Rear Panel 2 8 Figure 3 1 Amplifier Front Panel Controls and Indicators 3 2 Figure 3 2 Remote Control Unit Front Panel 3 4 Figure 3 3 Remote Control Unit Control Keys 3 7 Figure 3 4 Display and LED Group 3 8 Figure 3 5 Remote Control Unit Menu Tree 3 9 Figure B 1 Startup Screen B 1 Figure B 2 Meters screen in HTD B 2...

Page 7: ...mbining State Diagram G 11 Figure G 5 Switching and Combining State Diagram G 11 LIST OF TABLES Table 1 1 MPA Hub Mount Amplifiers 1 1 Table 3 1 Hub Mount MPA Front Panel Controls and Indicators 3 3 Table 3 2 Helix and RF Settings Fault and Alarm Ranges 3 13 Table 4 1 RF Switch Pin Assignment J5 4 6 Table 6 1 Preventative Maintenance Operator 6 2 Table 6 2 Preventative Maintenance Technician 6 2 T...

Page 8: ...T A B L E O F C O N T E N T S viii Installation and Operation Manual This page is intentionally left blank ...

Page 9: ...and 22 1 of the Standard High Voltage Equipment Personnel Operating Guidelines This guideline document presents operating practices for operators and technicians who work with high voltage equipment In the context of this discussion any voltage that is lethal is viewed as high voltage Therefore even prime power 115 to 440VAC is dangerous because prime power potentials have been known to cause deat...

Page 10: ...be jolted injured or killed 440VAC can stimulate an involuntary muscle response that will either literally throw you across a room or seize and hold you across the voltage terminals 600 or more volts can hold you indefinitely If the potential is sufficient to drive 200 milliamps through your body you will be held indefinitely Some people consider the 200 to 600 volt range to be worse than potentia...

Page 11: ...uipment looks docile One reason the equipment is so big is to get the proper separation between high voltage points On the other hand just because the equipment is small is no assurance of safety Dense packaging results in more difficult access and increases the chance that you will accidentally hit the wrong point g Always discharge high voltage capacitors High voltage capacitors store a lot of e...

Page 12: ...ce is fore knowledge of hazards m Create a favorable environment for safe operations This means that if people are crowding you stop the operation if it involves high voltage Pressure can lead to carelessness In the same way fatigue is also an enemy STAY ALERT AT ALL TIMES WHEN WORKING WITH HIGH VOLTAGE n Do not become over confident Maintain a healthy respect for high voltage o A good operating p...

Page 13: ...terminals Unloaded high voltage lines or plugs can lead to arcing situations t Shut off the high voltage when you are making low voltage measurements It does not make sense to increase danger needlessly While there may be times when you cannot shut off the high voltage during a low voltage measurement this is generally not the case u Remove the test equipment when you have finished a measurement p...

Page 14: ... the equipment or the test instruments represent a real threat Do NOT use a setup that you know is unstable and or dangerous y Use the 30 second rule Wait 30 seconds after you have shut off the equipment before you work on a unit Part of the reason for the 30 second rule is that some of the dielectrics insulators used for high voltage circuits can store a charge While the amount of charge stored i...

Page 15: ...without proper termination on the input and output of the amplifier ELECTRICAL HAZARD PROTECT YOURSELF AND THOSE AROUND YOU FROM UNWANTED RF EXPOSURE ALWAYS TERMINATE THE AMPLIFIER INPUT AND OUTPUT WITH A RF DUMMY LOAD BEFORE YOU TURN THE HIGH VOLTAGE ON THIS WILL REDUCE THE CHANCES OF OSCILLATION DUE TO INTERNAL AMPLIFIER NOISE Microwave Discussion Limit exposure to microwave radiation to prevent...

Page 16: ...gun Your eyes are particularly vulnerable parts of your body c Shut off the unit if you are trying to locate a RF leak As noted earlier the levels of concern are very low Examine the physical unit with the high voltage OFF If you have to survey the RF runs with the power ON to find the leaky joint or component start by testing the system with low RF input with a radiation meter If the microwave ra...

Page 17: ...reason these amplifiers are referred to as MPA Hub Mount Amplifiers Table 1 1 shows the model numbers frequency ranges and power outputs of these amplifiers Figure 1 1 is a photograph of an MPA All models have the same appearance Table 1 1 MPA Hub Mount Amplifiers Model Number Frequency Range GHz Rated Power Watts T04UO 12 75 to 14 5 GHz 400 W T04CO 5 85 to 7 1 GHz 400W By industry convention the ...

Page 18: ...ifiers are air cooled The cooling air enters the bottom of the unit and exits the front end See Chapter 2 for more details MPAs can operate in direct sunlight at ambient temperatures ranging from 40 to 50 C Detailed specifications for the MPA Hub Mount are provided in Chapter 7 Drawings The MPAs can be operated in either local or remote mode the latter being the primary mode of operation Remote op...

Page 19: ...PA Option with optional pin diode attenuator A Linearizer option Forward power detection over CIF option An L band block up converter option Ku Band Only An internal 1 1 switch controller with drive option An internal hybrid switch controller with drive option A separate MPA Hub Mount Remote Control Unit is also available Doc 01031254 Rev 1 1 3 ...

Page 20: ...ial checkout after the amplifier has been installed Chapter 4 Interfaces describes The Hub Mount Medium Power Amplifier external interfaces and external connector pinouts The commands used to setup the serial interface hardware characteristics Chapter 5 Operation describes the procedures for normal start up and shutdown and describes the operational modes of the amplifier Chapter 6 Maintenance des...

Page 21: ...erations or procedures that could potentially damage the equipment Warnings There are three different warnings Electrical Hazards Radiation microwave Hazards and Physical Hazards mechanical chemical miscellaneous ELECTRICAL HAZARD IDENTIFY CONDITIONS OPERATIONS OR PROCEDURES THAT EXPOSE THE OPERATOR TO POTENTIALLY LETHAL HIGH VOLTAGES RADIATION HAZARD IDENTIFY CONDITIONS OPERATIONS OR PROCEDURES T...

Page 22: ...MICAL HAZARDS 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 e g RESET Sometimes the actual labels are abbreviated e g TWT TEMP References to other parts of the manual are shown in Italics...

Page 23: ... 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 d...

Page 24: ...rawing These holes are 10 32 UNC 2B thread and are 0 38 inch deep In order to provide secure mounting screws with locking hardware must be used in all six holes 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 It is recommended that locations subject to electrical interference su...

Page 25: ...delines must be observed There must be at least two inches of clearance on the bottom of the unit air intake There must be at least three inches of clearance on the end of the unit that has the exhaust ducts the end with the visible cooling fins The hot exhaust air must be directed away from the air intake area The area below the air intake must be free of foreign material loose dirt debris and an...

Page 26: ...ower 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 2 No connection Pin 3 Neutral or Phase B Pin PE Ground Prepare the prime power cable but do not connect the cable to the amplifier at this time 2 4 3 2 Grounding Proper grounding of the MPA Hub Mount amplifier to the station ground bus or to ear...

Page 27: ... CPI Remote Control Unit connected to J6 REMOTE to remotely monitor and control the amplifier J6 is a 10 pin MS type connector ITT Canon KPT07E12 10S A mating connector is supplied in the ship kit The PC can use either RS 232 or RS 422 485 communication standards while the CPI Remote Control Panel uses only RS 422 Doc 01031254 Rev 1 2 5 ...

Page 28: ...S 232 or RS 422 485 but not both A cable assembly similar to CPI drawing 01026580 see Chapter 7 should be used for RS 422 485 communication A wiring diagram for a cable using RS 232 is shown in Figure 2 2 F 3 2 G H 5 ITT Cannon p n KPSE06F12 10P Mates with J6 9 pin D Connector Female RS 232 Interface Cable for 9 pin D Connector F 2 3 G H 7 25 pin D Connector Female RS 232 Interface Cable for 25 pi...

Page 29: ...ndalone configuration this connector must be used 2 4 6 RF Coaxial Cable Connections J3 J4 Refer back to Figure 2 1 for connector locations Prepare a user supplied coaxial cable and connect this RF drive cable to RF Input connector J3 A power monitor cable can be connected directly to front panel connector J4 40 dB nominal coupling Tighten the connector s CAUTION Position the coaxial cables so tha...

Page 30: ...eguide flange proceed as follows a Install the O ring gasket supplied in the output flange of the MPA Hub Mount b Position the interconnecting waveguide so that it aligns precisely with the waveguide flange at the rear of the MPA Hub Mount Figure 2 3 MPA Hub Mount Rear Panel CAUTION If flange alignment is not precise or if the installation is subject to motion or severe vibration a flexible wavegu...

Page 31: ...er alignment d A progressive tightening procedure is recommended Tighten each bolt until the lockwasher starts to compress and then proceed to the next bolt until you have partially tightened all the bolts e Starting with the first bolt fully tighten them to the desired torque level 15 in lbs for 6 32 screws Do not over tighten the screws because this can strip the threads or distort the mating fl...

Page 32: ...I N S T A L L A T I O N 2 10 Installation and Operation Manual This page is intentionally left blank ...

Page 33: ...ored by five LEDs Once the amplifier has been manually set for REMOTE operation all of the amplifier monitor and control functions can be used This chapter describes The MPA Hub Mount LOCAL controls and indicators Section 3 2 The optional Remote Control Unit controls and indicators Section 3 3 Operation with P C computer and remote control software Section 3 4 Pre power checks Section 3 5 The proc...

Page 34: ...re flagged LED blinking in the text If the LED is lighted and does not blink the text indicates that the LED is lighted 3 2 Front Panel Controls and Indicators The front panel of the Hub Mount MPA is shown in Figure 3 1 Table 3 1 which is keyed to Figure 3 1 lists the front panel controls and indicators and defines the function of each listed item Installation and Operation Manual Figure 3 1 Ampli...

Page 35: ...d unit is ready for XMT transmit XMT Transmit LED green LED blinks during BONS steady in XMT TRANSMIT mode See Note 1 FLT LED red Blinks when unit is in latched fault state Press RESET to clear fault RMT LED amber Lights when unit is set for Remote Control Operation LCL RMT Momentary Pushbutton Switch Toggles between LOCAL and REMOTE control each time the pushbutton is pressed RMT LED lights in RE...

Page 36: ...nits of the same type Types cannot be mixed At start up the Panel will scan the full address range looking for units and assigning a unit number to the units found 1 for the first 2 for the second etc After the address scanning is complete the display will show the Main menu for the first unit found Operation from this point on is the same as that described for the particular unit type in the sing...

Page 37: ...unction and up down keys as described above The switch position can be monitored by using the function key to scroll through the Function menu until the switch position A or B is shown on the display The switch mode AUTO or MANUAL can also be displayed by scrolling with the function key The switch mode of the selected unit can be changed using the Auto Man key to toggle between the two modes If th...

Page 38: ...s The RESET key is used to clear faults in the REMOTE mode The ENTER key is used in conjunction with the keys to increment the parameters accessible via the FUNCTION key These keys active in REMOTE mode only The AUTO MAN key is used to change the operational mode of the optional internal 1 1 switch controller The manual mode must be selected for the switch key to be active The SWITCH key is used w...

Page 39: ...T STANDBY METERS FUNCTION RESET ENTER AUTO MAN SWITCH Control Keys RF Out No RF Accept Value Increase Decrease Parameter Value Optional Redundant System Operation Keys Reset Fault RCUFP3 DSF Access and Scroll through Meter Readings Access and Scroll through Sub Menu Figure 3 3 Remote Control Unit Control Keys Doc 01031254 Rev 1 3 7 ...

Page 40: ... display modes When the Main Menu is displayed the first part of the display indicates the current control point set by the LOCAL REMOTE switch Seven sets of messages are possible when the Main Menu is selected Normally one of the messages shown directly below the Main Menu box in Figure 3 5 is displayed If an ALARM condition exists one of the messages shown below the ALARM CONDITION box is displa...

Page 41: ...M P A H U B M O U N T Figure 3 5 Remote Control Unit Menu Tree Doc 01031254 Rev 1 3 9 ...

Page 42: ...er running in DOS mode with the CPI supplied remote software The functions controls and monitors are the same as those accessed by the remote control panel Refer to Appendix B for a complete description of operation with this software program 3 5 First Time Pre Power Procedure Before applying prime AC power to the MPA Hub Mount verify that the following conditions are met AC prime power is 100 240...

Page 43: ...al Check High Voltage OFF Each time the MPA Hub Mount power is switched on the microprocessor controller performs a series of self tests to ensure that it has the ability to control and monitor the MPA Hub Mount Once the initial tests POST are successfully completed the amplifier initiates a heater time delay cycle of about three minutes to allow the TWT traveling wave tube heater to warm up Proce...

Page 44: ...r to Appendix B for a description of the CPI supplied Setup Remote control software program Refer to table 3 2 and record factory set values for each parameter 3 6 1 2 Check Factory Set Values via RCU In the following procedure you check and record the values currently set for the amplifier You will be able to change these values to the desired operational values before you place the amplifier in ...

Page 45: ...etting Factory Preset Default Settings Maximum Setting Remarks Low RF Alarm 0 W 0 W 0 W 600 W See 3 8 for normal operation Low RF Fault 0 W 0 W 0 W 600 W See 3 8 for normal operation High RF Alarm 0 W 425 425 W 600 W See 3 8 for normal operation High RF Fault 0 W 475 475 W 600 W See 3 8 for normal operation High Reflected RF Fault 0W 25 W 25 W 40 W Factory Set Do not change Helix Over Voltage 8 2 ...

Page 46: ...nu NOTE The amplifier should be in the STANDBY mode at this time Successful completion of steps a through c and 3 6 1 1 and 3 6 1 2 indicates Self tests were successfully completed Alarm and fault limit levels are properly set The TWT Traveling Wave Tube heater is warmed up High Voltage can be turned ON 3 6 2 Initial Check High Voltage ON Proceed as follows a Verify that the amplifier output J8 is...

Page 47: ...t at the factory for initial checkout purposes These values can be set to the desired operational values via the serial interface after initial checkout g After approximately 3 seconds the Beam On Sequence BONS should complete and the XMT LED should light h Starting at 40 dBm slowly increase the RF drive until rated output is achieved CAUTION Do not exceed a RF drive of 0 dBm i Press the HV ON swi...

Page 48: ...ntrol Unit STANDBY LED lighted and display reads REMOTE STANDBY NOTE Pressing TRANSMIT in the REMOTE mode is equivalent to setting the amplifier HV ON OFF switch to ON in the LOCAL mode d Press TRANSMIT The TRANSMIT LED will blink while the amplifier goes through the Beam On Sequence BONS The display will read REMOTE BEAM ON SEQ When BONS is complete the TRANSMIT LED will stop blinking and remain ...

Page 49: ...ed interface configuration and to drawings in chapter 7 for CIF protocol document If the optional Remote Control Panel is to be used the interface parameters do not require adjustment To change operational parameters via the Remote Control Panel use the procedure below to change selected parameters a Press FUNCTION until the option for the desired parameter is displayed b Use the keys to change th...

Page 50: ...I N I T I A L P O W E R O N A N D C H E C K O U T 3 18 Installation and Operation Manual This page is intentionally left blank ...

Page 51: ...face connector J5 provides additional control functions for redundant system operation and user external interlock circuits The LCL RMT switch on the front panel of the amplifier determines the amplifier control mode LOCAL or REMOTE The LCL RMT switch transfers the control point from the amplifier front panel to a remote control device At any time the LCL RMT switch can be used to establish LOCAL ...

Page 52: ...ch run Selection of the serial hardware interface is automatic based on which pin connections are used for the serial interface cable 4 3 RF Switch Interface J5 On standard units not equipped with optional internal 1 1 switch controller the RF Switch Interface provides the relay reported MPA Hub Mount status and RF inhibit command required by an external waveguide switch controller as well as two ...

Page 53: ...n J to pin K and pin L to pin M 4 3 1 Relay Definitions Each of the two status relays can be programmed to indicate one of several conditions The configuration of these relays is controlled through the computer interface CIF port The provided Remote Setup control software allows control of this configuration on the RF control tab See Appendix B figure B 5 Doc 01031254 Rev 1 4 3 ...

Page 54: ...s condition occurs except during an RF Switch port 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 that the MPA Hub Mount s RF output is below the Low RF Alarm level any time this condition occurs during the Transmit state except during an RF Inhibit The Low RF status will not assert during a Fault...

Page 55: ...urned on and the RF is not inhibited This is the normal operating state of the amplifier Note that the amplifier will cease transmitting and the Transmit indication will be negated when any of the interlock circuits External Latching I L External Non Latching I L or RF Inhibit opens Note When the amplifier is in the Transmit state the relay is energized There is continuity between the NO and COM c...

Page 56: ...rnal Non Latching I L Open from Return pin K for non latching RF Inhibit Interlock K Ext Non latch I L Rtn Non Latching interlock Return L RF Inhibit Open from Return pin M for non latching RF Inhibit M RF Inhibit Rtn RF Inhibit Return N Reset to Defaults Shorting this to return pin P while unit is turned on will reset the serial communication parameters to the factory defaults P Reset to Defaults...

Page 57: ...ion An open will cause a RF Inhibit This RF Inhibit command is executed regardless of the current control mode 4 The External Interlocks both Latching and Non latching require a maintained closed contact with their respective interlock returns for normal operation An open will cause either a Fault or RF Inhibit condition 5 Pins R through Y are used only when the Switch Option has been installed 6 ...

Page 58: ...E X T E R N A L I N T E R F A C E S 4 8 Installation and Operation Manual This page is intentionally left blank ...

Page 59: ...trol equipment developed supplied by the user NOTE Only one remote control device can be connected to the amplifer to connector J6 at one time If the amplifier has been set up for normal operation and the remote control device is temporarily unavailable the amplifier can be set for operational service in the LOCAL mode until the remote capability is restored for operational service Control command...

Page 60: ... the amplifier is in the STBY state the HV ON switch is pressed to initiate the Beam On Sequence BONS During this sequence the amplifier XMT LED blinks Two different fault conditions may occur during the turn on sequence Fault Non Latched Beam off malfunction state The amplifier will automatically recycle to the state which existed prior to the fault Fault Latched Beam off malfunction state The SD...

Page 61: ...mplifier STBY LED lights after the 3 minute heater time delay e Press the HV ON switch once the amplifier XMT LED flashes during the Beam On Sequence and stays ON if BONS was successful The amplifier is now in the XMT mode NOTE If high voltage was ON when the unit was shut down amplifier was in the XMT state high voltage will automatically be restored when the HTD and BONS cycles are complete f Al...

Page 62: ...nsmission is planned for an hour or two the amplifier AC power should be switched off to conserve electricity and prolong the life of the TWT traveling wave tube Proceed as follows a Place the amplifier in STANDBY mode Verify that the STANDBY LED is lit b Wait approximately 5 minutes to allow the TWT to cool off The fan will still be operating c Switch off the applied AC power 5 4 2 Prime Power In...

Page 63: ...ay be divided into several states and sequences They are as follows POST Power On Self Test Initial power on HTD Heater Time Delay Beam off state while cathode heats to operating temperature STANDBY Normal beam off state High Voltage not applied to the TWT BONS Beam On Sequence Transition from the STANDBY state beam off to the TRANSMIT state beam on TRANSMIT Beam on state in this state the Hub Mou...

Page 64: ...at the failed test and reports the error FAULT LED lights 5 6 2 Heater Time Delay HTD HTD Heater Time Delay allows the TWT heater to warm the cathode to its operating point HTD is nominally 3 minutes but can be a shorter period after a prime power failure as follows HTD proportional time delay If time off 5 seconds no HTD If 5 seconds time off 1 5 minutes HTD 1 5 x time off If time off 1 5minutes ...

Page 65: ...ty can be reduced 5 6 4 Beam On Sequence Beam on sequence BONS covers the transition from Standby beam off to Transmit beam on During BONS the green Transmit light will flash 5 6 5 Transmit State Transmit is the normal beam on state high voltage on heater reduce off RF Inhibit may be on or off If a fault occurs the unit will transition via the BOFS Beam Off Sequence to the Fault state A successful...

Page 66: ...ts should be investigated Damage can occur if a Reset is made without corrective action 5 6 7 1 Auto Fault Recycle Mode Rules Latch into Fault state sum fault If three faults occur within a 20 second period the unit latches in the Fault state Recycle to prior state If fewer than three faults occur within 20 seconds the system recycles back to the appropriate operational state During a Fault event ...

Page 67: ...e the unit is in the Fault state the Fault LED flashes Once the unit leaves the Fault state the Fault LED is OFF If the unit is latched into the Fault state the Fault LED flashes To exit the latched Fault state the user must clear the fault cause then toggle the RESET switch The amplifier returns to Standby 5 6 7 2 Fault log A fault log is available to the user via either the remote panel or the C...

Page 68: ...O P E R A T I O N 5 10 Installation and Operation Manual This page intentionally left blank ...

Page 69: ...eter readings This can be helpful in identifying trends and potential problems The daily log is a good source for clues that could indicate an intermittent or marginal condition Any increase in reflected power or unexplained fault conditions could point to a deteriorating condition 6 2 Preventive Maintenance Tasks To function safely and effectively the AMPLIFIER requires periodic maintenance This ...

Page 70: ...onment Note 2 Replace fan after 50 000 hours of operation Service Technician Task ELECTRICAL HAZARD THE PERSONS PERFORMING MAINTENANCE PER TABLE 6 2 MUST BE SERVICE PERSONNEL WHO HAVE ATTENDED A FORMAL TRAINING PROGRAM FOR SERVICE OF THE MPA HUB MOUNT Table 6 2 Preventive Maintenance Performed by Technician Tasks Daily 1 Mo 3 Mo 6 Mo 1 Yr Perform initial Power ON check X Verify limit settings X Ve...

Page 71: ...ion which can cause short circuiting arcing corrosion or overheating Clean contaminated areas with a lint free cloth a small vacuum cleaner or a compressed air blower at low pressure d Inspect all waveguide for discoloration cracks loose connectors and improper sealing Have a service technician tighten or replace waveguide as required e Check for other defects These include but are not limited to ...

Page 72: ...aner or compressed air d Monitor the operation of the fan with AC power ON e With the amplifier in STANDBY State verify that the fan is operating smoothly If a mechanic s stethoscope is available check for bearing rumble which indicates wear If a fan is faulty have the service technician replace it f Check for dust in the fan assembly An accumulation of dust is a sign that the TWT heatsink fins ne...

Page 73: ...agram MPA Hub Mount C 0103129100 RF Diagram MPA Hub Mount Ku 0103125000 LM Power Supply MPA Hub Mount 0103125100 Interconnect Diagram Power Supply Assembly 0103104803 LM Ship Kit C 0103104800 LM Ship Kit Ku 0103129900 LM Fan Assembly 0103140400 Specification Hub Mount Amplifier 400W C Band 0103074000 Specification Hub Mount Amplifier 400W Ku Band 0103123300 CIF protocol 0102658000 Cable Remote 010...

Page 74: ...D R A W I N G S 7 2 Installation and Operation Manual This page is intentionally left blank ...

Page 75: ...n assistance Telephone Directory Customer Location CPI Office Telephone No America West and Latin America Palo Alto CA USA 1 800 231 4818 24 hours 1 650 846 3600 24 hours No America East and Caribbean South Amboy NJ USA 1 732 727 6300 Western Europe Middle East and Africa Utrecht Netherlands 31 30 262 38 58 Eastern Europe Moscow Russia 7 095 230 2008 Far East Singapore 656 225 0011 Japan Tokyo 81 ...

Page 76: ... facility Refer to the Warranty Claim Form in the back of this section Place the equipment in the original shipping containers making sure that there is adequate packing around all sides of the equipment and that all front panels are protected If original shipping containers were discarded use heavy wooden boxes with adequate padding Please write the words FRAGILE DELICATE INSTRUMENT etc in severa...

Page 77: ... Manual Doc 01031254 Rev 1 Warranty Support A 3 Shipping Use the following address for all returned products CPI Satcom Division 811 Hansen Way Palo Alto CA 94303 Attention Customer Support RMA NUMBER __________________ ...

Page 78: ...___________________ F3______________________________________ F4______________________________________ F5______________________________________ OPERATING VALUES FROM METERING AT TIME OF FAILURE OR LAST RECORDED VALUES HELIX VOLTAGE ____________ HELIX CURRENT DC ____________ HELIX CURRENT FS ____________ HELIX CURRENT RATED ____________ COLLECTOR 1 VOLTAGE ____________ COLLECTOR 2 VOLTAGE __________...

Page 79: ...mply copy it remote exe to your local disk drive or run the program directly from the supplied floppy Starting the program Make sure the MPA is connected via either an RS232 or RS422 485 cable to the computer See chapter 2 for more information To run the program either create an icon in windows mode or type in the command remote exe at the dos prompt in the directory the program was installed The ...

Page 80: ...ar Figure B 2 shows the meters screen in HTD Heater time delay Figure B 2 Meters screen in HTD If no communication is established with the MPA the screen will flash a fault message per figure B 3 Figure B 3 No Communication fault B 2 Setup remote control software Doc 01031254 Rev 1 ...

Page 81: ...ed to match Also check to see that the Port setting matches the port you are connected to on your computer To change the CIF settings use the up down arrow keys to select the setting and press F1 scroll data Now use the up down keys to change each setting followed by F1 to save each setting RF Control Tab Use the left right arrow keys to select the RF control tab see Figure B 5 These are the RF sy...

Page 82: ...creen Power Supply Screen Use the left right arrow keys to select the Power supply screen Figure B 6 These are the Power Supply operating and trip point parameters Figure B 6 Power supply settings B 4 Setup remote control software Doc 01031254 Rev 1 ...

Page 83: ...Function keys The letter function keys are shown in the lower right hand corner on all screens except the startup screen Pressing these letters on the keyboard will perform the corresponding action Transmit Standby Reset and Inhibit The Inhibit I key is used for RF inhibit in both standby and transmit states When this key is pressed the message upper left corner in blue will tell the used that the...

Page 84: ...meter to change highlighted in green Press F1 and the color changes to yellow Now you can use the up down arrow keys to scroll through the available settings Press F1 again to exit once you have the desired setting or value In some cases you can enter the number value directly followed by enter Figure B 9 Changing parameters B 6 Setup remote control software Doc 01031254 Rev 1 ...

Page 85: ...tting They are shown in both a graphical color bar graphs and numerical format RF output bar graph shows the current alarm yellow area and fault trip red area settings Reflected RF and Helix current show the trip setting in red Helix voltage shows the under and over voltage trip levels also in red The wide bar graph is the current analog value with the numeric or digital value in the box above the...

Page 86: ...ult press R on the keyboard Fault log While in the meters screen the fault log can be accessed To access the fault log press F2 and the screen per Figure B 12 should appear The fault log will show the last 5 faults that occurred in the MPA If multiple faults occurred at the same time they will be reported on the same entry line To clear the fault log press F5 Return to meters screen by pressing F3...

Page 87: ...tings in this appendix If the MPA is also equipped with the internal switch controller option the switch position and control screens will become active Figure B 14 shows the WG switch system screen is now active and can be accessed by pressing F3 Pressing F1 now will give the command to toggle the W G switch Two types of 1 1 systems can be shown with input ganged switch or a split input The scree...

Page 88: ...MPA Hub Mount I O Manual Figure B 13 Optional Linearizer settings Figure B 14 WG switch F3 is active B 10 Setup remote control software Doc 01031254 Rev 1 ...

Page 89: ...MPA Hub Mount I O Manual Figure B 15 Switch system with separate input Figure B 16 Switch system with switched ganged input Doc 01031254 Rev 1 Setup remote control software B 11 ...

Page 90: ...MPA Hub Mount I O Manual B 12 Setup remote control software Doc 01031254 Rev 1 Figure B 17 Switch system type setup ...

Page 91: ... 00 CCA Fan Power 01035290 00 CCA Controller 01030520 01 Assy Control status 01027260 00 CCA RF Monitor 01025010 01 Fan Assy Main 01031299 00 Fan Assy PS WASH FAN 01031035 00 Tunnel Diode C 01000769 XX Tunnel Diode Ku 01002559 XX TWT Assy C Band 01031410 00 TWT Assy Ku band 01031297 00 Output Component C Band 01031408 00 Output Component Ku Band 01031294 00 Doc 01031254 Rev 1 Replaceable parts C 1...

Page 92: ...MPA Hub Mount I O Manual C 2 Replaceable parts Doc 01031254 Rev 1 This page is intentionally left blank ...

Page 93: ... details The user may modify the linearizer settings from the factory values Doing so may cause the MPA Hub Mount performance to degrade For this reason it is recommended that if the user wants to change these settings they should always record the factory set values below before making any changes Linearizer Adjustment Factory set value 0 255 Gain Phase Magnitude The Linearizer settings can be ac...

Page 94: ...MPA Hub Mount I O Manual D 2 Optional Linearizer Doc 01031254 Rev 1 This page is intentionally left blank ...

Page 95: ...ption allows the user to operate the MPA Hub Mount with L band input frequencies 950 1450 MHz The BUC converts the L band frequencies to Ku band 14 to 14 5 GHz If the BUC internal oscillator fails or drifts outside of the capture range a BUC alarm signal will be reported on the optional CPI remote panel or through the supplied Setup Remote software ...

Page 96: ...MPA Hub Mount I O Manual E 2 Optional L band BUC Doc 01031254 Rev 1 This page is intentionally left blank ...

Page 97: ...interface and are reported on either the CPI remote control panel or the supplied setup remote control software Note See Appendix B for info on remote software Additionally the user can change modes or remotely toggle the wave guide position through the remote or computer CIF control The internal controller receives external relay status signals from the other amplifier These relays can be configu...

Page 98: ... controller Drawings List Table F 1 Drawings Outline Ku Band 1 1 System 0103098500 Block Diagram Ku Band System 0103155400 Interconnect Diagram 1 1 Ku Band System 0103155300 Switch Interface Assembly 0103151400 Switch Interface Cable Assembly 0103151300 Mounting Plate 400W Hub Mount System 0103144200 Mounting Bracket 0103144100 ...

Page 99: ...in satellite uplink systems The RF frequency range is 13 775 to 13 975 GHz When power amplifiers PA s are installed with the linearizer option the combined output power delivers 220 Watts at an NPR of 20 dB minimum 110 Watts without linearizer The hybrid combiner is designed to be mounted in an antenna hub and to allow the service of one PA without interrupting operation of the other Figure G 1 is...

Page 100: ...MPA Hub Mount I O Manual Figure G 1 Front view of the Sub System Front Panel Figure G 2 Top view of the Switch Sub System Appendix G 2 Doc 01031254 Rev 1 ...

Page 101: ...tion 110 Watts at 20dB NPR without linearizer option Gain at Rated Output Power 71 dB Minimum At Small Signal 74 dB Minimum Input VSWR 1 3 1 Maximum Output VSWR 1 3 1 Maximum Gain Slope 0 04 dB MHz Gain Variation 1 0 dB pk pk over full bandwidth 0 4 dB pk pk over any 60 MHz 0 2 dB pk pk over any 20 MHz Gain Control 30 dB with 0 1 dB resolution RF inhibit mute 60 dB when inhibited Gain Stability 0 ...

Page 102: ...00 Hz 80 dBc Hz 1000 Hz 100 dBc Hz 10 KHz 106 dBc Hz 100 KHz 110 dBc Hz 1MHz 125 dBc Hz Prime Power Voltage 100 264VAC Frequency 47 63 Hz Power Factor 0 95 GHz Power Consumption 1500VA per HPA Input Connector Type N Female Output flange WR75 Grooved Flange Remote Serial Connector J1 KPT07E 12 10S mate with Amphenol KPSE06F 12 10P M C Connector J2 KPT07E 16 26S mate with Amphenol KPSE06F 16 26P Ope...

Page 103: ...the indicators as follows 1 Both green LED s of PA1 Combine and PA2 Combine illuminate when both outputs are combined and connected to the antenna feed 2 Amber LED of PA1 Bypass illuminates when PA1 output is routed to the antenna directly bypassing the hybrid 3 Amber LED of PA2 Bypass illuminates when PA1 output is routed to the antenna directly bypassing the hybrid 4 None of the indicators illum...

Page 104: ...out Specifications for RS 485 J 1 Functional Description Notes A RS 485 TX B RS 485 TX C RS 485 GND D RS 485 RX E RS 485 RX Table G 2 Pin out Specifications for M C Interface FROM Functional Description Notes A S 1 COMMON B S 1 POSITION 1 INDICATOR C S 1 POSITION 2 INDICATOR D N C E S 2 COMMON F S 2 POSITION 1 INDICATOR G S 2 POSITION 2 INDICATOR H N C J S 3 COMMON K S 3 POSITION 1 INDICATOR L S 3...

Page 105: ...ainer for damage The shipping container and packing material should be retained for onward shipment Check that all parts materials and documentation have been shipped with the amplifiers The hybrid combiner assembly and interconnect cables should be inspected for possible damage and then tested for proper operation before final installation G 2 2 Subsystem Installation The Hybrid combiner subsyste...

Page 106: ...ignated location PA1 on the left and PA2 on the right with the gasket in place until the amplifier is locked in the bottom sliding bars Verify that the output flange is even below the waveguide switch Start securing the amplifier by turning the captivating screws on the mounting brackets Don t over tighten the screws Align the output flange and start tightening the screws a few turns on a rotation...

Page 107: ...utput 1 to PA1 and output 2 to PA2 G 2 4 Prime Power Cable Check the main section of this manual for proper input voltage before connection G 3 0 System Operation G 3 1 General This section contains instructions for operating the hybrid combiner subsystem For operation of the amplifier see other sections of this manual The hybrid combiner is matched at the input coaxial assembly and at the RF outp...

Page 108: ... PA1 output is routed to the antenna bypassing the hybrid combiner Single PA2 ONLINE PA2 output is routed to the antenna bypassing the hybrid combiner There is also a set of serial commands that can be used to control the waveguide switches individually The hybrid combiner can be set to either manual mode or automatic mode via a set of serial commands in the Combined to Antenna operation The ampli...

Page 109: ...MPA Hub Mount I O Manual Figure G 4 Switching and Combining State Diagram Figure G 5 Switching and Combining State Diagram Doc 01031254 Rev 1 Appendix G 11 ...

Page 110: ...nse to the Secondary Status query The four combiner states are decoded by the Station M C Table G 4 Four Combiner States State PA Outputs S1 S2 S3 0 Combined to Antenna Position 1 Position 2 Position 2 1 Single PA1 Online Position 1 Position 1 Position 1 2 Single PA2 Online Position 2 Position 2 Position 1 3 Combined to RF Load Position 1 Position 2 Position 1 G3 3 CIF Commands The protocol struct...

Page 111: ...1 pos2 Manual mode U 2 1 S2 pos2 S2 pos1 Manual mode U 2 2 S2pos1 S2 pos2 Manual mode U 3 1 S3 pos2 S3 pos1 Manual mode U 3 2 S3pos1 S3 pos2 4 0 Drawing List Table G 6 Drawings Assembly Combiner System 400W Ku Outdoor 0103195000 Option hybrid combiner 400W Ku ODU 0103142100 Schematic Switch Expander 0103145100 Assembly Cable Interface 0103099600 CCA Switch Interface 0103119000 RF Block Diagram Com...

Page 112: ...MPA Hub Mount I O Manual Appendix G 14 Doc 01031254 Rev 1 This page is intentionally left blank ...