Technalogix TAV2000L VHF Television Broadcast Transmitter User Manual TAV 1000

Technalogix, Ltd. VHF Television Broadcast Transmitter TAV 1000

USERS MANUAL

TAV-2000 BROADCAST TRANSMITTER OPERATING MANUAL
You’ve already unpacked it, haven’t you? You’ve unpacked it and plugged it in and turned it on and fiddled with the knobs. No? Okay, good. Please take a few minutes to read the manual and familiarize yourself with your new Technalogix power amplifier. We believe that this manual, and of course our equipment, should be everything you need to get on the air with superb broadcast quality video. We understand that a capable and confident user will get the most out of our product and we have made every attempt to educate readers of all technical levels. If there is something that is not clear, or you require further information, please do not hesitate to contact us and we’ll be glad to help out. Technalogix Ltd. #4, 8021 Edgar Industrial Place Red Deer, Alberta, Canada T4P 3R3 Phone: 403.347.5400 Fax: 403.347.7444 URL: www.technalogix.ca Email: technical@technalogix.ca sales@technalogix.ca We truly appreciate that you have chosen us as your television broadcast system supplier. Happy viewing.
Table of Contents SECTION I- SAFEGUARDS .............................................................................................................................I-1 SAFETY AND FIRST AID ................................................................................................................................I-2 OPERATING SAFEGUARDS ............................................................................................................................I-3 SECTION II - WARRANTY............................................................................................................................ II-1 SECTION III - OVERVIEW ..........................................................................................................................III-1 STANDARD FEATURES ...............................................................................................................................III-1 PRINCIPLE OF OPERATION ........................................................................................................................III-2 BLOCK DIAGRAM (TAV-2000)...................................................................................................................III-3 RF SIGNAL PATH .......................................................................................................................................III-4 BLOCK DIAGRAM (TAV-1000)...................................................................................................................III-3 SPECIFICATIONS........................................................................................................................................III-5 SECTION IV - RF COMPONENTS ................................................................................................................ IV-1 AMPLIFIER PALLETS ................................................................................................................................. IV-1 SPLITTER/COMBINER ................................................................................................................................ IV-4 DIRECTIONAL COUPLER ............................................................................................................................ IV-4 ISOLATOR................................................................................................................................................... IV-4 FILTER....................................................................................................................................................... IV-4 SECTION V - POWER SUPPLY SECTION ........................................................................................................V-1 SECTION VI - MONITOR AND CONTROL SYSTEM ....................................................................................... VI-1 CONTROL BOARD OVERVIEW (INSIGHT) ................................................................................................... VI-1 USER INTERFACE MODULE........................................................................................................................ VI-2 COUPLER CONDITIOING MODULE.............................................................................................................. VI-3 RF CONDITIONING MODULE ..................................................................................................................... VI-3 TEMPERATURE SENSOR MODULE.............................................................................................................. VI-3 TXNET MODULE ........................................................................................................................................ VI-3 REMOTE PORT ........................................................................................................................................... VI-4 FAULT SHUTDOWN .................................................................................................................................... VI-5 BILL OF MATERIALS ................................................................................................................................. VI-6 SCHEMATICS............................................................................................................................................ VI-12 SECTION VII - MECHANICAL SECTION.....................................................................................................VII-1 SECTION VIII - INSTALLATION ............................................................................................................... VIII-1 BUILDING RECOMMENDATIONS ............................................................................................................. VIII-1 HEATING AND COOLING REQUIREMENTS............................................................................................... VIII-2 ELECTRICAL SERVICE RECOMMENDATIONS .......................................................................................... VIII-3 ANTENNA AND TOWER RECOMMENDATIONS.......................................................................................... VIII-4 SHELTER SECURITY................................................................................................................................ VIII-5
UNPACKING AND INSPECTION ................................................................................................................ VIII-6 LOCATION AND FUNCTION OF CONTROLS AND CONNECTORS (TAV-1000 POWER AMPLIFIERS) .......... VIII-7 LOCATION AND FUNCTION OF CONTROLS AND CONNECTORS (POWER SUPPLY).................................... VIII-9 LOCATION AND FUNCTION OF CONTROLS AND CONNECTORS (COMBINER ENCLOSURE ...................... VIII-11 INITIAL HOOK UP…………………………………………………………………… VIII-13 SECTION IX - OPERATING PROCEDURE..................................................................................................... IX-1 SECTION X - MAINTENANCE AND TROUBLESHOOTING................................................................................X-1 TROUBLESHOOTING.....................................................................................................................................X-2
I-1 Section I - Safeguards General Safeguards This section is written as a general guide to keep all 5 fingers on your hand and is intended for those having previous knowledge and experience with these kinds of equipment. It is not intended to contain a complete statement of all safety precautions, which should be observed by personnel using this or other electronic equipment. DOCUMENTATION - Read, retain and follow instructions before operating the equipment. There is a lot of useful information in the manual, and besides, we spent a lot of time writing it! ENVIRONMENT - To reduce the risk of fire or electric shock, do not expose this equipment to rain, moisture, or rye and sodas at the company Christmas party. Refer all servicing to qualified service personnel. SERVICING - Do not attempt to service this equipment yourself as opening or removing covers can result in a warm tingly feeling and will void the warranty. Refer all servicing to qualified service personnel.
I-2 Safety and First Aid Personnel engaged in the installation, operation, maintenance, or servicing of electronic equipment are exposed to the hazard of high voltage. It is imperative that all safety regulations and precautions are consistently observed. Knowledge of first aid procedures is recommended. The following information is presented as a reference only. • At all times, avoid placing any part of the body in series between ground and circuit points, whether power is on or off. • Dangerous voltage may be present in equipment even though power is off. Do not open the cabinet. Refer servicing to qualified service personnel. • It is the duty of all personnel to be prepared to give adequate emergency first aid treatment and thereby prevent avoidable loss of life. • There are three principle degrees of burns, recognizable as follows: • a first-degree burn reddens the skin. • a second-degree burn blisters the skin. • a third degree burn chars the flesh and frequently places the victim in a state of shock accompanied by respiratory paralysis. • Respiratory paralysis can cause death by suffocation within seconds. It is imperative that the approved methods of artificial respiration are initiated immediately and continue until the victim’s breathing is normal. • A muscular spasm of unconsciousness may render the victim unable to break free of the electric power. If this is the case, turn the power off immediately. DO NOT TOUCH THE VICTIM OR YOU MAY SHARE THE SAME PREDICAMENT. • If the power cannot be turned off immediately, very carefully loop a dry rope, article of clothing, length of strong cloth or a rolled-up newspaper around the victim and pull the victim free of the power source. Carefully avoid touching the victim or clothing. • Once free of the power source, the victim must be placed in a reclining position and covered with a blanket or newspapers to keep warm. At the first opportunity, enlist help in summoning a doctor. If a doctor cannot be summoned, transport the victim to the doctor or a hospital. Be sure the victim is kept well covered and warm while awaiting professional treatment.
I-3 Operating Safeguards It is a known fact that our broadcast transmitters and translators enjoy 50-ohm load impedances. So much so, that it is imperative you maintain 50-ohm impedances throughout your system. In return, your equipment will provide you with maximum power transfer to the antenna and decreased reflected power heading back towards the amplifier pallets, reducing the amount of magic smoke that gets let out of the power amplifier. Before anything is turned on, ensure that there is a 50-ohm path from the output of each stage to the input of the next, all the way to the antenna. In addition to maintaining proper 50-ohm impedances throughout the signal chain, it is also important, whenever possible, to make sure the RF drive going to the input of the power amplifier is removed before turning on or turning off the DC power supply. This is because all of the RF transistors used in the individual amplifier pallets are fabricated with LDMOS (Laterally Diffused Metal Oxide Semiconductor) technology. Nice and linear yes, but they do not like to make any RF power when their supply voltages are not within a specific range. When you first turn your power amplifier on or off, the DC power supply’s output voltage may take a while to stable out to a safe operating voltage. Ten seconds wait before applying the RF drive will ensure no issues arise. Our power amplifiers are designed to reliably generate a specific RF output power. Failing to adhere to overdriven amplifier warnings can decrease the reliability of your system, and frankly, makes our repair department busy and grumpy. If you need to transmit to a little larger coverage, you are better off increasing antenna gain, and more importantly, antenna height above average terrain. On TV and FM broadcast frequencies, insufficient antenna height puts an upper limit on your range, regardless of power levels, as the distance from your antenna to the radio horizon is limited.
II-1 Section II - Warranty Our legalese is straightforward. It is simply designed to give you peace of mind and helps you resist the temptation to have your electronics friend try to repair your Technalogix product. Technalogix Ltd. products have been completely tested and found to meet specifications and be in proper operating condition. They are warranted to be free from defects in materials and workmanship for a period of one year from the date of shipment. If the system becomes damaged in shipment and there are obvious signs of damage to the outside of the packaging, notify your courier immediately before that courier walks out the door. Technalogix Ltd. will not be liable for damages of whatever nature arising out of or in connection with the equipment or its use thereof. Technalogix does not assume responsibility for injury or damage resulting from the practices of untrained or unqualified personnel in the handling of this equipment. Technalogix Ltd. warranty does not include: • misuse, neglect or accident. • incorrect wiring and /or improper installation. • unauthorized repairs, modifications or use in violation of instructions issued by Technalogix. • incidental or consequential damages as a result of any defect. • reshipment cost or insurance of the unit or replacement units or parts. • acts of nature or terrorism. Technalogix agrees, at our option, to remedy warranted defects or furnish a new part in exchange for any part of a unit which, under normal installation, use and service, becomes defective. The user will pay for transportation costs to and from the repair center. If you require technical service on the site, the cost to you will be $800.00 per day plus air fare and meals.
II-2 To claim your rights under this warranty: • Contact Technalogix and describe the problem in as much detail as possible. See troubleshooting section in this manual. If a solution cannot be found at this time, it may be determined that the unit will have to be returned to Technalogix for repair, once a Return Materials Authorization (RMA) number is provided. Please look under our web site (www.technalogix.ca) for the RMA form (Service) and fill it out. Either fax it to us or email to us. • Package equipment carefully for prepaid shipment to Technalogix. Include a written description of the problem experienced, a copy of the original invoice establishing warranty status, and the RMA. Technalogix reserves the right to make revisions in current production of the equipment and assumes no obligation to incorporate these changes in earlier models. Shipping Address: Technalogix Ltd. ATTN: RMA# #4, 8021 Edgar Industrial Place Red Deer, Alberta, Canada T4P 3R3 Ph: 403.347.5400 Made in Canada, returned for repairs
III-1 Section III – Overview Standard Features • Narrow output bandpass filter allows adjacent channel operation • Front panel Liquid Crystal Display (LCD) to monitor forward and reflected RF power, and DC voltage • Microcontroller-based monitoring and control ensures amplifier will never be overdriven and high VSWR will not damage amplifier • AC circuit breaker on back panel to eliminate replacement of fuses • All aluminium enclosure maintains power amplifier’s light weight • Simple design using commonly available parts ensures reliable operation • Predominate and third-order intermodulation distortion exceeds Industry Canada and FCC specification.
III-2 Principle of Operation The TAV-2000 power amplifier supplies a 2000-watt peak video signal with 10% aural power on any of the VHF television channels 2 through 13. Please note that channel selection must be made at time of order, as the transmitter or translator is calibrated and tested to the channel requested and is not field tuneable. The TAV-2000 power amplifier is a modular solid-state 2000-watt broadcast amplifier utilizing readily available RF components wherever possible, thus enhancing the serviceability of the equipment. The TAV-2000 features ultra linear amplification and individual channel RF output bandpass filtering. The amplifier modules are stable for high reliability and long service life.
III-3 The amplification of the TAV-2000 is comprised of (2) TAV-1000 1000-watt power amplifiers. Firstly, the output of the modulator or processor gets split into (2) RF signals of equal amplitude. Each output of the 2-way power divider is then fed into a TAV-1000 Power Amplifier. Finally, the outputs of each TAV-1000 are combined to generate 2000-watts of peak visual power in addition to an aural carrier, as seen in the TAV-2000 block diagram. Inside the 1000-watt power amplifier, the signal passes through an RF attenuator to limit the output power level of the power amplifier and to help buffer any transients that may come into the power amplifier. After attenuation, the signal gets preamplified through a VHFTV-25 and a VHFTV-200 driver amplifier before the signal gets split into (4) signals for final amplification using a 4-way Wilkinson microstrip power divider. The final amplification stage is comprised of (4) VHFTV-400 final amplifiers. The outputs of the (4) final amplifier pallets are combined with a 4-way Wilkinson microstrip combiner and pass through an isolator as illustrated in the following TAV-2000 block diagram.
TAV-1KW AMPLIFIERTAV-1KW AMPLIFIERCOMBINER/FILTER2 WAY SPLITTEExternal power supplyModulator or ProcessorRF Out TAV-2000 BLOCK DIAGRAMDate: mAY 25, 2005 Page: 1 of 1Rev ID
III-5 After amplification, the signal exits the power amplifier enclosure and goes into the filter/coupler enclosure. The amplified signals are filtered with a bandpass filter and monitored again with another directional coupler before heading out to an antenna for broadcast, as depicted in the following filter/coupler block diagram.
VHFTV-400VHFTV-400VHFTV-400VHFTV-400VHFTV-200HCIRCULATOR4 WAY COMBINER4 WAY SPLITTERVHFTV-25HA=-0.3dB typicalA=-0.3dB typicalTo Wattmeter and AntennaA=+38dB min.RF INPUT RF OUT TERMINATION50 OHMATTENUATIONTAV-1000 Block DiagramDate: May 24, 2005 Page: 1 of 1Rev ID
III-7 Specifications The following specifications were taken with a Technalogix modulator/processor. Should a different modulator or processor be used, specifications could vary. For this reason, we recommend that any different modulator/processor be shipped to Technalogix so the system can be matched and set up optimally. In addition, the audio/video ratio the input to the power amplifier needs to be –10 dB in order for the software and LCD readout to be accurate. RF Characteristics Frequency range any specified VHF Channel 2 to 13** Frequency Response (one channel) ±0.5 dB Frequency Stability ±250 Hz Selectivity 60 dB (adjacent channel) Minimum Input Level 0 dBmV Rated Visual Output Power 1000 Watts Rated Aural Output Power 10% of peak visual power IF Output Level +35 dBmV nominal Input Impedance 75 Ohms Output Impedance 50 Ohms Harmonics > 60 dB below rated power Predominant Intermodulation Distortion dBc = decibels below visual carrier + 920 kHz > -53 dBc - 920 kHz > -53 dBc + 2.66 MHz > -53 dBc - 2.66 MHz > -53 dBc + 5.42 MHz > -53 dBc + 7.16 MHz > -53 dBc 3rd Order Intermodulation Distortion + 4.5 MHz > -60 dBc + 9.0 MHz > -60 dBc All others > -60 dBc Spurious Emissions > -60 dBc ** Stand-alone power amplifier will operate from channels 14-69. PAL Video Characteristics Input Level to modulator (for 87.5% modulation) 1.0 VPP Differential Phase (at 87.5% modulation) ±2 Degrees Differential Gain (at 87.5% modulation) 2% Group Delay < ±40 nS Video Group Delay Pre-emphasis Conforms to IC/FCC specifications K-Factor 1.9% for 2T Pulse Hum and Noise > 60 dB below rated power
III-8 Aural Characteristics Input Level for 25 kHz Deviation 0.3 VPP Frequency Response (Standard Pre-emphasis) ±1 dB Harmonic Distortion (25 kHz Deviation) < 1% 50 Hz to 15 kHz Amplitude Modulation Noise > 50 dB Frequency Modulation Noise > 60 dB Intercarrier Stability ±250 Hz Physical Characteristics Power Requirements Power Supply 230 VAC, 10 AAC Operating Temperature 0 - 50°C Dimensions TAV-1000 Power Amplifier W-19" flange (17” encl.), D-25-¼", H-101/2” (6U) Filter/coupler W-19" flange (17” encl.), D-25-¼", H-8-¾” (5U)
IV-1Section IV – RF Components Amplifier Pallets The VHFTV-25 pallet is a two stage ultra linear class-A linear pallet. The VHFTV-25-L has a typical gain of 40dB and the VHFTV-25-H has a typical gain of 34dB. These pallets draw no more than 3.25Adc total drain current (the exact bias and drain currents of your system are found in the spec sheet supplied with each manual). The quiescent and drain currents can be measured on the VHFTV-25 pallet by measuring the voltage drop across the current sense resistor found directly at the DC power supply lead input to the pallet. This resistance is 0.01-ohms, providing a 10mV per ampere ratio. The VHFTV-200 pallet is a two stage ultra linear class-A linear pallet. The VHFTV-200-L has a typical gain of 40dB and the VHFTV-200-H has a typical gain of 18dB. These pallets draw no more than 17 Adc total drain current (the exact bias and drain currents of your system are found in the spec sheet supplied with each manual). The final amplifier stage is comprised of a VHFTV-400-L or VHFTV-400-H amplifier pallet and are characterized with typical gains of 18 dB (low band) or 16dB (high band) and maximum drain currents of 11 A (low-band) or 14 A (high-band). Each of the amplifier pallets is connectorized. All amplifier pallets must have the transistor drain voltages reach at least 26Vdc before the RF drive is applied.
Technalogix Ltd.25 Watt High Band VHF PalletPA25-VHF-HS. KazarianNovember 12, 2001BB
AA11TECHNALOGIX LTD.25 W VHF LO BAND DRIVERP25-VHF-LR.S. MCDONALD14 SEPTEMBER, 2000
Technalogix Ltd.200 Watt High Band VHF PalletP200-VHF-HR.S. McDonaldDecember 17, 2001BAA
TECHNALOGIX LTD.200 W VHF HI BAND PALLETP200 VHF-LR.S. MCDONALD31 AUGUST, 2000AA11
IV-4 Filter The passive bandpass filter rejects spurious and harmonic output products and passes the VHF channel RF output. The cavity resonator uses aperture coupling and is a linear resonator design. Typical insertion loss is 0.6 dB to 1.0 dB depending on channel frequency. Average roll off is –33 dBc at a point 4.5 MHz below the peak visual carrier frequency and –30 dBc 9.0 MHz above the peak visual carrier frequency. The filter is DC grounded on both the input and output for additional lightning protection. Directional Coupler The Technalogix dual directional couplers provide DC voltages proportional to forward and reflected RF power monitoring. These analog voltages are converted for processing using analog-to-digital converters and provide the control system with valuable data for monitoring purposes. The directional couplers installed in the power amplifier and filter enclosures have peak detection circuits on the forward RF power side of the coupler and average detection circuits on the reflected RF power side of the coupler. This is to allow the end user to set power in a manner that is more independent of modulation and closer to a true tip-of-sync meter. Hence the readings of the displays in the power amplifier system are peak for forward and average for reflected. Output power should be set following the operating procedure found elsewhere in this manual. The directional coupler has a typical insertion loss of 0.5dB and its Type N connectors can handle 1,500 watts peak. Isolator The power amplifier pallets are protected in part by the isolator located in the filter enclosure. It is actually made up of a circulator and 50-ohm dump resistor. The circulators’ specifications include an insertion loss of less than 0.2dB with an isolation rating better than 20dB. Any reflected power gets dumped into the flanged power resistor. Even though the flanged power resistor is rated for only 150-watts, and there could potentially be 500-watts being reflected back into the circulator, the software will recognize quickly that reflected power is present and turn the carrier off. This way, there is instantaneous protection due to the isolator setup and long term protection due to the software.
V-1Section V – Power Supply Switching AC-DC power supplies are used to power the amplifier pallets, the control circuits, and all of the fans. The power supply is set at 30.0 Vdc nominally. All fans run off this same supply, though they pass through a series dropping resistor to lower the supply voltage, as the fans are 24Vdc. The power supplIES found in the filter/coupler enclosure are Mean Well RSP-1500-27. The switching power supplies are fully protected against short circuit and output overload. Short circuit protection is a cycling type power limit. The internal AC fuse is designed to blow only on a catastrophic failure in the unit – the fuse does not blow on overload or short circuit. The thermal shutdown automatically recovers when the power supply chassis cools down. AC (220Vac) is fed into the power supply enclosure via a filtered AC entry and then through a resettable circuit breaker.
Stock No. Model No. Output Tol. Effi.R&N112311123211233112341123511236RSP-1500-5RSP-1500-12RSP-1500-15RSP-1500-24RSP-1500-27RSP-1500-485V, 0~240A12V, 0~125A15V, 0~100A24V, 0~63A27V, 0~56A48V, 0~32A²2%²1%²1%²1%²1%²1%150mV150mV150mV150mV150mV200mV80%87%87%90%90%91%ƤUniversal AC input / Full rangeƤPF>0.98@115VAC; >0.95@230VACƤUsing ZVS technology to reduce powerdissipationƤHigh power density 8.3W/in3ƤBuilt-in 12V / 0.1A auxiliary outputƤAlarm signal outputƤDC output voltage adjustment 70~100%by external resistorƤActive current sharing up to 6000W (3+1)ƤBuilt-in remote sense functionƤBuilt-in remote ON/OFF controlƤProtections: Short circuit / OverloadOver voltage / Over temp.ƤForced air cooling by built-in DC fanƤ3 years warrantyAC input voltage rangeDC adjustment rangeOverload protectionOver voltage protectionSetup, rise, hold up timeWithstand voltageWorking temperatureSafety standardsEMC standardsPacking90~264VAC; 127~370VDC-30~+10% rated output voltage105%~135% constant current limiting,shut off after 5 sec.115%~140% rated output voltage1500ms, 100ms, 10ms at full load and 230VACI/P-O/P:3KVAC, I/P-FG:1.5KVAC, 1 minute-20~70OC (refer to output derating curve)UL60950-1, TUV EN60950-1 approvedEN55022 class B conducted, EN61000-3-2,3,EN61000-4-2,3,4,5,6,8,11, ENV502042.6kg ; 6pcs / 16.6kg / 1.75CUFT1500W with PFC and Parallel Function1500W with PFC and Parallel Function. . . .. . . . . .. . . . . . . .. . . .. .. . . . . . . . .. . . . . .............................................278x 127x 83.5 mmCASE: 943²
VI-1 Section VI – Monitor and Control System Control System Overview (Insight) The Insight control system is used for a variety of functions, the most important of which is ensuring that the transmitter continues to operate in a safe manner. The control system also allows the user to monitor and control the transmitter from both the front panel and the remote access port. Five modules comprise the Insight control system. These modules work together to provide all the functions of the control system. The modules are: the user interface module, the coupler condition module, the RF conditioning module, the temperature sensor module, and the TxNET module. The operation of each module is outlined in the following sections. User Interface Module The primary function of the user interface module is, as the name suggests, providing the user interface for the control system. This circuit board is mounted to the front panel of the transmitter, directly behind the LCD display. The membrane switch on the front panel is also connected to the user interface module. These components together provide the user with the ability to monitor the transmitter from the front panel. The following parameters can be monitored from the front panel: • Forward (incident) power at the transmitter output. • Reflected (reverse) power at the transmitter output. • DC voltage of the transmitter power supply. • DC current for each pallet in the transmitter. • Temperature of the heat sink of the transmitter. • The time since the transmitter was last shut down. The hardware of the user interface module is based around a microcontroller (U112). This microcontroller interfaces directly with the LCD and the membrane switch to provide output and receive input from the user. The microcontroller also communicates with the coupler conditioning board over a controller area network (CAN) bus. This communication is facilitated be two ICs, U113 and U114, and passes through a CAT5 cable attached to connector J105. The communication link with the coupler conditioning module allows the user interface module to receive information about the foreword power, reflected power, and temperature of the transmitter, as well as relay commands from the user to the rest of the system. If the transmitter includes more than on amplifier module, a second CAN connection will be present between the user interface module (J106) and the TxNET board to facilitate communication between enclosures. Other elements of the user interface module are also controlled by the microcontroller. A buzzer (BZ101), a status LED (D113), and a relay to control the backlight of the LCD (RL101), are all controlled through a buffer (U116). In order for the user interface module to monitor the current draw of each pallet in the system, the DC supply wires pass through the user interface module on their way from the power supply to the pallets. The DC enters through connector J101 from the power supply, and exits through J102 to go to the pallets. As the current passes through shunt resistors (R117, R118, R120, R121, R123, R124, R126, R127, R129, R130), the voltage drop is
VI-2 monitored by U101 to U105, buffered by U106 to U108, and sent to the analog to digital converter integrated into the microcontroller. There are five circuits for which the current is monitored by this system. As the DC supply passes through the user interface module, it undergoes filtering to ensure that the supply to the pallets is as clean as possible. Each of the five circuits passes through a network of transient voltage suppressors, capacitors, and inductors. Each connection is also fused at the input to insure an over-current condition does not persist. The fuses are a replaceable mini blade type fuse with a 42V voltage rating, and a current rating depending on application. Coupler Conditioning Module The coupler conditioning module serves to monitor the output of the directional coupler which provides a voltage proportional to the foreword and reflected power at the output of the transmitter. The coupler conditioning module also interfaces with each of the other boards in the control system, acting as the hub of communications for the system. Lastly, the coupler conditioning board sends and receives signals through the remote access port, via the TxNET board. The analog signals produced by the coupler for forward and reflected power are passed onto the coupler conditioning module by connectors J206 and J207 respectively. Each signal is filtered by CLC networks, and buffered and amplified by the op-amp U214. The level of the forward signal can be adjusted by VR201, and the reflected signal by VR202. These two potentiometers can be used to fine tune the power readings of the transmitter if they go out of calibration. The analog signals are converted to digital by an analog-to-digital converter integrated into the microcontroller U202. Aside from taking readings from the coupler, the microcontroller on the coupler conditioning module also interfaces with the RF conditioning module (through J201A) and the temperature sensor (through J201B). The microcontroller interfaces with the CAN bus using U203 and U204. Through the CAN bus, the coupler conditioning board is able to communicate with the user interface module, and any other amplifiers that are in the system. The CAN bus is connected through J201C, and J201D if there are multiple amplifiers in the transmitter system. The last task of the coupler conditioning board is to send and receive remote access signals to and from the TxNET board. Two analog outputs, proportional to forward and reflected power and produced by the digital-to-analog converter U212 after it receives input from the microcontroller. The analog outputs are then buffered by U211 before being sent through J203 to the TxNET board. J203, along with J204, also bring the digital inputs and outputs from the TxNET board to the coupler conditioning module. The digital signals are then connected to the microcontroller through the opto-isolators U205, U206, U207, U208, and U209.
VI-3 RF Conditioning Module The RF conditioning board is located at the RF input of the amplifier. Its main function is to act as a variable attenuator, so that the control system can add attenuation to the input of the amplifier in order to limit the output power of the transmitter. The RF signal comes in to the RF conditioning module through J302 before it passes through a manually variable attenuator made up of R305, VR303, and R307. The signal then passes through the digitally-controlled variable attenuator U302 before exiting through J303. The input for the digital attenuator comes from the coupler conditioning module through J304. The input signals are passed through the opto-isolators U303, U304, and U305 before being sent to the digital attenuator. In total, five control signals go to the digital attenuator, allowing for attenuations of up to 31dB in 1dB steps. Temperature Sensor Module The temperature sensor module is a small board mounted to the main heatsink of the amplifier. The main purpose of the temperature sensor module is to take temperature readings of the heatsink. The temperature sensor IC is U1 which, after it has taken a reading, relays the digital information to the coupler conditioning module through J1. Also passing through J1 is a driver disable signal coming from the coupler conditioning module. The temperature sensor module simply takes this signal and passes it through to J2, where it is connected to the driver pallet. TxNET module The TxNET module is simply a passive board that acts as an interface between the wiring on the inside of the amplifier enclosure and connections on the outside of the enclosure. The DB-25 connector for the remote port (J602) is attached to the TxNET module. The signals travelling through this port are connected to the coupler conditioning module through J601 and J603. The TxNET module also includes up to four straight through RJ45 connections: J604 to J605, J606 to J607, J608 to J609, and J610 to J611. These connections are only used on systems with multiple enclosures, to pass control signals between enclosures.
VI-4 Remote Port The remote port allows external control of the transmission system via the DB25. The functions of each pin on the remote port are indicated in the following table: Pin Number Description 1 Ground 2 Forward power sample1 3 Reflected power sample1 4 Carrier off2 5 Carrier on2 6 Increase carrier level (level must have been decreased) 2 7 Decrease carrier level (1dB increments) 2 8 Soft reset2 9 Reset2 10 Power supply fault flag3 11 High temperature flag3 12 High VSWR flag3 13 Amplifier overdriven flag3 14 +5Vdc 15 +3.3Vdc 16 Ground 17 Ground 18 N/C 19 N/C 20 N/C 21 N/C 22 N/C 23 N/C 24 N/C 25 N/C Notes: 1. Analog output with voltage ranging from 0 to 5Vdc. 2. TTL level digital input, active on rising edge. 3. TTL level digital output, active high.
VI-5 Fault Shutdowns On the LCD (Liquid Crystal Display) the following messages may appear: If you see this message, the system has been driven to a power level higher than it is rated for. This message will likely only appear momentarily, before the amplifier will add attenuation at its input to bring the output power to a safe level. This message indicates that excessive reflected power has been detected at the output of the transmitter. Periodically, the amplifier will cycle on, and re-check for reflected power. If high reflected power continues, the transmitter will eventually shut down completely. This message indicates that the transmitter is experiencing unsafe internal temperatures. Output power is reduced until a safe temperature is reached.
VI-6 Monitor and Control System (Insight) Bills of Materials Circuit: User Interface Module Revision: 1.03 Designations Qty Description Package Manufacturer Mfg. Part Number U112 1 IC MICROCONTROLLER 256 BYTE RAM 64QFP Texas Instruments MSP430F135IPM C106, C107, C117, C118, C128, C129, C141, C142, C148, C149, C163 11 CAPACITOR 0.01 uF 50V 10% 0805 Yageo 08052R103K9B20D C108-116, C119-127, C130-140, C143-145, C161 33 CAPACITOR 0.1uF 50V 10% 0805 Yageo 08052R104K8B20D C146, C147 2 CAPACITOR 33pF 50V 5% 0805 Panasonic ECJ-2VC1H330J R101, R104, R107 R110, R113 5 RESISTOR 2.7K? 0805 Yageo 9C08052A2701FKHFT C162 1 CAPACITOR 1uF, 50V 0805 TDK Corporation C2012Y5V1H105Z R132 1 RESISTOR 37.4K? 0805 Yageo 9C08052A3742FKHFT R133 1 RESISTOR 3.3K? 0805 Yageo 9C08052A3301FKHFT R134, R135, R136, R137, R138, R139 6 RESISTOR 249K? 0805 Yageo 9C08052A2493FKHFT R140, R141, R144 R145, R146, R147 R150, R151, R156 9 RESISTOR 10K? 0805 Yageo 9C08052A1002FKHFT R142, R143, R148 R149, R154, R155 6 RESISTOR 1K? 0805 Yageo 9C08052A1001FKHFT R152 1 RESISTOR 100? 0805 Yageo 9C08052A1000FKHFT R119, R122, R125, R128, R131, R153 6 RESISTOR 100K? 0805 Yageo 9C08052A1003FKHFT R158 1 RESISTOR 430? 0805 Yageo 9C08052A4300FKHFT R160 1 RESISTOR 1.4K? 0805 Yageo 9C08052A1401FKHFT R161 1 RESISTOR 27K? 0805 Yageo 9C08052A2702FKHFT R162 1 RESISTOR 6.2K? 0805 Yageo 9C08052A6201FKHFT R157 1 RESISTOR 4.7? 2010 Panasonic ERJ-12ZYJ4R7U R117, R118, R120 R121, R123, R124 R126, R127, R129 R130 10 RESISTOR 0.006? 1% 1W 2512 Vishay WSL25126L000FEA R159 1 POTENTIOMETER 10K? 4mm SMD Bourns 3314G-1-103E R102, R103, R105 R106, R108, R109 R111, R112, R114 R115 10 RESISTOR 20? 1W 2512 Panasonic ERJ-1TYJ200U RN101 1 RESISTOR NETWORK 10K? SMT Panasonic EXB-A10P103J F107 1 RESETTABLE FUSE, POLYFUSE, 2A SMD Raychem MINISMDC200-2 F108 1 RESETTABLE FUSE, POLYFUSE, .5A SMD Raychem MINISMDC050-2
VI-7 L106, L107, L108, L109, L110 5 INDUCTOR 0.01uH 1210 TDK NLV32T-010J-PF Y101 1 6.00 MHz CRYSTAL SMT Citizen HCM49-6.00 U111 1 IC SUPERVISOR 2.70V LOW SOT23 Microchip Technology MCP130T-270I/TT U114 1 IC TXRX 3.3V CAN 8-SOIC Texas Instruments SN65HVD232D U113 1 IC CAN CONTROLLER W/SPI 18-SOIC Microchip Technology MCP2510-I/SO U115 1 IC REG SIMPLE SWITCHER TO-263-5 National Semiconductor LM2576HVS-5.0 U116 1 IC DARL TRANS ARRAY 16-SOIC Texas Instruments ULN2003ADR U117 1 IC REG LINEAR LDO SOT223 National Semiconductor LM1117MP-3.3 U118 1 IC VOLTAGE COMVERTER 8-SOIC National Semiconductor LM2660M U109, U110 2 OPTOCOUPLER DUAL CHANNEL 8-SOIC Fairchild Semiconductor MOCD211M U101, U102, U103 U104, U105 5 IC CURRENT MONITOR SOT23-5 Texas Instruments INA168NA U106, U107, U108 3 IC OP AMP SINGLE SUPPLY 8-SOIC Texas Instruments OPA2340UA D101, D103, D105 D107, D109, D111 6 DIODE TVS 30V D0214AA Crydom SMBJ30A D102, D104, D106 D108, D110 D113, D115, D117 8 DIODE LED GREEN 1206 Lumex SML-LX1206GC-TR D114 1 DIODE SCHOTTKY SMC International Rectifier 30BQ060 D116 1 DIODE RECTIFIER 1A 200V SMA Diodes Inc. S1D-13 D118 1 DIODE SCHOTTKY 5A 50V SMC Diodes Inc. B550C-13 or B550C-13F C152 1 CAPACITOR 10uF 16V TANTALUM 3528 Kemet T491B106K016AS C156-160 5 CAPACITOR 22uF 35V TANTALUM D (SMT) Kemet T495D226K035ASE300 S101 1 SWITCH DIP 7 POSITION SMT 0.1" CTS 219-7MST S102 1 HEADER 3POS 0.1" Through Hole AMP/Tyco 640452-3 RL101 1 RELAY SPST 5VDC SMT Omron G6L-1F-DC5 L101, L102, L103, L104, L105 5 INDUCTOR 1.3uH SMT Panasonic ETQ-P6F1R3LFA C153, C154, C155 3 CAPACITOR 100uF, 10V D (SMT) Panasonic ECE-V1AA101SP U119 1 IC REG SIMPLE SWITCHER TO-263-7 Texas Instruments LM2679S-ADJ C101, C102, C103, C104, C105, C150 6 CAPACITOR 100uF 63V G (SMT) Panasonic ECE-V1JA101P BZ101 1 BUZZER SMT CUI Inc. CT-1205C J107 1 CONNECTOR 14POS HEADER Through Hole AMP/Tyco 103308-2 J108 1 CONNECTOR SCREW TERMINAL Through Hole Keystone 7701 J105,J106 2 CONNECTOR MODULAR JACK 8 VERTICAL Through Hole AMP/Tyco 5556416-1 F101, F102, F103, F104, F105, F106 6 FUSE AND FUSE HOLDER 42V MINI Through Hole Littelfuse 02970xx.WXNV and 01530008Z J103 1 CONNECTOR 5POS HEADER Through Hole AMP/Tyco 3-644695-5 J102 1 CONNECTOR, 2 PART 0.3" 10POS Through Hole Weiland 25.390.4053.0 J101 1 CONNECTOR 2 PART 0.3" 6POS Through Hole Weiland 25.390.3653.0 L111 1 INDUCTOR 150uH S6 Talema SWS-2.0-150 L112 1 INDUCTOR 33uH 5A 260kHz Through Hole Pulse P0849NL J104 1 16 POST HEADER Through Hole Samtec TSW-116-18-T-S C151 1 CAPACITOR 1000uF, 10V G (SMT) Panasonic ECE-V1AA102P
VI-8 Circuit: Coupler Conditioning Revision: 1.04 Designations Qty Description Package Manufacturer Mfg. Part Number C201, C203, C204, C205, C208, C209, C212, C213, C214, C215, C216, C217, C218, C219, C220, C221, C222, C223, C224, C225, C226, C227, C228, C229 24 Capacitor, ceramic, 0.01uF, 50Vdc, +/-20% SMD 0805 Kemet C0805C103K5RACTU C202 1 Capacitor, ceramic, 0.1uF, 50Vdc, +/-20% SMD 0805 Yageo America C0805C104M5UACTU C206, C207 2 Capacitor, ceramic, 33pF, 50Vdc, 5% SMD 0805 Panasonic ECJ-2VC1H330J C210, C211 2 Capacitor, electrolytic, 100uF, 10V, +/-20% SMD 'D' Panasonic ECE-V1AA101SP D201, D202 2 Diode, TVS, 5.0Vdc, 600W, unidirectional SMB General Semiconductor SMBJ5.0A-13 D203, D204 2 Diode, LED, red, 2.0V SMD 1206 Lumex SML-LX1206IW-TR D205 1 Diode, rectifier, 200V, 1A SMA Diodes Inc. S1D-13 D206 1 Diode, zener, dual, 10V SOT-23 Diodes Inc. AZ23C10-7-F J201 1 Connector, modular, female, 4-port, 8-position, rt. angle Through Hole AMP/Tyco 557562-1 J202 1 Connector, header, IDC, 0.1" spacing, 14-pos Through Hole AMP/Tyco 103308-2 J203, J204 2 Connector, modular, female, 8-position, vertical Through Hole AMP/Tyco 5556416-1 J205 1 Connector, header, 3-position, 0.1", square post Through Hole AMP/Tyco 644695-3 J206, J207 2 Connector, header, vertical, 3-pos, 0.1" spacing Through Hole Molex 22-02-2035 K201 1 Relay, SPST, 5Vdc coil, SMT SMT Omron G6L-1F-DC5 L201, L202, L203, L204, L205, L206, L207, L208, L209, L210, L211, L212 12 Inductor, 0.01uH, Imax=0.45A, DCR=0.13 omhs SMD 1210 KOA KL32TE010K R201 1 Resistor, thick film, 5%, 100ohm, 1/8W SMD 0805 Panasonic ERJ-6GEYJ101V R203, R204, R207, R208, R211, R212, R213, R214, R217, R218, R219, R220, R221, R222, R223, R224 16 Resistor, thick film, 5%, 1kohm, 1/8W SMD 0805 Panasonic ERJ-6GEYJ102V R205, R206, R209, R210, R215, R216 6 Resistor, thick film, 5%, 10kohm, 1/8W SMD 0805 Panasonic ERJ-6GEYJ103V RN201, RN202, RN204 3 Resistor network, 10kohm, 8-resistors, 10-terminations, bussed, 5% SMD 2512 Panasonic EXB-A10P103J RN203 1 Resistor network, 1kohm, 8-resistors, 10-terminations, bussed, 5% SMD 2512 Panasonic EXB-A10P102J S201 1 Switch, DIP, 7-position, SPST SMD 0.1" CTS 219-7MST U201 1 IC, supervisor, 2.7V, internal pull-up resistor, open drain, active low SOT-23 Microchip Technology MCP130T-270I/TT
VI-9 U202 1 IC, microcontroller, 16-bit, 16k X 8 program, 48 I/O, flash 64-QFP Texas Instruments MSP430F135IPM U203 1 IC, CAN transceiver, 3.3V SOIC-8 Texas Instruments SN65HVD232D U204 1 IC, CAN controller, industrial temp, 3 transmit buffers, 2 receive buffers 18-SOIC Microchip Technology MCP2510-I/S0 U205, U206, U207, U208, U209 5 IC, optoisolator, dual, transistor o/p, Vceo=30V SOIC-8 Fairchild MOCD211M U210 1 IC, buffer, Darlington, array SOIC-16 Texas Instruments ULN2003ADR U211, U214 2 IC, op-amp, dual, single supply SOIC-8 Texas Instruments OPA2340UA U212 1 IC, DAC, dual, 8-bit, serial SOIC-8 Texas Instruments TLV5625CD U213 1 IC, voltage reference, 2.50V, +/- 0.2% SOT-23 National Semiconductor LM4040BIM3-2.5 VR201, VR202 2 Potentiometer, 2kohm, 11-turn, 5mm, top SMT Murata PVG5A202C01R00 Y201 1 Crystal, 6.000MHz SMT Citizen HCM49-6.00 Circuit: RF Conditioning Revision: 1.05 Designations Qty Description Package Manufacturer Mfg. Part Number C301, C306, C311 3 Capacitor, ceramic, 0.1uF, 50Vdc, +/-20% SMD 0805 Yageo America C0805C104M5UACTU C302, C303, C305, C312, C320 5 Capacitor, ceramic, 0.01uF, 50Vdc, +/-20% SMD 0805 Kemet C0805C103M5RACTU C304 1 Capacitor, ceramic, 0.022uF, 50Vdc, +/-10% SMD 0805 Panasonic ECJ-2VB1H223K C307, C308, C310 3 Capacitor, ceramic, 1000pF, 50Vdc, +/-10% SMD 0805 Kemet C0805C102K5RACTU C309 1 Capacitor, ceramic, 330pF, 50Vdc, +/-10% SMD 0805 Panasonic ECJ-2VC1H331J C313, C314, C315, C316, C317, C318, C319 4 DNS SMD 0805 D301 1 Diode, TVS, 30V, 600W SMB Diodes Inc. SMBJ30A-13 D302 1 Diode, LED, green, Vf=2.2V SMD 1206 Lumex SML-LX1206GW-TR D303, D304, D305, D306, D307 5 Diode, LED, red, Vf=2.0V SMD 1206 Lumex SML-LX1206IW-TR D308 1 Diode, ultrafast SOT-23 Fairchild Semiconductor MMBD914 D309, D310 2 DNS TO-92 F301 1 Fuse, resettable, miniSMD, Ihold = 0.14A, Itrip = 0.34A Fuse-miniSMD Littelfuse MINISMDC014-2 J301 1 Connector, terminal block, header, 2-position, straight PCB THT (0.2") Wieland 25.350.3253.0 J301 1 Connector, terminal block, plug, 2-position, straight - Wieland 25.340.3253.0 J302, J303 2 Connector, SMA, PCB End Launch, 50-ohms PCB End Launch Johnson Components 142-0701-801 J304 1 Connector, modular, female, 8-position, vertical PCB THT Amp (Tyco) 5556416-1 L301 1 Inductor, 0.01uH 1210 TDK NLV32T-010J-PF PCB301 1 Printed circuit board, FR4, proto 2 or equivalent - Alberta Printed Circuits PCB301
VI-10 R301 1 Resistor, thick film, 5%, 620ohm, 1W SMD 2512 Panasonic ERJ-1TYJ621U R302, R303 2 DNS R304, R312, R313, R318, R319, R322 6 Resistor, thick film, 5%, 1.0kohm, 1/8W SMD 0805 Yageo America 9C08052A1001JLHFT R305, R307 2 Resistor, thick film, 1%, 130ohm, 1/8W SMD 0805 Yageo America 9C08052A1300FKHFT R308, R309, R314, R315, R320 5 Resistor, thick film, 5%, 1.2kohm, 1/8W SMD 0805 Yageo America 9C08052A1201JLHFT R310, R311, R316, R317, R321 5 Resistor, thick film, 5%, 10kohm, 1/8W SMD 0805 Panasonic 9C08052A1002JLHFT R323 1 Resistor, 100ohm, 1/8W SMD 0805 Yageo America 9C08052A1000FKHFT R324 1 Resistor, 3.3ohm, 1/8W SMD 0805 Yageo America 9C08052A3R32FGHFT R325, R326, R327, R328, R329 5 DNS SMD 0805 VR301 1 Potentiometer, 5kohm SMD 5MM Murata PVG5A502C01R00 VR302 1 DNS SMD 5MM VR303 1 Potentiometer, 200ohm SMT 5MM Murata PVG5A201C01R00 S301 1 Switch, DIP, 5-position, SPST, gold finish, sealed CTS 219-5 SMD CTS Corporation 219-5MST U301 1 IC, voltage regulator, 5V output, 500mA TO-252 National Semiconductor LM78M05CDT U302 1 IC, digital attenuator, 5-bit, 1dB LSB SSOP-20 Skyworks (Alpha) AA110-85 U303, U304, U305 3 IC, optoisolator, dual, transistor o/p, Vceo=30V SOIC-8 Fairchild MOCD211M U306 1 Directional coupler Mini-Circuits DBTC-20-4 U307 1 IC, power detector TSSOP-16 Analog Devices AD8362ARU U308 1 DNS (replace with two 0805 0ohm resistors) U309 1 DNS TO-243 Circuit: Temperature Sensor Revision: 1.02 Designations Qty Description Package Manufacturer Mfg. Part Number C701 1 CAPACITOR 0.1uF 50V 10% 0805 Yageo 08052R104K8B20D J701 1 CONN MOD JACK 8-8 R/A PCB 50AU SMT Molex 44144-0003 J702 1 TERMINAL SCREW VERTICAL PC MNT Keystone 8191 U701 1 IC DIG TEMPERATURE SENSOR 8-MSOP National Semiconductor LM70CIMM-3 Circuit: TxNet Revision: 1.02 Designations Qty Description Package Manufacturer Mfg. Part Number F601, F602, F603, F604 4 Fuse, resettable, Ihold=0.14A, Itrip=0.34A, Vmax=60V SMD Tyco MINISMDC014-2
VI-11 J601, J603, J604, J605, J606, J607, J608, J609, J610, J611 10 Connector, modular, jack, 8-position, vertical, PCB mount Tyco 5556416-1 J602 1 Connector, D-sub, 25 position, female, vertical, PCB mount Kycon K85-BD-25S-R
VI-12 Insight System Schematics The following pages contain the schematics for the Insight system.
IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 8 1J60423456781J605 OUT 1 2345678OUT 2 OUT 3 OUT 4 OUT 5 OUT 6 OUT 7 OUT 8 OUT 8 OUT 7 OUT 6 OUT 5 OUT 4 OUT 3 OUT 2 8765432OUT 1 1J60787654321J606IN 8 IN 7 IN 6 IN 5 IN 4 IN 3 IN 2 IN 1 IN 1 IN 2 IN 3 IN 4 IN 5 IN 6 IN 7 IN 8 1J61023456781J611 OUT 1 2345678OUT 2 OUT 3 OUT 4 OUT 5 OUT 6 OUT 7 OUT 8 OUT 8 OUT 7 OUT 6 OUT 5 OUT 4 OUT 3 OUT 2 8765432OUT 1 1J60987654321J608IN 8 IN 7 IN 6 IN 5 IN 4 IN 3 IN 2 IN 1 12345678910111213141516171819202122232425J602F60487654321J603F602875432RESET Soft RES+3.3 VdcCAR down+5 Vdc CAR up CAR off CAR on ground ODRVflagVSWRflagFWD sampTEMPflagRFL sampPSUflag F601F6031J601TxNET1.02Date: Dec. 5, 2005 Page: 1 of 1Rev ID
1Temperature SensorJ2C11uFJ1GDRV DIS TMP GND TMP CS TMP SO TMP SCK TMP VCC J1CJ1HJ1DJ1BJ1ATMP VCC P1P2P3P4 P5P6P7P8U1LM70N. Hendrickson, A. SivacoeTemperature Sensor Board1.02 Insight Control SystemDate: May 8, 2005 Page: 1 of 1Rev ID
RF 2 D308ShutdownC302 C303L301C301S3015S3014S3013+5 Vdc S3012S3011INCOMOUTU301D302+5 Vdc D301F301J3012J3011Ground PSU In RF OUT D307D303 D304D306D305CTL 16dBCTL 4dB CTL 8dB CTL 1dB CTL 2dB 16dB in P1P2P3P4 P5P6P7P8U305C306Ext 5Vdc4dB in 8dB in 1dB in 2dB in P1P2P3P4 P5P6P7P8U304P1P2P3P4 P5P6P7P8U303+5 Vdc C305C304CTL 16dBCTL 8dB CTL 4dB CTL 2dB CTL 1dB P1P2P3P4P5P6P7P8P9P10 P11P12P13P14P15P16P17P18P19P20U302Alpha 110-85J303J304 4J304 2J304 1J304 5J304 3J304 7R303R302 R304R301R322R312 R313R319R318R321R320R317R316R311R310R314 R315R308 R309A. Sivacoe, N. HendricksonRF Conditioning Module1.04 Insight Control SystemDate: Sept. 19, 2005 Page: 1 of 2Rev ID
VR303RF 1 RF 2 RF 1 C320C317PSU In INCOMOUTU30978L20C318 C319VR302C316C315D310D309C312C314C313J302RF IN VR301ShutdownC310 C311+5 Vdc C309C308C307DIP16P1P2P3P4P5P6P7P8 P9P10P11P12P13P14P15P16U307AD8362VVDIR. COUPLERU306DBTC-20-4HYBRID COUPLEU308SAGE WIRE -HCT2R329 R328R327R326R325R305 R307R324R323A. Sivacoe, N. HendricksonRF Conditioning Module1.04 Insight Control SystemDate: Sept. 19, 2005 Page: 2 of 2Rev ID
- DIP SWITCH 3,2,1 SET ID- DIP SWITCH 7 ENABLES CAN TERMINATIONCoupler Conditioning Module1MicrocontrollerTMP SO TMP CS TMP SCK TMP VCC TMP GND J201b3J201b8J201b4J201b2J201b1C2080.01uF C2090.01uFL2030.01uHC2050.01uFC2030.01uFL2020.01uHC2020.1uFC2040.01uFL2010.01uHLED2 LED1 DRVR DISCANterm1CANterm2RN201 10k +3.3 Vdc1234567S201VSWR PSU TEMP OVERDRV CAR UP CAR DOWNCAR ON CAR OFF SOFT RES+5 Vdc ATEN5 ATEN4 ATEN3 ATEN2 ATEN1 ATEN-VccJ201a5J201a7J201a1J201a3J201a2J201a4DAC CS C2010.01uFTDO TDI TMS TCK CAN CS SCK SIMO SOMI DVccP1A3P2A4P3A5P4A6P5A7P6P7XinP8XoutP9P10P11P1 0P12P1 1P13P14P15P16P17P18P19P20P21P2 2 P22P23P24P25P26P27P28SIMO0 P29SOMI0 P30UCLK0 P31P32P33P34P35P36P37P38P39P40P41P42P43P44P45P46P47MCLKP48P49P50P51P52P53TDOP54TDIP55TMSP56TCKP57RST P58A0P59A1P60A2P61AVssP62DVssP63AVccP64U202MSP430F133+3.3 Vdc RESET CAN CLK VccGNDResetU201MCP130C20733pFC20633pF Y2016.00MHZRFL-POW FWD-POW N. Hendrickson, A. SivacoeCoupler Conditioning1.04 Insight Control SystemDate: June 17, 2005 Page: 1 of 4Rev ID
Coupler Conditioning Module2CAN and Programmer Interface+3.3Vdc +5Vdc +3.3V-2 +3.3V-1 +5V-1 +5V-2 D202D201C2120.01uFL2040.01uHC210100uFC211100uFJ201d4J201c4J201d6J201c6J201c1J201c2J201d2 GND-1 GND-2 RESET-1 RESET J201d8J201c8CANH-2 CANL-2 +3.3Vdc CANterm2CANterm1J201d7C2130.01uFCAN CLK DP1GNDP2VccP3RP4 P5CANLP6CANHP7P8U203SN65HV232CAN CS SCK SIMO SOMI +3.3Vdc RESET CANL-1 CANH-1 J201c7TDO TDI TMS TCK JTAG headerJ202U204MCP2510R201100N. Hendrickson, A. SivacoeCoupler Conditioning1.04 Insight Control SystemDate: June 17, 2005 Page: 2 of 4Rev ID
Coupler Conditioning Module3Remote Access Port12345678J20312345678J204P1P2P3P4P5P6P7P8 P9P10P11P12P13P14P15P16U210ULN2003P1P2P3P4 P5P6P7P8U206MOCD211MP1P2P3P4 P5P6P7P8U208MOCD211MP1P2P3P4 P5P6P7P8U207MOCD211MP1P2P3P4 P5P6P7P8U209MOCD211MP1P2P3P4 P5P6P7P8U205MOCD211M+3.3 VdcCAR OFF CAR ON CAR DOWNCAR UP SOFT RESRESET OVERDRV VSWR TEMP PSU +5 Vdc LED1 LED2 D203 D204+3.3 VdcRFL-OUT FWD-OUT DRVR DIS+5 Vdc J205J201b7 DISABLE K201D205L2050.01uHC2150.01uFC2140.01uF4203RN1k8203RN1k3202RN10k4202RN10k1202RN10k2202RN10k3203RN1k1203RN1k6203RN1k7203RN1k2204RN10k3204RN10k1204RN10k7202RN10k6202RN10k9202RN10k8202RN10kR2041kR2031kR2081kR2071kR20510k R20610kR20910k R21010kR2111k R2121kR2131kN. Hendrickson, A. SivacoeCoupler Conditioning1.04 Insight Control SystemDate: June 17, 2005 Page: 3 of 4Rev ID
Coupler Conditioning Module4Coupler InputRF Power OutputC2160.01uF L2060.01uHP1P2P3P4 P5P6P7P8U212TLV5625DAC CS SCK SIMO +5 Vdc U213LM4040-2.5+OPA2340UAU211A+OPA2340UAU211BFWD-OUT RFL-OUT 1 3D206A1 2D206B+5Vdc RFL-5V RFL-GND FWD-5V FWD-GND J207AJ207BJ206AJ206BJ207CJ206C +OPA2340UAU214A+OPA2340UAU214BFWD-IN RFL-IN FWD-POW RFL-POW +3.3 VdcVR202VR201C2170.01uFL2100.01uHL2120.01uHC2240.01uF C2250.01uFC2280.01uF C2290.01uFL2070.01uHL2090.01uHC2220.01uF C2230.01uFC2260.01uFL2110.01uHC2270.01uFC2180.01uF C2190.01uFL2080.01uHC2210.01uFC2200.01uFR2141kR21510k R21610kR2191kR2171kR2231kR2211kR2181kR2221kR2201kR2241kN. Hendrickson, A. SivacoeCoupler Conditioning1.04 Insight Control SystemDate: June 17, 2005 Page: 4 of 4Rev ID
1DC Supply ConditioningFuse Table7.5 A/side3 A15 A15 A/sideP750-FMP350-FM 10 A/side15 A/side10 A/side10 A3 A2 AP400-VHF-HP400-VHF-L 15 A15 AP200-VHF-LP200-VHF-HPA25-VHF-HPA25-VHF-LU200LD UHFU60LD UHFP150-UHFP50-UHF 5 APA10-UHFPA5-UHF 4 AUser Interface ModuleVin J101CTAC 58VF103see tableV3 Cond +63VC103100uFV3 InputETQ-P6F1R3LFAL103J101BTAC 58VF102see tableV2 Cond +63VC102100uFV2 InputSML-LX1206GWD104GreenETQ-P6F1R3LFAL102ETQ-P6F1R3LFAL101SML-LX1206GWD102GreenV1 Input+63VC101100uFV1 Cond TAC 58VF101see tableSMBJ48A FM D101SMBJ30A TVJ101AJ101DTAC 58VF104see tableV4 Cond +63VC104100uFV4 InputETQ-P6F1R3LFAL104SML-LX1206GWD106GreenSML-LX1206GWD108GreenSMBJ48A FM D103SMBJ30A TVSMBJ48A FM D105SMBJ30A TVSMBJ48A FM D107SMBJ30A TVJ101FGND IN SMBJ48A FM D109SMBJ30A TVSML-LX1206GWD110GreenETQ-P6F1R3LFAL105V5 Input+63VC105100uFV5 Cond TAC 58VF105see tableJ101ETAC 58VF106tbdVgenCondSMBJ48A FM D111SMBJ30A TVR10820R10920R10520R10620R10320R102202.7k TVR1014.87k FMR11120R112202.7k TVR1044.87k FM2.7k TVR1074.87k FM2.7k TVR1104.87k FM2.7k TVR1134.87k FM R11520R11420A. Sivacoe, N. HendricksonUser Interface ModuleB Insight Control SystemDate: April 30, 2005 Page: 1 of 9Rev ID
Current Monitoring2User Interface ModuleC1180.01uF C1170.01uFL1070.01uHC1070.01uF C1060.01uFL1060.01uH+3.3 VdcC1090.1uFINA16851234U101V1 Cond V1 Out J102AI1 Buff C1080.1uFC1130.1uFI2 Buff J102B V2 Out V2 Cond INA16851234U102C1100.1uF+OPA2340UAU106A+3.3 Vdc+OPA2340UAU106B C1140.1uFC1110.1uF C1120.1uFC1150.1uF C1160.1uFC1200.1uFI4 Buff INA16851234U104V4 Cond V4 Out J102DC1240.1uFC1190.1uFI3 Buff J102C V3 Out V3 Cond INA16851234U103C1210.1uFC1250.1uF+OPA2340UAU107A+OPA2340UAU107BC1220.1uF C1230.1uFC1260.1uF C1270.1uFR1170.012R1180.012R119100kR122100kR1210.012R1200.012R1260.012R1270.012R128100kR125100kR1240.012R1230.012A. Sivacoe, N. HendricksonUser Interface ModuleB Insight Control SystemDate: April 30, 2005 Page: 2 of 9Rev ID
Membrane Switch Inputs3Voltage/Current MonitoringUser Interface ModuleC1290.01uFC1280.01uFL1080.01uH+3.3 VdcC1310.1uFI5 Buff INA16851234U105V5 Cond V5 Out J102EC1300.1uFC1320.1uF+OPA2340UAU108A C1330.1uF C1340.1uF+OPA2340UAU108B C1350.1uFVin V1 ADC I1 ADC I1 Buff I2 ADC I2 Buff I5 Buff I5 ADC I3 ADC I3 Buff I4 Buff I4 ADC C1360.1uFC1370.1uFC1380.1uFC1390.1uFC1400.1uFNav-uPC Pow-uPC Nav-IN Pow-IN P1P2P3P4 P5P6P7P8U109MOCD211MJ103DJ103AJ103EJ103B P1P2P3P4 P5P6P7P8U110MOCD211MSel-IN Res-IN Sel-uPC RESET +3 Vdc +3 Vdc J103CGND R1290.012R1300.012R131100kR134249kR1333.3k68.1k - FMR13237.4k - TVR135249kR136249kR137249kR138249kR139249kR14510kR14410kR1431kR1421kR14110kR14010kR14610k R14710k R1481k R1491k R15010k R15110kA. Sivacoe, N. HendricksonUser Interface ModuleB Insight Control SystemDate: April 30, 2005 Page: 3 of 9Rev ID
4MicrocontrollerUser Interface Module- DIP SWITCH 7,6,5 SET ID- DIP SWITCH 2 SETS CALIBRATION MODE- DIP SWITCH 1 ENABLES CAN BUS TERMINATIONC1420.01uFC1410.01uFL1090.01uHtbdC145Buzzer BkLtCtrlLED1 LCD Vss LCD Vdd LCD Vo LCD RS LCD R/*WLCD E J104 LED A LED K CANterm1CANterm2RN101 10kSel-uPC Nav-uPC Pow-uPC Pin15LCDPin3LCD +5 Vdc LCD D4 LCD D3 LCD D2 LCD D1 LCD D0 LCD D5 LCD D7 LCD D6 C1440.1uFC1430.1uFTDO TDI TMS TCK CAN CS SCK SIMO SOMI DVccP1A3P2A4P3A5P4A6P5A7P6P7XinP8XoutP9P10P11P1 0P12P1 1P13P14P15P16P17P18P19P20P21P2 2 P22P23P24P25P26P27P28SIMO0 P29SOMI0 P30UCLK0 P31P32P33P34P35P36P37P38P39P40P41P42P43P44P45P46P47MCLKP48P49P50P51P52P53TDOP54TDIP55TMSP56TCKP57RST P58A0P59A1P60A2P61AVssP62DVssP63AVccP64U112MSP430F133+3.3 Vdc RESET CAN CLK VccGNDResetU111MCP130C14730pFC14630pF Y1016.00MHZV1 ADC I5 ADC I4 ADC I1 ADC I2 ADC I3 ADC +3.3 Vdc7654321S101A. Sivacoe, N. HendricksonUser Interface ModuleB Insight Control SystemDate: April 30, 2005 Page: 4 of 9Rev ID
5CAN and Programmer InterfaceUser Interface ModuleC1480.01uFL1100.01uHJ106DJ105DJ106FJ105FJ106AJ105EJ106E+3.3V-1 GND-1 GND-2 +3.3V-2 +5V-2 +5V-1 RESET-2 RESET +3.3Vdc +5Vdc J106HJ105HCANH-2 CANL-2 +3.3Vdc CANterm2CANterm1TXCANP1RXCANP2P3P4P5P6P7P8OSC1P9VssP10 P11P12P13SCKP14P15SIP16SOP17CSP18RESETP19VddP20U113MCP2510J106GC1490.01uFCAN CLK DP1GNDP2VccP3RP4 P5CANLP6CANHP7P8U114SN65HV232CAN CS SCK SIMO SOMI +3.3Vdc RESET CANL-1 CANH-1 J105GTDO TDI TMS TCK JTAG headerJ107R153100kR152100A. Sivacoe, N. HendricksonUser Interface ModuleB Insight Control SystemDate: April 30, 2005 Page: 5 of 9Rev ID
6Power SuppliesUser Interface ModuleJ108 FanOut C1630.01uFD118DIODEL11233uHC15922uF C16022uFC1610.1uFC1621uFC15622uF C15722uF C15822uFLM2679VinGndRadsSoftStartFeedbkCboostVoutU119VgenCondBuzzer Littlefuse 1812LF108Littlefuse 1812LF107S102INCOMOUTU117LM1117MP-3.3D117+3.3V LEDD115+5V LEDPin15LCDRL101G6L-1F 5Vdc+C150100uFSML-LX1206GWD113GreenLED1 D116S1D-13BkLtCtrl10V tantalumC15210uFPin3LCD R15910k 40%+C155100uF+C154100uFC153100uF+5 Vdc +3.3 Vdc+C1511000uFL111100uHVinVoutFeedbkGndOn/OffU115LM2576S-5.0+5 Vdc VgenCondD11430BQ060P1P2P3P4P5P6P7P8U118LM2660MP1P2P3P4P5P6P7P8 P9P10P11P12P13P14P15P16U116ULN2003R1601.4k R16127kR1626.2kR1574.7BZ101R158430tbdR154R1551kR15610kA. Sivacoe, N. HendricksonUser Interface ModuleB Insight Control SystemDate: April 30, 2005 Page: 6 of 9Rev ID
VII-1 Section VII – Mechanical Section The heat sink allows the amplifiers to operate at a cooler temperature and prevents overheating, which helps the longevity of the entire system. The heat sink has hollow fins, which help dissipate the heat from the amplifiers faster than a conventional serrated or corrugated fin. In addition to the cooling effects of the heat sink, within each 1000-watt power amplifier enclosure, there are four fans that each provide 170 cubic feet per minute (CFM) of air flow (into zero static pressure). There are two fans mounted at the front of the heat sink and two mounted at the back end of the heat sink operated in a push-pull configuration to assist with heat dissipation. The fans are a 24Vdc variety, so there are series dropping resistors to drop the higher power supply voltage down to a safe level.
Technalogix Ltd. VIII-1 Section VIII - Installation This section contains unpacking, inspection, and installation instructions for the power amplifier. We are sure that you are chomping at the bit to install your new system, so we recommend that you read the following sections very carefully. Building Recommendations The quality of the building is of great importance if you are to expect long life and continued performance from the power amplifier. The building must be clean, dry, temperature controlled and secure. Don’t forget to allow space in the building for any additional racks to house test equipment, a workbench area, line regulating transformers, ladders, equipment and parts storage, first aid kit, emergency generator if used, as well as heating and cooling devices that may be unique to your installation. A sloping roof will tend to develop leaks less rapidly. The building should be well roofed with good material. The cooling load will be lowered with reflective or light colored roofing material.
Technalogix Ltd. VIII-2 Heating and Cooling Requirements The environment’s temperature will contribute greatly to the length of the power amplifier’s life. Technalogix recommends that the building’s filtered air intake must have capacity for all air-flow in the building plus an additional 20%. The TAV-2000 uses (10) ball bearing fans – (4) for each power amplifier, (1) for the power supply enclosure, and (1) for the combiner. Keep the intake below the roofline to avoid intake of solar heated air. Please ensure that the intake and exhaust areas are on the same side of the building to avoid pressure differentials during windy conditions. Also, do not position intake near exhaust’s preheated air. If air conditioning is required to cool the shelter, discuss the situation with a qualified HVAC technician. Under average conditions, 12,000 BTUs will cool approximately 500 square feet to a comfortable level.
Technalogix Ltd. VIII-3 Electrical Service Recommendations Technalogix recommends that a qualified, licensed local electrician be consulted for the required electrical service. We suggest local electricians because: • The personnel knows the local codes • The personnel can be on site readily • You are apt to get better overall support if you give what business you can to local suppliers Technalogix recommends that proper AC line conditioning and surge suppression be provided on the primary AC input to the power amplifier. All electrical service should be installed with your national electrical code in your area, any applicable provincial or state codes, and good engineering practice. Special consideration should be given to lightning protection of all systems in view of the vulnerability of most transmitter or translator sites to lightning. Lightning arrestors are recommended in the service entrance. Straight and short grounds are recommended. The electrical serviced must be well grounded. Do not connect the unit to an open delta primary power supply, as voltage fluctuations could harm the unit. Branch your circuits. Do not allow your lights, your workbench plugs, and your transmitting or translating equipment to operate on one circuit breaker. Each transmitter or translator should have its own circuit breaker, so a failure in one does not shut off the whole installation.
Technalogix Ltd. VIII-4 Antenna and Tower Recommendations Your preliminary engineering workgroup should establish your antenna and tower requirements, both for receiving and transmitting antennas. Construction of sturdy, high quality antenna/tower systems will pay off in terms of coverage of your service area, the overall quality and saleability of your radiated signal, and reduced maintenance expenses. Technalogix provides complete turnkey antenna systems if needed. If your site is serving as a translator, your receiving antenna should be in line of sight to the originating station all year round. The foliage will change with season. Transmitting antennas can enhance or seriously impair the transmitter/translator output. The selection, routing, and length of coaxial cable are extremely important in the installation. If there is a 3 dB line loss in the cable between your unit’s output and the transmitting antenna, a 2000-watt unit will only deliver 1000 watts to the antenna. Buy the best cable you can obtain, route it via the shortest way to the antenna, and keep it straight. Do not form it into sharp bends on its way. Do not use any more cable fittings for the installation than absolutely necessary. All cautions here apply equally to all coaxial cables in the system - input and output. Pay attention to radial ice accumulation when designing the transmission system. It is not uncommon for at least an inch of ice to build up on the tower and antenna. This in turn significantly increases the weight, cross section, and wind loading of the system. Attaching the transmission line to the tower is crucial to maintain a safe and reliable operation. Nylon wire ties and electrical tape will breakdown in the sunlight and ultimately fail, creating a potentially dangerous situation. It is important to use proper clamps and hoisting grips and also ensure that the transmission line is grounded to the tower in several locations. When high currents flow through the tower in the event of lightening strikes, some of that current will flow through the outer conductors of the transmission lines. Due to the resistance difference between the steel tower and copper transmission line, a significant voltage can be developed, often resulting in arcing between the outer jacket and outer conductor, thus pitting the conductor. • Preventative maintenance is crucial in ensuring that safety is maintained. Specifically, check that transmission line grounds are tight and are not missing any hardware. Frequently inspect support clamps or spring hangers. Consider investing in an ice break (ice bridge), if you haven’t already done so, as shards of falling ice can damage the transmission line – and if it is going to happen, it will happen at an important time. Check the tower light photocells and conduit. The better-known tower manufacturers offer complete technical and safety documentation with their towers. Be sure that you have this information as it regards wind loading, guying, etc. The best-designed antenna system will function poorly if shortcuts and compromises are used during installation. Follow the manufacturer’s instructions exactly, along with any engineering data prepared for the site. Be absolutely safe and certain about this aspect as human lives may be at stake.
Technalogix Ltd. VIII-5 Shelter Security The FCC requires that the transmitter or translator be secure from entry or control by unauthorized persons, and that any hazardous voltages or other dangers (including most tower bases) be protected by locks or fences as necessary to protect personnel and prevent unauthorized tampering or operation. Security of the building further implies that it be secure from wildlife. Use sturdy construction materials, including sheet metal if necessary. Holes around conduit, cable, and other similar entry points should be stuffed with steel wool and caulked to prevent entry of wildlife. Other features of security for your shelter may include its location with respect to the prevailing wind conditions. A location leeward of some natural topographical feature will prevent wind damage and snowdrifts. Check the soil runoff conditions that may slow or hasten wind or water erosion and other concerns that may be unique to your location.
Technalogix Ltd. VIII-6 Unpacking and Inspection Check the outside of the container. Carefully open the container and remove the power amplifier. Retain all packing material that can be reassembled in the event that the equipment must be returned to the factory. Exercise care in handling equipment during inspection to prevent damage due to rough or careless handling. • Visually inspect the enclosure of the power amplifier for damage that may have occurred during shipment. • Check for evidence of water damage, bent or warped chassis, loose screws or nuts, or extraneous packing material in connectors or fan failures. • Inspect all connectors for bent connector pins. • If the equipment is damaged, a claim should be filed with the carrier once the extent of the damage is assessed. Technalogix cannot stress too strongly the importance of immediate careful inspection of the equipment and subsequent immediate filing of the necessary claims against the carrier if necessary. • If possible, inspect the equipment in the presence of the delivery person. If the equipment is damaged, the carrier is your first area of recourse. • If the equipment is damaged and must be returned to the factory, phone for a return authorization. • Claims for loss or damage may not be withheld from any payment to Technalogix, nor may any payment due be withheld pending the outcome thereof. Technalogix cannot guarantee the carrier’s performance.
Technalogix Ltd. VIII-7 Location and Function of Controls and Connectors (TAV-1000 Power Amplifier) The following illustration depicts the location of the connectors when installing each of the 1000-watt power amplifiers (TAV-1000).
Technalogix Ltd. VIII-8 POWER - Tactile button to turn carriers on and off. To turn off, must be depressed for at least 2 seconds. Tied internally through DB9 connectors to all other POWER buttons. NAVIGATE - Tactile button to refresh screen after two minute screen saver times out. All monitoring and protection continues during screen saver. SELECT- Tactile button to refresh screen after two minute screen saver times out. All monitoring and protection continues during screen saver. RESET - Tactile button to reset microcontroller in control board. Also clears existing faults. Individual control board with reset comes back on with soft start feature. RF IN – RF input from the output of the RF splitter. BNC connector, 50 Ω. RF OUT – 1000-watt RF output to be combined with the other 500-watt output. Connects to RF IN PA 1 or 2 on combiner unit. N connector, 50 Ω. CONTROL – Control signals communicating with the combiner / Filter enclosure. Connects with the PA 1 and PA 2 CTRL connector on the combiner. DB9 connector (see Amplifier Monitoring section for pinout description). AC IN – AC input to switching power supply. Switching power supply draws a maximum of 10 AAC at 220 VAC on each TAV-500 enclosure. AC BREAKER – Resettable circuit breaker is used to protect against inrush currents and high current draw from switching power supply. The thermal circuit breaker is a single pole configuration. REMOTE PORT - pin 1: ground to reset microcontroller, float otherwise pin 2: ground for 2 seconds to toggle carrier on/off, float otherwise pin 3: common ground pin 4: DC power supply sample
Technalogix Ltd. VIII-12 RF IN – RF input from the combiner. RF OUT – RF output to the directional coupler.
Technalogix Ltd. VIII-13 Location and Function of Controls and Connectors (Power Supply) The following illustration depicts the location of the connectors when installing the power supply enclosure.
Technalogix Ltd. VIII-14 POWER - Tactile button to turn carriers on and off. To turn off, must be depressed for at least 2 seconds. Tied internally through DB9 connectors to all other POWER buttons. NAVIGATE - Tactile button to refresh screen after two minute screen saver times out. All monitoring and protection continues during screen saver. SELECT- Tactile button to refresh screen after two minute screen saver times out. All monitoring and protection continues during screen saver. RESET - Tactile button to reset microcontroller in control board. Also clears existing faults. Individual control board with reset comes back on with soft start feature. AC IN – AC input to switching power supply. (220 VAC) DC OUT – DC output to power amplifier enclosures. (30 Vdc)
Technalogix Ltd. VIII-15 Initial Hook Up 1. Ensure that the antenna has been swept and has a return loss of greater than 20dB (VSWR = 1.2:1). This should be done before connecting the antenna cable to the transmitter output. 2. Place the transmitter/translator in its permanent location near a receptacle supplying required AC voltage. DO NOT APPLY AC POWER AND TURN ON POWER TO THE TRANSMITTER / TRANSLATOR AT THIS TIME SINCE THE RF OUTPUT MUST BE PROPERLY LOADED BEFORE OPERATION. 3. Place an appropriate AC power line protector, conditioner, and/or surge suppressor across the AC supply line. 4. Connect the DC power connections between the power supplies and all the power amplifiers. 5. Hook up the modulator or processor as shown in their respective manuals for a transmitter or translator. Do not connect the modulated signal from the RF OUT on the modulator or processor to RF IN on the power amplifier at this time. Because of the characteristics of LDMOS devices, the RF drive should not be connected to the power amplifier until after the power supply and bias voltages are present and stable. 6. Ensure that modulator or processor RF output level is turned down as far as possible. 7. Ensure that the audio modulation is set to 100% with the audio signal supplied, as described in the appropriate modulator/processor manual (will be factory set). 8. Ensure that the video modulation level is set to 87.5% with the video signal supplied, as described in the appropriate modulator/processor manual (will be factory set). 9. Install the CAT5 cables between combiner and power amplifier enclosures 10. Hook up the RF cabling from the output of each power amplifier to the RF input on the combiner enclosure. 11. Hook up the RF cabling from the output of the combiner enclosure to the RF bandpass filter. 12. Connect the transmitting antenna cable to the RF OUT 7/16-type connector on the filter RF output.
X-1 Section X – Maintenance and Troubleshooting Periodic Maintenance If your unit employs a filter on the air inlet for the fans, the filter should be cleaned every 30 days. If the equipment is operated in a severe dust environment, the filters on the inlet fan may need to be cleaned more regularly. Turn the system off and unplug all of the AC inlet cords. The filter can be lifted off the fan and cleaned using an air compressor at low pressure. While the filter is out, clean the fan blades themselves with a small brush. The fans themselves do not need lubrication. The interior of the cabinets should be cleaned and inspected annually. Turn the system off and unplug all of the AC inlet cords. Remove the top lid by unscrewing the 6-32 machine screws. Use extreme caution when working near the AC input terminal. The power amplifier and power supply store hazardous capacitances and voltages. Using either compressed air or a brush with soft bristles, loosen accumulated dust and dirt and then vacuum the interior of the cabinet. Complete a visual inspection of the interior, making sure there are no loose connections or discolorations on any components from heat. Nothing inside the power amplifier enclosure exceeds a temperature that is not comfortable to the touch under normal operating conditions, so any signs of discoloration indicate potential damage. All modular components inside the enclosure are attached to aluminium mounting plates for easy removal and replacement. Ensure that plates are secured and the mounting hardware is tight.
X-2 Troubleshooting The first and most important aspect of troubleshooting anything is to be systematic. Note where you have looked and what you found. Look first for the obvious. • Make a physical inspection of the entire facility. Are all necessary connections properly made? Do you see any signs of obvious damage within the equipment? • Is the AC power ‘ON’ to the site and the equipment? (Check fuses and circuit breakers if necessary.) • Are all the switches in the correct operating position? • Is the input signal present? • Check LCD readings for presence of forward and reflected power and 31 V DC supply levels. The above is an aid in determining the fault if some aspect of the system is not operating. The following table deals with quality of operation: Symptom Possible Fault Correction Horizontal bars in picture (may roll either way depending on phase) AC grounding / AC interference Install EMI/RFI filter in AC line Ensure modulator/processor and power amplifier share a common ground Diagonal lines in picture Interference Install EMI/RFI filter in AC line Determine source and frequency of interfering signal (spectrum analyzer may be required)
X-3 Symptom Possible Fault Correction Weak output or picture Low level input signal Verify presence and level of input signal Low output power Verify power amplifier output with wattmeter and dummy load Incorrect modulation depth Adjust to meet specification High reflected power Incorrect load Ensure amplifier connected to transmission line Ensure correct antenna impedance (50 ohms) Check antenna tuning and VSWR. Verify correct cable for transmission line length Check all cables for visible damage (kinks, nicks or cuts) Check all connectors for poor connections, water or corrosion Check alignment of antenna Check for physical damage of antenna, including ice build-up
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