CPI T02KO Installation & Operation Manual Download Page 1

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. 01031492 R

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INSTALLATION

OPERATION

MANUAL

250W Ka-Band TWT Amplifier

For Use With Model Numbers . . .

T02KO

T03KO

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

Summary of Contents for T02KO

Page 1: ...L 250W Ka Band TWT Amplifier For Use With Model Numbers T02KO T03KO 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 ...

Page 2: ...PI 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 2007 by Communications Power Industries All rights reserved DOC 01031492 REV 3 ...

Page 3: ...s S 5 S 3 2 Microwave Discussion S 5 S 3 3 General Microwave Guidelines S 6 S 4 Physical Safety S 7 S 4 1 Lifting Heavy Objects S 7 S 4 2 Extending Rack Slides S 7 CHAPTER 1 Introduction 1 1 1 1 Overview 1 1 1 2 Optional Features 1 3 1 3 About This Manual 1 3 1 4 Conventions 1 4 1 4 1 Notes and Cautions 1 4 1 4 2 Warnings 1 5 1 4 3 Text Conventions 1 5 CHAPTER 2 Unpacking And Installation 2 1 2 1 ...

Page 4: ...nel Controls and Indicators 3 2 3 3 Optional RCU Controls and Indicators 3 4 3 3 1 Multi Drop Operation 3 4 3 3 3 1 Amplifier Address Assignment 3 4 3 3 1 2 Operational Summary of the Remote Control Unit RCU 3 5 3 3 2 Control Keys 3 7 3 3 3 LED Group and Display 3 8 3 4 Operation with PC Computer and Setup Remote Control Software 3 11 3 5 Operation with Ethernet 3 12 3 6 First Time Pre Power Proce...

Page 5: ...4 5 Amplifier Information 4 12 4 4 6 Download Upload Files using FTP 4 13 4 4 7 Firmware updates 4 14 4 4 8 LAN Interface Port Numbers 4 15 4 5 JAVA CIF Remote Program 4 16 Java JRE 4 16 4 5 1 Running CIF Remote 4 16 4 5 2 Meters 4 18 4 5 3 Setup 4 19 4 5 4 Settings 4 20 4 5 5 Engineering 4 21 4 5 6 Configuration 4 22 4 5 7 Meter Log 4 23 4 5 8 Switch System 4 24 CHAPTER 5 Normal Operation 5 1 5 1...

Page 6: ...6 6 Beam Off Sequence 5 6 5 6 7 Fault State 5 6 5 6 7 1 Auto Fault Recycle Mode Rules 5 6 5 6 7 2 Meter log 5 7 CHAPTER 6 Operator Maintenance 6 1 6 1 Introduction 6 1 6 2 Preventive Maintenance Tasks 6 1 6 2 1 Visual Inspection 6 2 6 2 2 Air System Maintenance 6 3 6 3 Other Preventive Maintenance Tasks 6 4 6 4 Customer Service 6 4 CHAPTER 7 Drawings 7 1 APPENDIX A Warranty And Support Information...

Page 7: ...tion Diagrams B 12 B 2 6 Alerts B 15 B 2 6 1 Media Player B 15 B 2 6 2 Restore Window B 16 B 2 6 3 Confirmation B 16 B 2 7 Tuning Screen Setup B 16 B 2 7 1 Millitron B 16 B 3 Troubleshooting B 17 B 3 1 Communication B 17 APPENDIX C Replaceable Parts C 1 APPENDIX D Optional Linearizer D 1 D 1 Optional Linearizer D 1 APPENDIX E 250w ODU Functional Trees E 1 APPENDIX F Optional Internal 1 1 Switch Co...

Page 8: ...____________ B 4 FIGURE B 4 TYPICAL SETTING SCREEN GENERAL TAB _____________________________________ B 6 FIGURE B 4A CONFIGURATION TAB _____________________________________________________ B 7 FIGURE B 4B ENGINEERING TAB ________________________________________________________ B 7 FIGURE B 4C CIF TAB ________________________________________________________________ B 8 FIGURE B 5 TYPICAL METER LOG ...

Page 9: ... RF SETTINGS FAULT AND ALARM RANGES 250W 275W CW______________3 17 TABLE 4 1 RF SWITCH PIN ASSIGNMENT J5 1 1 SWITCH OPTION _____________________________4 5 TABLE 4 2 DEFAULT CONFIGURATION ETHERNET INTERFACE OPTION __________________________4 7 TABLE 4 3 ETHERNET INTERFACE PORT NUMBERS _________________________________________4 15 TABLE 6 1 PREVENTIVE MAINTENANCE PERFORMED BY OPERATORS ____________...

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Page 11: ...and 22 1 of the Standard S 2 High Voltage Equipment S 2 1 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 100 to 480 VAC is dangerous because prime power potentials have been known to...

Page 12: ...tentials of thousands of volts S 2 3 General High Voltage Guidelines In addition to the above the following practices have proven effective for personnel who deal with high voltage equipment a Hands off Avoid contact with any potential source of high voltage Keep hands out of the equipment when it is operating b Avoid accidental contact Make sure that some other part of your body does not come in ...

Page 13: ... voltage circuits activating interlocks that prevent high voltage turn on etc Know where the disconnects are and use them Do NOT rely on anyone not to turn on the high voltage j Set up your test equipment with the power off Conduct the power on operations when you have your hands out of the equipment k Do not use short probes for high voltage measurements A short probe does not allow any margin fo...

Page 14: ... conducted in a haphazard manner rather than in an orderly progression from start to finish Experience has shown in many instances when a little order would have prevented a tragedy or avoided an expensive mistake v Be extremely wary when making filament voltage measurements The cathode of tubes is elevated above or below ground and the filament voltages usually cannot be measured with reference t...

Page 15: ... voltage ON and without proper termination on the input and output of the amplifier ELECTRICAL HAZARD PROTECT YOURSELF AND THOSE AROUND YOU FROM UNWANTED RF EXPOSURE ALWAYS TERMINATE THE AMPLIFIER INPUT AND OUTPUT WITH A RF DUMMY LOAD BEFORE YOU TURN THE HIGH VOLTAGE ON THIS WILL REDUCE THE CHANCES OF OSCILLATION DUE TO INTERNAL AMPLIFIER NOISE S 3 2 Microwave Discussion Limit exposure to microwav...

Page 16: ...particularly vulnerable parts of your body c Shut off the unit if you are trying to locate a RF leak As noted earlier the levels of concern are very low Examine the physical unit with the high voltage OFF If you have to survey the RF runs with the power ON to find the leaky joint or component start by testing the system with low RF input and a radiation meter If the microwave radiation exceeds 0 5...

Page 17: ...l of the drawers from the rack assembly S 4 2 Extending Rack Slides 1 Serious injuries can result from heavily loaded racks or drawers falling forward Due to the weight of the drawers the rack must be securely bolted to the floor in all four corners to prevent tipping when the drawer slides are extended Verify that all slides are securely mounted and that all latches and stops are functioning prop...

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Page 19: ...tputs of these amplifiers Figure 1 1 is a photograph of a Ka Band TWT Amplifier All models have the same appearance Table 1 1 Ka BAND TWT Amplifiers Model Number Frequency Range GHz Rated Power Watts T02KO 27 5 to 31 0 GHz 250W Peak T03KO 27 5 to 31 0 GHz 250W CW By industry convention the rated power of an amplifier is the output power of the high power amplifying component a traveling wave tube ...

Page 20: ... enters the bottom of the unit and exits the rear end A feature standard in Ka Band TWTAs regulates the fan speed control using a sensor to vary the speed with TWT temperature This greatly increases the fan life while reducing acoustical noise See Chapter 2 for more details Care should be taken to ensure the airflow path is not blocked If the amplifier is to be powered up on a test bench then it s...

Page 21: ...ures The Ka Band TWTA has five main internal optional features An IPA Option with pin diode attenuator A Linearizer option An internal 1 1 switch controller with drive option An internal hybrid or 1 2 switch controller with drive option A separate Ka Band TWTA Remote Control Unit is also available 1 3 About This Manual This manual describes the Ka Band TWTA installation and operation procedures Th...

Page 22: ...hapter 5 Operation describes the procedures for normal start up and shutdown and describes the operational modes of the amplifier Chapter 6 Maintenance describes the procedures for scheduled maintenance and the procedures for return of equipment to CPI Chapter 7 Drawings contains relevant engineering drawings and specifications The Appendices contain additional topics such as Service and Warranty ...

Page 23: ...LARLY TO YOUR EYES PHYSICAL HAZARD IDENTIFY CONDITIONS OPERATIONS OR PROCEDURES THAT COULD INDUCE STRAIN MAIM OR KILL PEOPLE THIS INCLUDES HEAVY WEIGHTS SHARP EDGES OR PROTRUSIONS AND CHEMICAL HAZARDS 1 4 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 ENT...

Page 24: ...KA BAND OUTDOOR TWT AMPLIFIER 1 6 This page is intentionally left blank INSTALLATION AND OPERATION MANUAL ...

Page 25: ... 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 carri...

Page 26: ...aust areas must not be blocked For further information see the outline drawing and the yellow Operational Warnings document located at the front of this manual 2 4 2 Cooling Considerations The Ka Band TWTA is forced air cooled by an internal fan that draws air into the bottom of the unit The air is exhausted through ducts located on the front panel Refer to outline drawing 01031382 in Chapter 7 Dr...

Page 27: ...d 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 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 Ka Band TWTA ODU amplifier to the statio...

Page 28: ...munication standards while the CPI Remote Control Panel uses only RS 422 Default settings are as follows STX ETX protocol 9600 baud rate even parity seven 7 data bits with one 1 start bit and one 1 stop bit The operator may change these settings Refer to Drawings chapter 7 for the Computer interface protocol document Interconnect cables should be wired for either RS 232 or RS 422 485 but not both ...

Page 29: ...plug is supplied with the unit If the amplifier is to be used in a standalone configuration this connector must be used 2 4 6 RF Coaxial Cable Connections J4 Refer back to Figure 2 1 for connector locations A power monitor cable can be connected directly to front panel connector J4 40 dB nominal coupling Tighten the connector CAUTION Position the coaxial cables so that there is no stress on connec...

Page 30: ... interconnecting waveguide 3 After alignment is verified in all three planes loosely attach the interconnecting waveguide to the input waveguide flange of the Ka Band TWTA with 4 40 stainless steel screws flat washers lock washers and nuts Start all bolts and verify proper alignment 4 A progressive tightening procedure is recommended Tighten each bolt until the lock washer starts to compress and t...

Page 31: ...rified in all three planes loosely attach the interconnecting waveguide to the output waveguide flange of the Ka Band TWTA with 4 40 stainless steel screws flatwashers lockwashers and nuts Start all bolts and verify proper alignment 8 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 partiall...

Page 32: ...KA BAND OUTDOOR TWT AMPLIFIER 2 8 This page is intentionally left blank INSTALLATION AND OPERATION MANUAL ...

Page 33: ...unctions can be used This chapter describes 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 procedures for the first time power up and initial checkout of the system in LOCAL mode Section 3 6 Verify RF Output Section 3 7 Setup for opera...

Page 34: ...nt panel of the Hub Mount Ka Band TWTA 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 Figure 3 1 Amplifier Front Panel Controls and Indicators INSTALLATION AND OPERATION MANUAL ...

Page 35: ... OFF and 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 light...

Page 36: ...op Operation Multi Drop Functionality can control up to 10 units of the same type types cannot be mixed or a Single Switch System 1 1 1 1 Power Combined 1 2 After installation the first step is to assign amplifier addresses 3 3 3 1 Amplifier Address Assignment The Remote Panel has a built in utility to easily change the address from 48 to 111 of the units to be connected together in any of the abo...

Page 37: ...nual 2 Once the desired amplifier is reached pressing the up down arrows followed by the ENTER key will change the state of the selection If the Manual mode is selected the switch position can be changed between A1 and A2 by using the ENTER key followed by the left right arrow keys to cycle to either amplifier ON line or OFF line position Once the desired amplifier is selected use the up down arro...

Page 38: ... display Pressing the ENTER key takes you to the Main menu for that unit If a fault occurs in a unit not currently selected the Panel will automatically switch to the faulted unit and display its fault status Other units can be selected as described above but the alarm will sound as long as any unit has a fault If another fault occurs in a unit other than the first faulted one the Panel will switc...

Page 39: ...em is detected 1 1 1 1 Power Combined 1 2 1st press Switch system status screen 2nd press Switch system configuration screen AMP Shows the amplifier status screen When several amplifiers are connected use LEFT RIGHT keys to switch amplifier as indicated by the amplifier number on the left hand side of the display TRANSMIT If the RCU control point is local a transmit command will be sent to the amp...

Page 40: ...n if the control point is set to Serial or Ethernet DISPLAY Amber Displays Amplifier and RCU information TRANSMIT Green On when the amplifier is in Transmit state STANDBY Amber On when the amplifier is in Standby state REMOTE Amber On if the amplifier is in Remote control mode Off when in Local control mode FAULT Red Flashes whenever any amplifier is in fault state RF INHIBIT Red On if the amplifi...

Page 41: ...Unit display modes with an Amplifier selected For a more complete Menu tree refer to Figures E 1 E 2 in Appendix E or Figures 3 6a 3 6b in chapter 3 Amp Screen AMPLIFIER REMOTE LOCAL STATUS FTD MM SS STANDBY BEAM ON SEQUENCE TRANSMIT RF OUT XXX W POWER MODE ALC MAN SELECTABLE METERS System Screen SYSTEM CONFIGURATION SYSTEM STATUS TOGGLE SYSTEM BUTTON Control Screen LOCAL SERIAL ETHERNET TOGGLE CO...

Page 42: ... LINES U D ENTER MORE DATA LINES ENTER U D TIME HH MM SS MM DD YYYY STANDBY TIME DDD HH MM SS UNIT ON TIME DDD HH MM SS TRANSMIT TIME DDD HH MM SS HEATER TIME DELAY MM SS BOOT XX XX XX MAIN XX XX XX MENU Press MENU key until P appears on left hand side then select L R U D ENTER UNITS RF OUTPUT UNITS WATT dBm U D ENTER BUZZER U D DISPLAY ENTER MUTE ALARM YES NO MUTE KEYPAD YES NO DISPLAY BRIGHTNESS...

Page 43: ... Combined System A2 XMIT NN N dBm OUT MANUAL A1 MANUAL ON line A2 MANUAL OFF line A1 ON line A2 OFF line A3 MANUAL ON line A1 XMIT NN N dBm LOAD MANUAL A2 XMIT NN N dBm OUT MANUAL A2 OUT MANUAL A1 LOAD MANUAL SW1 2 SW2 1 SW3 2 SYSTEM SYSTEM SYSTEM CONTROL SET PWR ENTER TO SELECT U D ENTER TO ADJUST TO ACCEPT CHANGE CIF CONTROL POINT DISPLAY LOCAL SERIAL ETHERNET REPEAT PRESSING CONTROL KEY TO CYCL...

Page 44: ...as indicated by the label located on exhaust end of unit and single phase The AC power cord is connected to J1 but the AC power is not turned on A ground strap is connected from the station s ground bus to the 6 32 ground screw mounting hole located on the amplifier front panel The RF Input and RF Output are connected to a matched source and test load RF input power is off All RF connections are t...

Page 45: ...the amplifier initiates a heater time delay cycle of about three minutes to allow the TWT traveling wave tube heater to warm up Proceed as follows 1 Temporarily disconnect the remote CIF connector at J6 if used 2 Turn on the prime power distribution system so that AC power is applied at J1 3 Verify that the following sequence occurs after AC power is applied 4 PWR ON LED lights 5 The cooling fan c...

Page 46: ...these values to the desired operational values before you place the amplifier in operational service If you want to verify RF output levels connect a power monitor to amplifier connector J4 K type or 2 92 mm SMA 40 dB nominal coupling before you power up the amplifier Proceed as follows 1 Press the LCL RMT switch once for RMT control mode RMT LED lighted 2 Set the Remote Control Unit AC Power Swit...

Page 47: ...0W 110 130 W 130 W See 3 8 for normal operation High RF Fault 0 W 115 140W 115 140 W 140 W See 3 8 for normal operation High Reflected RF Fault 0W 10 W 10 W 25 W Factory Set Do not change Helix Over Voltage 13 0 kV TWT NPV 300V 14 0 kV 14 5 kV Factory Set Do not change Helix Under Voltage 0 00 kV TWT NPV 300V 13 5 kV 14 0 kV Factory Set Do not change Helix Over Current 1 0 mA 3 0 mA 3 0 mA 5 0 mA ...

Page 48: ...55W 155 W 175 W See 3 8 for normal operation High RF Fault 0 W 160W 160 W 185 W See 3 8 for normal operation High Reflected RF Fault 0W 10 W 10 W 25 W Factory Set Do not change Helix Over Voltage 13 0 kV TWT NPV 300V 14 0 kV 14 5 kV Factory Set Do not change Helix Under Voltage 0 00 kV TWT NPV 300V 13 5 kV 14 0 kV Factory Set Do not change Helix Over Current 1 0 mA 3 0 mA 3 0 mA 5 0 mA Factory Set...

Page 49: ...ver Voltage 13 0 kV TWT NPV 300V 14 0 kV 14 5 kV Factory Set Do not change Helix Under Voltage 0 00 kV TWT NPV 300V 13 5 kV 14 0 kV Factory Set Do not change Helix Over Current 1 0 mA 3 0 mA 3 0 mA 5 0 mA Factory Set Do not change Helix voltage in standby 1 00 kV 4 00 kV 4 00 kV 4 00 kV Factory Set Do not change 4 Press FUNCTION until The display reads LOW RF ALARM 0N 5 Continue to scroll through ...

Page 50: ...ET to clear the fault 5 Verify that a power meter is connected to the RF monitor J4 6 Press the HV ON switch NOTE The Low and High RF limits are set at the factory for initial checkout purposes These values can be set to the desired operational values via the serial interface after initial checkout 7 After approximately 3 seconds the Beam On Sequence BONS should complete and the XMT LED should lig...

Page 51: ... LED lighted Remote Control 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 4 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 sto...

Page 52: ...lect the desired 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 Press FUNCTION until the option for the desired parameter is displayed Use the keys to...

Page 53: ...mines 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 mode operation Remote control devices cannot affect selection of the LOCAL or REMOTE control mode NOTE If the amplifier is to be operated via the optional Remote Control Unit section 4...

Page 54: ...interface RF Inhibit is active at all times and is not subject to the control mode hierarchy The RF Switch Interface is located on connector J5 located on the Ka Band TWTA front panel J5 is a 26 pin MS type connector with pin assignments as shown in Table 4 1 NOTE For alternate switch configuration options such as 1 2 or Hybrid Switch Option Table 4 1 does not apply NOTE If the RF Switch Interface...

Page 55: ...a Fault state The Flexible mode allows the user to operate a switch controller in Automated Switching mode without triggering waveguide switch action while operating the Ka Band TWTA ODU in any normal operating state or issuing RF Inhibit commands 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 R...

Page 56: ...nuity between the NO and COM contacts The relay will de energize when a fault occurs BEAM ON Beam On tracks the Beam state HV applied to TWT Note When the Beam is On the relay is energized There is continuity between the NO and COM contacts The relay will de energize when a fault occurs INSTALLATION AND OPERATION MANUAL ...

Page 57: ... return J External 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 Res...

Page 58: ...ation options such as 1 2 or Hybrid Switch Options Table 4 1 does not apply 4 4 Ethernet Interface This interface allows amplifier to be accessed via 10BASE T Ethernet Refer to Table 4 2 for optional drawings This interface has the following functionality Monitoring and control of the amplifier via TCP using the ASCII Based CIF protocol and the STX ETX header ending byte message format using TCP p...

Page 59: ...nder NTP Server Address 192 043 244 018 IP address of Network Time Server Time Server Enabled No Enables the HPA to request time data from the Time Server at the above address Username cpi Password cpi To change the default settings use a web browser to connect the amplifier Make sure that the PC is configured for the same subnet as the amplifier e g set the IP address mask of the PC to 192 168 0 ...

Page 60: ...er is restarted When configuring the SMTP address make sure to enter a domain name that is recognized by the SMTP server The domain name will appear in the from field of the email as in AMP1 cpii com To quickly configure the amplifier connect using FTP and drag and drop a config ini file as shown in section 3 6 INSTALLATION AND OPERATION MANUAL ...

Page 61: ...mplifier state Power mode RF Output Switch Control and the meter readings Also the last 10 latched fault events can be checked using the drop down menu The buttons on the right hand side of the screen can be used to put the TWTA into Transmit or Standby reset any current faults set the switch controller to either Manual or Auto mode and change the attenuation level of the TWTA DOC 01031492 REV 3 4...

Page 62: ...ults Up to 4 groups with up to 8 email recipients each can be configured Select any combination of events to trigger email and select Send Meter Log to have the amplifier attach a file containing the log When all fields have been filled out hit the submit button to store the configuration INSTALLATION AND OPERATION MANUAL ...

Page 63: ...he Login To change the login user name and password select the Set Login menu on the left hand side of the screen Type in the old user name and password default is cpi the new user name and password and hit the apply button DOC 01031492 REV 3 4 11 ...

Page 64: ...fo on the menu bar to show the Amplifier type and firmware version numbers To change the name of the amplifier type in a name and hit Apply The amplifier name will show on the top of the Main menu and is also used as the senders name for emails INSTALLATION AND OPERATION MANUAL ...

Page 65: ...hould contain two files config ini and the meter log for the amplifier The meter log file contains the fault and alarm events recorded by the amplifier and can be drag and dropped to a local directory The config ini file contains the IP and email configurations for the amplifier This file can be downloaded and edited and then uploaded to another amplifier to quickly set up other amplifiers in a sy...

Page 66: ...er an alarm or fault occurred Enter the email addresses in the SENDTO filed comma delimited if multiple addresses are entered Set the SENDLOG field to 1 to attach the meter log to the email 4 4 7 Firmware updates Using an FTP client or web browser new firmware can be uploaded to the TWTA Simply drag and drop the new firmware file to the FTP window When the transfer is done close the FTP window and...

Page 67: ...LIFIER 4 4 8 LAN Interface Port Numbers Table 4 3 Ethernet Interface Port Numbers Port Number Description Protocol 21 FTP Server TCP 80 HTTP Server TCP 123 NTP Client UDP 50000 CIF Protocol Server TCP DOC 01031492 REV 3 4 15 ...

Page 68: ...ntime Environment JRE must be installed on the PC The Java Runtime Environment can be downloaded from http www java com en download index jsp 4 5 1 Running CIF Remote Open a web browser and make an http connection to the TWTA Ex If the IP address of the ODU is 172 23 10 20 type http 172 23 10 201 in the Address field of the browser and hit enter Type in login and password info when the login promp...

Page 69: ...KA BAND OUTDOOR TWT AMPLIFIER To start the CIF Remote application click on CIF Remote in the side bar The Java program will load and automatically make a connection to the TWTA DOC 01031492 REV 3 4 17 ...

Page 70: ... Output power Power mode Manual ALC and the meter readings Any faults alarms will be shown in the status bar above the meter readings The buttons on the bottom of the screen are used to put the amplifier in Transmit or Standby mode Reset a fault or enable disable RF Inhibit INSTALLATION AND OPERATION MANUAL ...

Page 71: ...KA BAND OUTDOOR TWT AMPLIFIER 4 5 3 Setup The Setup menu shows the IP address Amplifier address and the CIF traffic status DOC 01031492 REV 3 4 19 ...

Page 72: ... RF Power windows sets the power output attenuation and Manual ALC gain control The Faults and Alarms windows shows the high low faults and alarm trip points Use the up down arrow on the side to adjust a setting or click in the text field and type a new value and hit enter INSTALLATION AND OPERATION MANUAL ...

Page 73: ...ide or click in the text field and type a new number 0 255 and hit enter The Software Versions window shows the ODU boot and main software versions In the Reset window the Settings trip points can be reset to default and the Meter Log and Timers cleared To clear select one of the options and type 123456 in the text field and hit Execute DOC 01031492 REV 3 4 21 ...

Page 74: ...k in the time date field and type in a new time and date in the correct format The Switch System window shows the switch system type the priority amplifier and the Amplifier ID Use the drop down menu to change the Priority amplifier or ID The Relays BUC shows the current configuration of the 2 relays and the BUC unlock type Use the drop down menus to change INSTALLATION AND OPERATION MANUAL ...

Page 75: ...ails in the Event Detail window In the Auto Log window the Auto Log Time can be set Setting the Auto Log Tome to 0 0 disables the Auto Log By Enabling Auto Update the current view of the Meter Log will automatically refresh every 20 seconds By clicking the Update All button the complete Meter Log will be updated In the Save Meter Log window the Meter log can be saved as a text file Select all curr...

Page 76: ...8 Switch System The Switch System screen shows the current switch configuration In the Switch Control window switch control mode can be set Auto Manual and clicking a Rotate sw button can rotate each switch INSTALLATION AND OPERATION MANUAL ...

Page 77: ... user Remote Control via Ethernet Interface NOTE Only one remote control device can be connected to the amplifier 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 commands...

Page 78: ...ically recycle to the state that existed prior to the fault Fault Latched Beam off malfunction state The SDBY LED is OFF and the FLT LED is ON The operator must intervene to return the amplifier to its normal operating state This is accomplished by pressing the RESET switch momentary pushbutton switch After successful reset the standby STBY LED stays ON 5 3 Normal Operating Procedures CAUTION Befo...

Page 79: ...r Control Refer to Chapter 2 for connection details and 01033829 CIF protocol for communication and command details Also refer to Appendix B for operation with CPI supplied Setup Remote Control Software ODUremote exe In the LOCAL mode turn the amplifier ON and set it for the REMOTE control mode Install the supplied ODUremote exe program or a user supplied amplifier control program in the computer ...

Page 80: ...s the trip settings should be given only to the authorized personnel 5 6 Description of Amplifier States The operation of the Ka Band TWTA may 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 BON...

Page 81: ...d 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 HTD 3 minutes Heater Reduce is off during this time If the TRANSMIT state is commanded during the HTD cycle the amplifier will automatically transition to the TRANSMIT state when the cycle is complete if there is no fault If a...

Page 82: ...fault condition is detected the unit transitions to the Fault state The fault system is always in auto recycle mode for most faults which allows the controller to return the unit to the pre fault state after a transient fault or a series of transient faults Three consecutive transient faults will place the unit into summary fault mode and a reset command is required to return to normal operation C...

Page 83: ...l 0 5 second before cycling back to the original state If the unit enters Fault from HTD the HTD countdown will continue While 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...

Page 84: ...KA BAND OUTDOOR TWT AMPLIFIER 5 8 Intentionally Left Blank INSTALLATION AND OPERATION MANUAL ...

Page 85: ...g 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 Ka Band TWTA requires periodic maintenance This consists of inspection cleaning testing and calibration of the subsystems at designated ...

Page 86: ...OGRAM FOR SERVICE OF THE KA BAND TWTA ODU 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 Verify Helix setting and metering X Run performance tests X 6 2 1 Visual Inspection AC Power Off Task At one month intervals the Amplifier should be visually inspected for physical defects If the equipment is sub...

Page 87: ...every three months AC Power On Test The amplifier airflow system must be open to ensure proper transfer of heat to the air stream created by the fan Periodically inspect and eliminate any airflow constraints After inspection and cleaning verify that airflow is strong and unimpeded The recommended cycle is three months but inspection may be required more often if local air pollution warrants it To ...

Page 88: ...nual for additional preventive maintenance tasks Requires a service technician who has attended a formal training program for service of the amplifier to perform these tests 6 4 Customer Service Refer to Appendix A Warranty and Support Information for CPI Satcom contact service and return information INSTALLATION AND OPERATION MANUAL ...

Page 89: ...W Peak 01031381 RF Diagram Ka Band TWTA 01031382 Outline Drawing Ka Band TWTA 01031490 Fan Assembly TBD Option 1 1 Switch Controller TBD Option 1 2 Switch Controller 01031640 Assembly RF Ka Band TWTA 01032322 Cable Remote 01033829 CIF protocol 01033839 ODU Setup Remote Control Software Windows version supplied with manual on CD NOTE Paper Manual Printed drawings follow this page CDROM Manual Drawi...

Page 90: ...KA BAND OUTDOOR TWT AMPLIFIER 7 2 This page is intentionally left blank INSTALLATION AND OPERATION MANUAL ...

Page 91: ...And Support Information For details refer to separate supplement included with this manual HARD COPY Refer to Warranty and Support supplement located at the front of this manual CD Refer to separate folder titled Warranty and Support DOC 01031492 REV 3 A 1 ...

Page 92: ...KA BAND OUTDOOR TWT AMPLIFIER A 2 This page is intentionally left blank INSTALLATION AND OPERATION MANUAL ...

Page 93: ...KA BAND OUTDOOR TWT AMPLIFIER B 1 APPENDIX B DOC 01031492 REV 3 B 1 ...

Page 94: ...specified media files can automatically be played to alert an operator when an amplifier fault condition occurs B 2 Installation Copy ALL files located on the supplied ODU Remote software CD to a directory on your PC s hard drive or run directly from the CD If storing files on a computer be sure to keep all the files in a common folder and create a shortcut to the desktop if needed B 2 1 Connectin...

Page 95: ...ength Protocol and CR LF settings that match the amplifier s configuration 9 If connecting using the PC s serial communication port select the appropriate Port and select COM Port as the Connection Type If connecting via Ethernet enter the appropriate IP address in the IP Address edit box and select Ethernet as the Connection Type Check the Enabled check box 10 Select the Amplifiers 1 5 tab Refer ...

Page 96: ...nications between the host PC and the amplifiers 13 Click Apply to establish communication with each enabled amplifier The connection status will read Connected if successful and the amplifier model will appear in the Type field If connection is unsuccessful an Unable to Connect message will appear in the Connection Status field B 2 2 Meters Window Once connected a Meters Window will appear for ea...

Page 97: ...r which sounds when a fault occurs B 2 3 Settings Window From the Edit menu select Settings This window consists of four tabs each containing settings specific to the individual amplifier B 2 3 1 General The General tab contains RF power fault and alarm settings as well as RF unit options These settings are pre set at the factory It is recommended not to dramatically change any of these values ALC...

Page 98: ...e than 3 hours the amplifier will go into Heater Time Out HTO where the TWT heater is disabled to prolong life The Heater Enable must be re selected after this occurs The amplifier will then go into Heater Time Delay HTD to warm the heater Figure B 4 Typical Setting Screen General Tab In Military version products the front panel Local indicators can also be turned on or off INSTALLATION AND OPERAT...

Page 99: ...ersion of the amplifier s controller software factory adjusted settings for the optional linearizer and the system reset The linearizer settings should not be changed as it can affect the RF performance of the amplifer Settings timers and meter log can be reset to factory defaults by checking the appropriate Reset check boxes typing in the password 123456 and pressing the Execute button Figure B 4...

Page 100: ... 2 4 Meter Log From the View menu select Meter Log The meter log displays up to sixteen meter log entries at a time Use the scroll bar on the right side of the window to scroll through the log Click on an entry to get further details This information is displayed in the Event Detail box Figure B 5 Typical Meter Log Screen INSTALLATION AND OPERATION MANUAL ...

Page 101: ...x 0 5M log every 30 seconds B 2 4 3 Search The Search feature is used to quickly search through the meter log for a specific type of event such as a fault or alarm To use the search feature the entire meter log must be downloaded from the amplifier This is accomplished by first clearing the Auto Update check box then pressing the Update All button Once the meter log is downloaded select an event u...

Page 102: ...h the filename set to the current time and date Specify a new filename and directory if desired and then press Save The software will first download the entire log if required then format and save the data to the file It is recommended to save the log file before performing any firmware updates or changes to the controller INSTALLATION AND OPERATION MANUAL ...

Page 103: ... Figure B 7 Typical Switch Diagram Screen When the path is green it indicates that communication is present A red path indicates the connection has been lost or the amplifier is not present Switches can be toggled by double clicking the switch to activate it Selecting Auto Mode will enable the software to control the switching When an amplifier goes offline the switch es will re route the path to ...

Page 104: ...KA BAND OUTDOOR TWT AMPLIFIER B 12 B 2 5 1 Switch Configuration Diagrams Figure B 8a 1 1A Figure B 8b 1 1B Figure B 8c 1 1C Figure B 8d 1 1D P INSTALLATION AND OPERATION MANUAL ...

Page 105: ...KA BAND OUTDOOR TWT AMPLIFIER Figure B 8e 1 1E Figure B 8f 1 1E P Figure B 8g 1 2A DOC 01031492 REV 3 B 13 ...

Page 106: ...KA BAND OUTDOOR TWT AMPLIFIER B 14 Figure B 8h 1 2B Figure B 8i 1 2C INSTALLATION AND OPERATION MANUAL ...

Page 107: ... additional means of alerting operators when a amplifier has failed To use the Media Player first select a media file then select the condition that will activate the Media Player When the Media Player is activated it will play and continuously repeat the specified media clip until the fault condition is cleared or the Mute MP control button is pressed The player can be chosen to be activated when...

Page 108: ...2 7 1 Millitron Within the Engineering tab the tuning screen allows channel specific parameters to be changed Tuning a channel consists of adjusting the beam voltage until the desired center frequency response is obtained Figure B 9 Millitron Channel Tuning Changing screens For bandwidths up to 1000 MHz a single voltage setting can be used for the Millitron Over 1000 MHz it is recommended that mul...

Page 109: ...actory trained technicians Consult the CPI service center for training class information B 3 Troubleshooting B 3 1 Communication If communications problems are occurring check to make sure the addresses set in the amplifier s controller and the software match To change the amplifier address in the controller use the Address Scanner program also located on the software utility CD see below This pro...

Page 110: ...Meters Windows of other PAs be minimized Setting changes are only accepted if the amplifier control point is set to REMOTE Settings will be colored in gray if the control point is incorrect Settings will be colored in gray if the amplifier is not configured to support them For proper ODU Remote operation use the STX ETX protocol INSTALLATION AND OPERATION MANUAL ...

Page 111: ...35290 00 CCA DC DC Converter 01031740 00 CCA Controller 01030520 05 Assy Control status 01027260 00 CCA RF Monitor 01030530 01 ASSY Fan Housing 01031490 00 Fan Assy PS Wash Fan 01031035 00 Tunnel Diode Ka Band 01031397 00 TWT Assy Ka Band 250W Peak 120W CW NEC 01031462 00 01 TWT Assy Ka Band 250W Peak 175W CW NEC 01031462 04 05 TWT Assy Ka Band 250W CW NEC 01031643 00 01 Output Component Ka Band 3...

Page 112: ...KA BAND OUTDOOR TWT AMPLIFIER C 2 This page is intentionally left blank INSTALLATION AND OPERATION MANUAL ...

Page 113: ...r may modify the linearizer settings from the factory values Doing so may cause the Ka Band TWTA 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 accessed via the op...

Page 114: ...KA BAND OUTDOOR TWT AMPLIFIER D 2 This page is intentionally left blank INSTALLATION AND OPERATION MANUAL ...

Page 115: ...s functions of the RCU Figure E 1 describes the controls that will be found using the MENU key Figure E 2 describes the controls that will be found using the AMP SYSTEM CONTROL and SET PWR keys Find the item on the tree that you wish to view or modify then follow the map pressing the appropriate keys as shown until you reach the function you the item DOC 01031492 REV 3 E 1 ...

Page 116: ...KA BAND OUTDOOR TWT AMPLIFIER E 2 This page is intentionally left blank INSTALLATION AND OPERATION MANUAL ...

Page 117: ...ENTER METER LOG 0000 HH MM SS MM DD YYYY STATE ENTER METER LOG NNNN CYCLE THRU LOG ENTRIES U D U D MORE DATA LINES U D ENTER MORE DATA LINES ENTER U D TIME HH MM SS MM DD YYYY STANDBY TIME DDD HH MM SS UNIT ON TIME DDD HH MM SS TRANSMIT TIME DDD HH MM SS HEATER TIME DELAY MM SS BOOT XX XX XX MAIN XX XX XX MENU Press MENU key until P appears on left hand side then select L R U D ENTER UNITS RF OUTP...

Page 118: ...ITION LOWER LINE SHOWS If a fault conditions occurs the Main menu will automatically be displayed SYSTEM DISPLAY A1 XMIT NN N dBm MANUAL ON line 1 1 System DISPLAY A1 XMIT NN N dBm ON line A2 FLT NN N dBm OFF line 1 2 System A3 XMIT NN N dBm ON line MANUAL A2 XMIT NN NN dBm MANUAL OFF line DISPLAY A1 XMIT NN N dBm LOAD MANUAL 1 1 Power Combined System A2 XMIT NN N dBm OUT MANUAL A1 MANUAL ON line ...

Page 119: ...ion back to the user through the CIF computer 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 t...

Page 120: ...KA BAND OUTDOOR TWT AMPLIFIER F 2 Figure F 1 Interconnect diagram optional SW controller INSTALLATION AND OPERATION MANUAL ...

Page 121: ...Switch Interface Cable Assembly 01031513 01 Switch Interface Assembly 01031514 01 Interconnect Diagram 1 1 Switch 01031553 RF Block Diagram TBD NOTE Paper Manual Printed drawings follow this page CDROM Manual Drawing files are in the Drawing folder Refer to service manual for respective LM s Drawings are in numerical order DOC 01031492 REV 3 F 3 ...

Page 122: ...KA BAND OUTDOOR TWT AMPLIFIER F 4 This page is intentionally left blank INSTALLATION AND OPERATION MANUAL ...

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