Technalogix TXV1000 TXV-1000 VHF Transmitter User Manual ContentsTAV1000

Technalogix, Ltd. TXV-1000 VHF Transmitter ContentsTAV1000

Manual-TAV1000

TAV-1000 POWER AMPLIFIER NEW ADVENTURES IN BROADCASTING Technalogix
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-1000) ........................................................................................III-3 BLOCK DIAGRAM (TAV-500)...........................................................................................III-6 BLOCK DIAGRAM (COMBINER/FILTER ENCLOSURE).......................................................III-8 SPECIFICATIONS...............................................................................................................III-9 SECTION IV - RF COMPONENTS................................................................................ IV-1 AMPLIFIER PALLETS....................................................................................................... IV-1 SPLITTER/COMBINER..................................................................................................... IV-4 CIRCULATOR/ISOLATOR ................................................................................................. IV-4 FINAL COMBINER............................................................................................................ IV-5 DIRECTIONAL COUPLER................................................................................................. IV-5 FILTER............................................................................................................................ IV-5 SECTION V - POWER SUPPLY SECTION......................................................................V-1 SECTION VI - MONITOR AND CONTROL SYSTEM....................................................... VI-1 CONTROL BOARD OVERVIEW (SERIES IIH)................................................................... VI-1 POWER SUPPLY COMPONENTS..................................................................................... VI-1 INTERFACE COMPONENTS ............................................................................................. VI-2 SIGNAL CONDITIONING COMPONENTS .......................................................................... VI-3 DISPLAY COMPONENTS ................................................................................................. VI-4 MICROCONTROLLER COMPONENTS............................................................................... VI-5 FAULT SHUTDOWN......................................................................................................... VI-6 ENCLOSURE INTERFACING............................................................................................. VI-7 REMOTE PORT............................................................................................................... VI-7 BILL OF MATERIALS....................................................................................................... VI-7 SCHEMATICS .................................................................................................................. VI-7
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-500 POWER AMPLIFIERS)..................................................................................................................VIII-7 LOCATION AND FUNCTION OF CONTROLS AND CONNECTORS (COMBINER/FILTER ENCLOSURE).................................................................................................................VIII-9 INITIAL HOOK UP.........................................................................................................VIII-11 SECTION IX - OPERATING PROCEDURES................................................................... 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-1Section 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.
II-2To 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. • 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-1Section 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-1000 power amplifier supplies a 1000-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-1000 power amplifier is a modular solid-state 1000-watt broadcast amplifier utilizing readily available RF components wherever possible, thus enhancing the serviceability of the equipment. The TAV-1000 features ultra linear amplification and individual channel RF output bandpass filtering. The amplifier modules are stable for high reliability and long service life. The amplification of the TAV-1000 is comprised of (2) TAV-500 500-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-500 Power Amplifier. Finally, the outputs of each TAV-500 are combined to generate 1000-watts of peak visual power in addition to an aural carrier, as seen in the TAV-1000 block diagram.
TO WATTMETERAND ANTENNA1U ENCLOSURE5U ENCLOSURE5U ENCLOSURE5U ENCLOSURERF OUT TAV-500COMBINERFILTERTAV-500SPLITTER2-WAYMODULATOR/PROCESSORTAV-1000 Overall Block DiagramDate: December 17, 2003 Page: 1 of 1Rev ID
III-4Inside each 500-watt power amplifier, the signal gets split into (2) signals for final amplification using a 2-way Wilkinson power divider. The final amplification stage is comprised of (2) P400-VHF-L or (2) P400-VHF-H final amplifiers, for low or high band VHF, respectively. The outputs of the (2) final amplifier pallets are combined with a 2-way Wilkinson combiner and pass through a dual directional coupler for protection and monitoring purposes, as illustrated in the following TAV-500 block diagram.
A=-0.05dB typ.A=-0.5dB typ.A=-0.08dB typ.A=-0.08dB typ.GAINCOMPENSATION ιPA1 OUTPA2 OUTA=40dB typ. low band VHFA=34dB typ. high band VHFA=18dB typ. low band VHFA=15dB typ. high band VHFA=18dB typ. low band VHFA=15dB typ. high band VHFRF INPUTRF OUT PA25-VHF DRIVERSPLITTER2-WAY P400-VHF FINALP400-VHF FINAL2-WAYCOMBINERVVDIRECTIONAL COUPLERVCIRCULATORTERMINATION50 OHMTAV-500 Block Diagram for use with TAV-1000 Power AmplifiersDate: December 17, 2003 Page: 1 of 2Rev ID
III-6After amplification, the signal exits the power amplifier enclosure and goes into the combiner/filter enclosure, where the signals from each 500-watt amplifier are combined. After combining, 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 combiner block diagram.
A=-0.6dB to -1.0dB A=-0.05dBA=-0.45dBTO WATTMETERAND ANTENNARF OUT PA2 OUT PA1 OUT 2-WAYCOMBINERVVCOUPLERDIRECTIONALU2Bandpass FilterTAV-1000 Combiner Enclosure Block DiagramDate: December 17, 2003 Page: 1 of 1Rev ID
III-8Specifications 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. All specifications below were taken with the audio/video ratio set -10dB. 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 -12 dBm 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 NTSC Video Characteristics Input Level to modulator (for 87.5% modulation) 1.0 VPP (100IRE + 40IRE sync) 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 Aural Characteristics
III-9Input 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, 30 AAC Combiner / Filter 115 VAC, 2 AAC Operating Temperature Range 0°C to 50°C Dimensions TAV-500 Power Amplifier (each) W-19" flange (17” encl.) , D-25", H-8 3/4” (5U) Combiner / Filter W-19" flange (17” encl.) , D-25", H-8 3/4” (5U)
IV-1Section IV – RF Components Amplifier Pallets The PA25-VHF pallet is a two stage ultra linear class-A linear pallet. The PA25-VHF-L has a typical gain of 40dB and the PA25-VHF-H has a typical gain of 34dB. These pallets draw no more than 3.0Adc 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 PA25-VHF 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 final amplifier stages are comprised of (2) P400-VHF-L or P400-VHF-H amplifier pallets and are each characterized with minimum gains of 18 dB (low band) or 15 dB (high band) and maximum drain currents of 28 A (low-band) or 20 A (high-band). All currents on the driver and final stages can be measured across the on-board shunt resistor (0.01-ohm) found at the DC supply inputs. With this resistance, a 1mV reading across this resistor indicates a current draw of 1.0A.
TECHNALOGIX LTD.25 W VHF HI BAND DRIVERP25-VHF-HR.S. MCDONALD14 SEPTEMBER, 2000AA11
Technalogix Ltd.400 Watt High Band VHF PalletP400-VHF-HR.S. McDonaldJuly 30, 2001BA
IV-4Power Divider/Combiner (internal to each TAV-500 enclosure) A Wilkinson power divider and combiner (identical printed circuit boards) are used to split the RF signal into, and combine the amplified RF signal out of the (2) P400-VHF final amplifier pallets. Flanged power resistors help ensure that any differences between the inputs or outputs is balanced. The Wilkinson design takes advantage of the fact that an impedance transformation can take place across a quarter-wavelength transmission line if the line has a different impedance than the source or load impedances being matched. In this case, quarter-wavelengths of 75-ohm coaxial are used to maintain 50-ohm impedances at the input and output of the Wilkinson divider/combiner. Due to its electrical and mechanical symmetry, the Wilkinson design’s performance over moderate bandwidths is superior to other types. This design maintains phase and amplitude equality, in addition to providing isolation and matched outputs. 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 250-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. Final Combiner (internal to combiner enclosure) The RF outputs from the (2) TAV-500 amplifier modules then pass into a final enclosure where the signals are combined, then filtered and monitored once again. The combiner is a 2-way, 1000-watt isolated power combiner with a maximum phase imbalance of +/-1 degree. Minimum isolation is -18 dB and maximum insertion loss is -0.45 dB from 170 to 280 MHz. Minimum return loss from ports 1 to 2 (input to input) is -25 dB and -20 dB on port 3 (output).
IV-5Directional Coupler (internal to TAV-500 and combiner enclosures) The Technalogix dual directional couplers provide DC voltages proportional to forward and reflected RF power monitoring. These analog voltages are converted for processing using a 10-bit analog-to-digital converter 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 on the displays in the power amplifier system are peak for forward and average for reflected. Output power should be set by the following procedure: THE POWER OUTPUT SHOULD NEVER BE ADJUSTED EXCEPT UNDER THE TEST CONDITIONS OF NO AURAL CARRIER, WITH THE VISUAL CARRIER MODULATED WITH SYNC AND BLANKING. The directional coupler has a typical insertion loss of 0.05dB and its Type N connectors can handle 1,500 watts peak. The coupler requires 8 to 8.5Vdc to power the internal electronics of the coupler and is supplied from the control printed circuit board at the front of each enclosure. 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.
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. There is one power supply located in each power amplifier enclosure to generate the necessary current for the amplifier pallets. These (2) supplies are set at 31.0 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. A 24Vdc nominal power supply is located in the combiner enclosure. It simply supplies power to the control PCB and the cooling fan. The power supplies in the power amplifier enclosure are Mean Well PSP-1500. The power supply found in the filter enclosure is a Mean Well S60-24. 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 each power amplifier enclosure via a filtered EMI AC entry and then through a resettable circuit breaker. The AC for the combiner enclosure (110Vac) is also fed through a filtered EMI AC entry. It is then current limited with a resettable circuit breaker before passing through a rocker switch. This switch turns the AC on and off to the switching power supply.
MEAN WELLSWITCHING POWER SUPPLYISO-9001 CERTIFIED MANUFACTURERPSP-1500SERIES.LOW COST, HIGH RELIABILITY .100% FULL LOAD BURN-IN TEST.BUILT IN EMI FILTER, CURRENT SHARING CIRCUIT .105ºC OUTPUT CAPACITOR.BUILT IN REMOTE CONTROL, REMOTE SENSE, .BUILT IN PFC CIRCUIT PFC>=0.95, POWER GOOD SIGNAL COMPLIES WITH EN61000-3-2.SHORT CIRCUIT, OVERLOAD, OVER VOLTAGE, OVER TEMP. PROTECTEDMODELSPECIFICATION PSP-1500-5PSP-1500-12 PSP-1500-13.5 PSP-1500-15 PSP-1500-24 PSP-1500-27 PSP-1500-48DC OUTPUT VOLTAGE 5V 12V 13.5V 15V 24V 27V 48VOUTPUT V. TOLERANCE ±2% ±1% ±1% ±1% ±1% ±1% ±1%OUTPUT RATED CURRENT 217.5A 112.5A 100.5A 90A 56.4A 50.4A 28.5AOUTPUT CURRENT RANGE 0-217.5A 0-112.5A 0-100.5A 0-90A 0-56.4A 0-50.4A 0-28.5ARIPPLE & NOISE 200mVp-p200mVp-p200mVp-p200mVp-p200mVp-p200mVp-p200mVp-pLINE REGULATION ±1% ±0.5% ±0.5% ±0.5% ±0.5% ±0.5% ±0.5%LOAD REGULATION ±2% ±1% ±1% ±1% ±1% ±1% ±1%DC OUTPUT POWER 1087.5W 1350W 1356.75W 1350W 1353.6W 1360.8W 1368WPEAK OUTPUT POWER 1200W 1500W 1500W 1500W 1500W 1500W 1500WEFFICIENCY 76% 82% 82% 82% 84% 84% 86%DC VOLTAGE ADJ. 4.75-5.5V 10-13.2V 12-15V 13.5-18V 20-26.4V 24-30V 41-56VINPUT VOLTAGE RANGE 90~264VAC 47~63Hz; 127~370VDCAC CURRENT 10.5A/230VPOWER FACTOR 0.95/230VACINRUSH CURRENT 100A/230VLEAKAGE CURRENT <3.5mA/240VACOVERLOAD PROTECTION 115%~140% TYPE:CONSTANT CURRENT LIMITING RESET:AUTO RECOVERYOVER VOLTAGE PROTECTION 5.75~6.75 13.8~16.2V 15.5~18.2V 18~21V 27.6~32.4V 31~36.5V 57.6~67.2VOVER TEMP.PROTECTION RTH2>=95ºC OUTPUT SHUTDOWNREMOTE CONTROL RC+/RC-: 0~0.8V=POWER ON; 4~10V=POWER OFF SINK CURRENT 4~10mATEMP. COEFFICIENT ±0.03% / ºC (0~50ºC) SETUP, RISE, HOLD UP TIME 1.5s, 50ms, 15msVIBRATION 10~500Hz, 2G 10min./1cycle, PERIOD FOR 60min. EACH AXESWITHSTAND VOLTAGE I/P-O/P:3KVAC I/P-FG:1.5KVAC O/P-FG:0.5KVACISOLATION RESISTANCE I/P-O/P, I/P-FG, O/P-FG:500VDC / 100M OhmsWORKING TEMP., HUMIDITY -10ºC~+60ºC(REFER TO OUTPUT DERATING CURVE), 20%~90% RH STORAGE TEMP., HUMIDITY -20ºC~+85ºC, 10%~95% RHDIMENSION 278*129*190.5mmWEIGHT 6.9 KgsSAFETY STANDARDS MEET UL1950EMC STANDARDS MEET CISPR22, EN61000-3-2, EN61000-4-2,3,4,5,6,8,11NOTE : 1.ALL PARAMETERS ARE SPECIFIED AT 230VAC INPUT, RATED LOAD, 25ºC 70% RH. AMBIENT.2.TOLERANCE GINCLUDE SET UP TOLERANCE, LINE REGULATION, LOAD REGULATION.3.RIPPLE & NOISE ARE MEASURED AT 20MHz BY USING A 12" TWISTED PAIR TERMINATED WITH A 0.1uF & 47uF CAPACITOR.4.LINE REGULATION IS MEASURED FROM LOW LINE TO HIGH LINE AT RATED LOAD.5.LOAD REGULATION IS MEASURED FROM 0% TO 100% RATED LOAD.6.REFER TO OUTPUT DERATING CURVE VS INPUT VOLTAGE.7.PEAK OUTPUT POWER LASTING <30 SECONDS WITH A MAX. 10% DUTY CYCLE. 2002-01-28
VI-1Section VI – Monitor and Control System Control Board Overview (Series IIH) The control printed circuit boards (PCB) are located at the front of each enclosure connected directly to the back of the liquid crystal displays (LCD) and are identified as Series IIH PCBs. The main purpose of the Series IIH PCB is to monitor the RF power and the DC supply voltages in the power amplifier and filter enclosures and to monitor the DC supply voltages in the power supply enclosure. In all cases, a DC voltage proportional to the parameter being sampled is conditioned, protected, buffered, and then run into an analog-to-digital converter (ADC) where software processes the signal. The software processing determines if the parameters are within the predetermined safe operating levels and displays the parameters on the LCD for monitoring purposes. The Series IIH PCB can be broken apart into (5) main component areas: the power supply, interface, signal processing, display, and microcontroller. Schematics are found later in this section. Power Supply Components There are (4) power supply voltages generated on the Series IIH PCB: 1. +5Vdc for all logic and general purpose PCB supply voltage. 2. +4Vdc for the LED backlighting on the LCD 3. -4Vdc for the contrast voltage required by the LCD 4. +8Vdc for the directional coupler supply The +5Vdc is generated from a small switching power supply comprised of C1, C2, D2, L1, and U1. This power supply accepts DC input voltages up to 40Vdc and outputs +5Vdc at 1Adc. This voltage is always on, as the ON/OFF pin on U1 is hard-wired to the ‘on’ configuration. The +4Vdc is generated from a small switching power supply comprised of components C3, C4, D3, L2, and U2. This power supply accepts DC input voltages up to 40Vdc and outputs +5Vdc at 1Adc. The voltage is then dropped to +4Vdc through R1. This backlight voltage can be turned on and off via the ON/OFF pin on U2. The PCB is setup in a manner that allows this voltage to be hard-wired ‘on’ all the time or controlled from the microcontroller through latch U11. This selection is made with jumper J2. The -4Vdc is generated using a switched capacitor voltage converter design, using components C6, C7, R2, R3, U4, and VR1. U4 accepts +5Vdc from the general purpose +5Vdc supply and generates -4Vdc. This voltage is then dropped across the voltage divider (R2, R3) to generate the contrast voltage specific to the LCD in the system. The +8Vdc required by the directional coupler is generated with a standard linear voltage regulator, U3. C5 cleans up any ripple or noise that might be on the output voltage.
VI-2Interface Components The interface section of the Series IIH PCB includes the front panel switch interfacing in addition to the buzzer and carrier disable output circuits. The (4) momentary switches found on the front panels of each enclosure are tied to the microcontroller through an isolation stage to avoid any static discharge or noise on the switch wiring from reaching the microcontroller. Optoisolators U5 and U6, in addition to R4…R15 create the necessary isolation for the sensitive microcontroller. By depressing any momentary switch, a ground (0V) is applied to the input of the optoisolators. The optoisolators will, in turn, output a ground (0V) to the microcontroller. The membrane tactile switches found on the front panels of the enclosures operate in the following manner with a depress: POWER – When unit is plugged in, AC is supplied to the fan and switching power supply input, but the amplifiers are still turned off. In order to turn the amplifiers on, wait ten seconds after plugging the PA in and push in the “POWER” tactile button. The LCD will read “Soft Start Warm Up, Please Wait”. After ten seconds the bias voltages will be turned on and you may then plug in the RF drive. Depress for (1) second to turn on and (3) seconds to turn system off. In the case of multiple enclosures, all POWER switches are tied together in each enclosure, so only one needs to be depressed. NAVIGATE – Turns on backlight to LCD and displays forward and reflected RF power and DC supply voltage parameters. When power amplifier is first turned on, the LCD comes on automatically and this information is displayed. Information is displayed for approximately 2 minutes before the backlight turns off and the display is cleared. This is set up so as not to burn any pixels into the LCD from extended on time. In the case of multiple enclosures, the NAVIGATE switches are individual to each enclosure. SELECT – Turns on backlight to LCD and displays forward and reflected RF power and DC supply voltage parameters. When power amplifier is first turned on, the LCD comes on automatically and this information is displayed. Information is displayed for approximately 2 minutes before the backlight turns off and the display is cleared. This is set up so as not to burn any pixels into the LCD from extended on time. In the case of multiple enclosures, the SELECT switches are individual to each enclosure. RESET – Tactile pushbutton resets the monitor and control system. The amplifier gets shut down for under 0.5 seconds and comes back on with each depress of the reset button. At the same time, all fault counters in the microcontroller software are reset and the LCD is reset in the same manner as it is with a depress of the NAVIGATE button. Reset switches are individual to each enclosure but may be tied together externally through the remote port, as explained later in this section.
VI-3 The buzzer control comes from pin 5 on microcontroller U14. The control signal turns on the base of transistor Q1, which allows current to flow through the single tone magnetic buzzer. Jumper J4 simply turns off the buzzer. The carrier disable circuit simply applies a shutdown voltage to the driver pallet in the system. The U14 generates the signal out of pin 21 and controls relay Q2 through R17. When Q2 is turned off, the shutdown voltage to the driver is floating and the carrier is on. During a fault condition, when Q2 is turned on, the shutdown voltage is applied to the carrier disable on the driver.
VI-4Signal Conditioning Components The signal processing section of the Series IIH PCBs is used to buffer potentially noisy or damaging signals from the ADC. Power supply voltages and forward and reflected power samples from a directional coupler are then digitized. Firstly, all analog signals are protected with a resettable fuse and transient voltage suppressor (TVS) combination. These components ensure that voltages above the Vbr breakdown voltage of the TVS get clamped and do not pass farther down the circuit. After this protection stage, the analog voltages are dropped with voltage dividers to safe levels for the buffers and ADC. For example, a 28Vdc power supply sample is dropped to a level below the +5Vdc supply voltage of the ADC. After the voltage dividers, the analog signals are buffered with U7 and U8, configured as unity gain voltage followers. Finally, after some further decoupling capacitors and filters, the analog signals get digitized by the 8-channel, 10-bit ADC (U10) and sent to the microcontroller through a serial interface. In the power amplifier and filter enclosures, there are (3) analog voltages that are conditioned and processed: DC power supply sample, forward RF power, and reflected RF power. Specifically, the components for the power amplifier and filter enclosure conditioning are as follows: DC power supply sample – J7 (pin8), F9, D11, R32, R33, U8, C33, C34, C35, and U10. Forward RF power – J7 (pin7), F8, D10, R30, R31, U8, C29, C30, C31, and U10. Reflected RF power – J7 (pin6), F7, D9, R28, R29, U8, C26, C27, C28, AND U10. In the power supply enclosure, there are (2) power supplies paralleled together. Hence, only (1) analog voltage is conditioned and processed for the LCD. Specifically, the components for the power supply sample are as follows: DC power supply sample- J7 (pin8), F9, D11, R32, R33, U8, C33, C34, C35, and U10.
VI-5Display Components The display section of the Series IIH PCB is comprised of the LCD and the components that make up the data bus which send the data from the microcontroller to the LCD. Specifically, the LCD is an alphanumeric 20X4 display that uses the industry standard 44780 controller and a parallel interface for data communications. The microcontroller sends out the data to be displayed via a serial bus, where the signals are latched with U11 and U12 and converted to a parallel data stream. The parallel data then transfers directly to the LCD through connector J8. J8 also carriers the power supply for the LCD.
VI-6Microcontroller Components The heart of the monitor and control system found in Series IIH PCBs is microcontroller U14. This microcontroller analyzes all RF power levels and voltages to ensure that all operating parameters are within their predetermined safe operating levels. If a fault is found, appropriate action is taken to help protect the system from damage, which may include turning the RF carriers off. A full description of all faults and their respective actions is found later in this section. The power supply for the microcontroller is monitored closely via supervisor U13. Should the +5Vdc supply drop below +4.5Vdc, a microcontroller reset is generated to ensure there are no brown out conditions that may latch up the microcontroller up to an unknown state. The front panel Reset momentary switch is also tied to this line after optoisolation. The microcontroller’s clock source (4.000MHz) is generated by ceramic resonator CR1. If the software is running, LED D12 will be lit. Finally, U15 stores all characters for the LCD to minimize the overhead required for the microcontroller, and also stores the current state of the power ON/OFF of the system. This ensures that, in the event of a power outage, the system returns to the exact state is was before power was interrupted.
VI-7Fault Shutdowns On the LCD (Liquid Crystal Display) the following messages may appear: If you see this message, the system will: - shut amp down for 1 minute - automatically turn amp on after 1 minute and check again for overdriven amplifier - come back to the same power level that it was set If you see this message, the system will: - shut amp down for 5 minutes - automatically turn amp on after 5 minutes and check again for high VSWR - come back to the same power level that it was set
VI-8 Enclosure Interfacing In the event of a fault in the combiner/filter enclosure, for example high reflected power or overdriven output levels, the power amplifier enclosures need to know that there is a fault. A DB9 cable accomplishes this by sending a fault signal from the combiner/filter enclosure to indicate to the power amplifier enclosure that action may need to be taken. Specifically, the shutdown circuitry on the combiner/filter enclosure’s control PCB sends a ground signal through the DB9 to one of the optoisolated inputs on the power amplifier’s control PCB. The power amplifier control PCB, in turn, then sends its shutdown voltage out to disable the driver and turn off the carrier. Remote Port The remote port allows external control of the transmission system via the DB25 connector on each enclosure. All functions on the remote port are simply hard-wired or paralleled to existing wiring to provide a secondary method of control to the user, and are activated as follows: 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
Series II - Bill of MaterialsH20-Aug-04Item Qty Components Description Tolerance Package Equivalency1 1 BZ1 BUZZER, magnetic, 5V, single tone Through holeChallenge Electronics TDB05; Global Components TDB05, Tranducers USA TRIE-1205P2 2C1 (solder side), C5 (solder side) CAPACITOR, electrolytic, 100uF, 63V <=20% SMT (Panasonic VS "G" size)Panasonic ECE-V1JA101P, NIC NACEW101M63V10x10.53 2C2 (electrolytic), C6 (solder side) CAPACITOR, electrolytic, 330uF, 35V <=20% SMT (Panasonic VS "G" size)Panasonic ECE-V1VA331P, NIC NACEW331M35V10x10.54 22C1 (0805 comp. side), C2 (0805 near U8), C3 (0805 PSU filter), C4 (0805 near buzzer), C4 (0805 RFL I/P), C5 (0805 comp. side), C6 (comp. side), C7 (0805 near FWD I/P), C8 (0805 near U8), C9 (solder side), C10 (solder side), C11, C12, C13, C14, C15, C16, C17, C18 (0805 beside uPC), C19, C20, C21 CAPACITOR, ceramic, 0.01uF, 63V <=20% SMT 08055 7C7 (1206 near pow. conn.), C10 (1206 solder side), C45, C46, C47, C48, C49 CAPACITOR, ceramic, 0.1uF, 25V <=20% SMT 1206 Utech GMC31X7R104K50NT6 2C8 (electrolytic), C9 (electrolytic comp. side) CAPACITOR, electrolytic, 100uF, 25V <=20% SMT (Panasonic VS "E" size) Panasonic ECE-V1EA101UP7 2C15, C18 (1210 tantalum) CAPACITOR, tantalum, 1uF, 16V <=20% SMT 3216 KOA TMC1CA105KLRH8 5C25, C28, C31, C34, C3 (electrolytic) CAPACITOR, electrolytic, 1uF, 16V <=20% Through hole, radial, 5mm diameterNichicon LB/VX/USA/SA; Panasonic KA/KS/SU; Sprague 501D/513D9 1 CR1CLOCK, ceramic resonator, 4.000 MHz, w/capsf <= 0.5% C <= 20% Through hole, 3-position, 0.1" spacing ECS Inc. ZTT-4.00MG10 1 D1DIODE, TVS, 600 watts, Vwm=30V, Vbr min=33.3 (for TV power amplifier) SMB Crydom SMBJ30A; GI SMBJ30A11 1 D1DIODE, TVS, 600 watts, Vwm=48V, Vbr min=53.3 (for FM power amplifier) SMB Crydom SMBJ48A; GI SMBJ48A12 2D2,D3DIODE, schottky, If=3A, Vr=60V SMC International Rectifier 30BQ06013 1 D4 DIODE, rectifier, If=1A, Vr=400V DO-41Micro Commercial 1N4004, ON Semiconductor 1N4004RL, General Semiconductor 1N400414 2 D9, D10DIODE, TVS, 600 watts, Vwm=5.0V, Vbr min=6.4 SMB Crydom SMBJ5.0A; GI SMBJ5.0A15 1D12DIODE, LED, RED, clear or diffused SMT 1206 Lumex SML-LX1206IW16 1 F1FUSE, resettable, Ihold=0.75A, Itrip=1.5A, Vmax=72V 0.23" lead spacing, 20AWG leads Raychem RXE075; Bourns MF-R07517 3 F6, F7, F8FUSE, resettable, Ihold=0.14A, Itrip=0.34A, Vmax=60V miniSMD Raychem miniSMDC014-218 1 J1CONNECTOR, 4-position plug, 180 degree wire entry, 90 degree screw access, 5.08mm -Wieland 25.340.3453, Weco 10.808.10419 1 J1CONNECTOR, 4-position header, pluggable, vertical, closed, 5.08mm Through hole, 0.2" spacing Wieland 25.350.3453, Weco 20.806.12820 3 J2, J5, J6CONNECTOR, breakaway header strip, 3- and 2-position required Through hole, 0.1" spacing Molex 22-28-4300; Samtec TSW-130-05-T-S21 3J2, J5, J6CONNECTOR, 2-position post shunts0.1" spacingAMP 382811-6; Samtec SNT-100-BK-T22 1 J3CONNECTOR, 5-position plug, 90 degree wire entry, 180 degree screw access, 5.08mm -Wieland 25.346.355323 1 J3CONNECTOR, 5-position header, pluggable, rt. angle, closed, 5.08mm Through hole, 0.2" spacing Wieland 25.352.3553, Weco 10.806.12924 1 J4CONNECTOR, 5-position, header, 0.1" spacing, 0.025" square post Through hole, 0.1" spacing (SIP5)25 2 J7, J8CONNECTOR, 3-position plug, 180 degree wire entry, 90 degree screw access, 5.08mm -Wieland 25.340.3353, Weco 10.808.10326 2 J7, J8CONNECTOR, 3-position header, pluggable, vertical, closed, 5.08mm Through hole, 0.2" spacing Wieland 25.350.3353, Weco 20.806.12727 1J9CONNECTOR, terminal strip, 16-position Through hole, 0.1" spacing Samtec TSW-116-18-T-S28 1J9CONNECTOR, socket strip, 16-position Through hole, 0.1" spacing Samtec SSW-116-03-T-S29 1 L1INDUCTOR, 680uH, Irms=0.4A, DCR=2.02 ohms SMT JW Miller 3316-681M30 11L2, L4, L5, L6, L7, L8, L9, L10, L11, L12, L13INDUCTOR, 0.01uH, Imax=0.45A, DCR=0.13 omhs +/- 10% SMT 1210 KOA KL32TE010K31 1 L3INDUCTOR, 680uH, Irms=1.3A, DCR=0.2 ohms SMT (Talema S5) Talema SWS-0.85-68032 1 LCD120 X 4 character liquid crystal display, LED backlit 4-40 pem mount (4) Varitronix 20464K33 1 PCB1Series II, revision H printed circuit board, soldermask, silkscreen, FR4 Alberta Printed Circuits, MPC, GRM, Enigma, …34 2 Q1, Q2 TRANSISTOR, NPN, Ic=1A, Vce=40V SMT SOT-23Fairchild MMBT2222A; Zetex FMMT2222A; Diodes Inc MMBT2222A-735 1 R1 RESISTOR, 4.7 ohm, 1/4 watt, carbon film 5% Through hole, axial 0.4 Yageo CRF-25JB-4R736 1 R2RESISTOR, 15.0 ohm, 1/10 watt, thick film 1% SMD 0805 Panasonic ERJ-6ENF15R0V37 1 R3RESISTOR, 75.0 ohm, 1/10 watt, thick film 1% SMD 0805 Panasonic ERJ-6ENF75R0V38 12R4, R5, R6, R7, R10, R11, R12, R13, R16, R32, R34, R36RESISTOR, 1.00 kohm, 1/10 watt, thick film 1% SMD 0805 Panasonic ERJ-6ENF1001V39 4 R8, R9, R14, R15RESISTOR, 10.0 kohm, 1/10 watt, thick film 1% SMD 0805 Panasonic ERJ-6ENF1002Vrevision:date:Optional part depending on power level of TV or FM
Series II - Bill of MaterialsH20-Aug-0440 1 R17RESISTOR, 4.99 kohm, 1/10 watt, thick film 1% SMD 0805 Panasonic ERJ-6ENF4991V41 1 R26 (next to VR2)RESISTOR, 2.7 KOHM, 1/10 watt, thick film 1% SMD 080542 1 R26 (next to VR2)RESISTOR, 680 OHM, 1/10 watt, thick film 1% SMD 080544 1 R31RESISTOR, 37.4 kohm, 1/10 watt, thick film (for TV PA >= 250W) 1% SMD 0805 Panasonic ERJ-6ENF3742V45 1 R31RESISTOR, 15 kohm, 1/10 watt, thick film (for FM amplifier) 1% SMD 0805 Panasonic ERJ-6ENF4991V46 2 R28, R30RESISTOR, 121 kohm, 1/10 watt, thick film 1% SMD 0805 Panasonic ERJ-6ENF1213V47 1R33RES, 120 ohm, 1/10 watt, thick film 1% SMD 0805 Panasonic ERJ-6ENF1200V48 1 RLY1RELAY, SPDT, 5Vdc contact, 5A@30Vdc/10A@125Vac contact Aromat JS1-5V; P&B T7CS5D-0549 1 U1REGULATOR, switching, 5Vdc, 3A, fosc=52kHz SMD TO-263-5 National LM2576HVS-5.050 1 U2REGULATOR, switching, 5Vdc, 1A, fosc=150kHz Through hole TO-220-5 National LM2595T-5.051 1U3REGULATOR, linear, 8V, 1A Through hole TO-220 7808CT52 1 U4 REGULATOR, inverter, 100mA SMD SOIC-8National LM2660M; Analog Devices ADM8660, Maxxim MAX66053 2 U5, U6OPTOISOLATOR, dual, Viso=2500V, Vce=30V Through hole, DIP-8 Fairchild MCT654 1U8OP AMP, quad, low voltageSMD SOIC-14 National LMV324M56 1 U9REFERENCE, 2.50V (for TV PA >= 250Wpk) +/-0.2% SMD SOT-23 National LM4040BIM3-2.557 1U10ADC, 10-bit, 10-channelSMD SOIC-16 Analog Devices AD7812YR58 2 U11, U12 LOGIC, 8-bit shift register with latches SMD SOIC-14Fairchild MM74HC595M; On Semi MC74HC595AD; Phillips 74HC595D59 1 U13SUPERVISOR, n-channel, open drain, internal pullup resistor SMD SOT-23 MCP130T-450I60 1 U14MICROCONTROLLER, OTP, 4k, 22 I/O lines Through hole DIP-28 Microchip PIC16C63A-04/SP61 1U15MEMORY, 8k X 8, EEPROM, SPISMD SOIC-8Microchip 25LC640I/SN623VR2, VR3, VR4RES, variable, 2 kohm, 11 turndate:revision: Optional part depending on power level of TV or FM
SOLDER SIDESOLDER SIDECOMPONENT SIDEBK LTCTRLSELECT1SERIES II, REV. H - Control SystemSOLDER SIDEVin CondNEAR BUZZERC40805 CHIPC14L5VR1+ELECTROLYTICC8+ELECTROLYTICC9P1P2P3P4P5P6P7P8U4BkLtCtrlGND +8V OUT GND Vin L1D2+ELECTROLYTICC1D1F13J1 1Vin2Vout4Feedbk3Gnd5On/OffU1+ELECTROLYTICC2+5Vdc 4J1+ELECTROLYTICC5+ELECTROLYTICC62Vin1Vout4Feedbk3Gnd5On/OffU2D3COMPONENT SIDEL3Pin15LCDINCOMOUTU3NEAR POW. CONN.C71206 CHIP1J1J12+5Vdc Pin3LCD J2R3R2R1A. SivacoeSERIES II: Control SystemH Power Supply SectionDate: May 14, 2004 Page: 1 of 1Rev ID
SERIES II, REV. H - Control System2BuzzerdeleteD4J4 3J4 5SEL In J4 4J4 2NAV In J4 1+5VdcJ6J3 5Ground J3 3J3 4J3 2+5Vdc+5VdcR4R17J72Q2Rly.Ctrl+5VdcRLY1Rly. COMRly. N/ORly. N/CJ73J71Buzzer J5Q1+5VdcR16RES In NC(RC6) VW In PWR In J3 1P1P2P3P4 P5P6P7P8U6P1P2P3P4 P5P6P7P8U5R5 R6R7+5VdcR8 R9VW uPC PWR uPC R13R10 R11 R12+5VdcR14 R15PIN17uPCRES uPC BZ1A. SivacoeSERIES II: Control SystemH Interface SectionDate: March 5, 2004 Page: 1 of 1Rev ID
SIDE3For U7SERIES II, REV. H - Control SystemPSUFWDRFLLow Threshold AdjustNEARSIDEuPCVR4VR3C3L2C19SOLDER SIDEC90805 CHIPSOLDER SIDEC100805 CHIPL1Vin Cond+TANTALUMC181210+C15FWD I/PC70805COMP.C50805L6L4COMP.C60805RFL I/PC40805VR2564117+U82/4324111+U81/41094118+U83/4121341114+U84/4J81Analog 1J8 2Analog 2J8 3Analog 3Isoltd 4Isoltd 3Isoltd 2Isoltd 1BESIDEC180805F8F7F6D9D10D11C13+5VL11D8D7D6F3F4F5SOLDER SIDEC101206 CHIPIsoltd 5Isoltd 6Isoltd 7Isoltd 8121341114+U74/4J88Analog 8D5F2Analog 7 J87Analog 6 J86Analog 5 J859104118+U73/4324111+U71/4564117+U72/4R26R32R31R30R29R28R27R19R18R20R21R22R23R24R25A. SivacoeSeries II: Control SystemH Analog Input SectionDate: May 14, 2004 Page: 1 of 2Rev ID
SERIES II, REV. H - Control System4Pin 3 on U9 is left unconnected on PCBFor U10FWDPSURFLLow ThreshC20L8C15L9NEAR U8C80805 SOLDER SIDEL31210 CHIPC11L7C17COMP. SIDEC10805 CHIPL102 1U9+5VdcC45+C42C41+C40C39+C38C37+C36C35+C34C21+C31C16+C28NEAR U8C20805C12+C25DtoUPC DfromUPCDclk ConvStrtIsoltd 1Isoltd 2Isoltd 3Isoltd 4Isoltd 5Isoltd 6Isoltd 7Isoltd 8VrefCrefVin1AGNDVin2Vin3Vin4Vin5Vin6Vin7 Vin8A0DGNDTFSRFSDoutDinDclkConvStartVddU10R33A. SivacoeSeries II: Control SystemH Analog Conversion SectionDate: May 14, 2004 Page: 1 of 1Rev ID
SERIES II, REV. H - Control System5U11: LCD control signals, LCD backlight control, and External interface outputsU12: LCD data bus (D0...D7) D0...D7 is text or instructionserial_outresetshift_clklatch_clkoutput_enserial_inQa(out_1)Vcc Qb(out_2)Qc(out_3)Qd(out_4)Qe(out_5)Qf(out_6)Qg(out_7)Qh(out_7)GNDU11J105J914DfromUPCDclk LCD D7 LCD D0 LCD D1 LCD D2 LCD D3 LCD D4 LCD D5 LCD D6 LCD E LCD R/*WLCD RS J913 J912 J911 J910 J99J98J97J94J95J96LCD Vss LCD Vdd LCD Vo J91J92J93LED K LED A J915 J916Unbuf D Unbuf C Unbuf B Unbuf A J104J103J102Pin15LCDBkLtCtrlC46+5VdcLatch1CSLatch2CSserial_outresetshift_clklatch_clkoutput_enserial_inQa(out_1)Vcc Qb(out_2)Qc(out_3)Qd(out_4)Qe(out_5)Qf(out_6)Qg(out_7)Qh(out_7)GNDU12Ext. PSUJ101Q3 uPCPIN14Pin3LCD R34R35A. SivacoeSeries II: Control SystemH LCD SectionDate: March 8, 2004 Page: 1 of 1Rev ID
6SERIES II, REV. H - Control System+C50C47D12Dclk DtoUPC Dig.In 3Dig.In 2Dig.In 1C49Buzzer Latch2CSLatch1CSDfromUPCRly.CtrlReset Dig.Out2CONVST Dig.Out1VccC48+5VdcMCLR/VppRA0RA1RA2RA3RA4RA5VssOSC1/CLKinOSC2/CLKoutRC0/T1CKIRC1/CCP2RC2/CCP1RC3/SCK/CLRC4/SDI/SDARC5/SD0RC6/TX/CKRC7/RX/CKVssVddRB0/INTRB1RB2RB3RB4RB5RB6RB7U14*CSSO*WPVss SISCK*HOLDVccU15VccGNDResetU13OSC1OSC2GNDCR1R36A. SivacoeSeries II: Control SystemH Microcontroller SectionDate: March 8, 2004 Page: 1 of 1Rev ID
VII-1Section 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 500-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-1Section 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-2Heating and Cooling Requirements The environment’s temperature will contribute greatly to the length of the power amplifier’s life. Refer to the specifications in Section 3.0 for humidity and temperature specifications. 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-1000 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-3Electrical 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-4Antenna 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 1000-watt unit will only deliver 500 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-5Shelter 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-6Unpacking 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-7Location and Function of Controls and Connectors (TAV-500 Power Amplifier) The following illustration depicts the location of the connectors when installing each of the 500-watt power amplifiers (TAV-500).
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 ON/OFF 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 - Momentary pushbutton 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 – 500-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. PA CTRL – Control signals communicating with the combiner enclosure. Connects with the PA 1 and PA 2 CTRL connector on the combiner. DB9 connector (see Amplifier Monitoring section for pinout description). 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 AC IN – AC input to switching power supply. Switching power supply draws a maximum of 8 AAC at 220 VAC
Technalogix Ltd. VIII-9Location and Function of Controls and Connectors (Combiner / Filter Enclosure) The following illustration depicts the location of the connectors when installing each of the 500-watt power amplifiers (TAV-500).
Technalogix Ltd. VIII-10 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. PA1 and PA2 RF IN – RF input from the output of each power amplifier. N connector, 50 Ω. RF OUT – 1,000-watt RF output to be connected with inline wattmeter and then to antenna. N connector, 50 Ω. PA CTRL – Control signals communicating from the combiner enclosure to the power amplifier enclosures. Connects with the PA 1 and PA 2 CTRL connector on the power amplifier. DB9 connector (see Amplifier Monitoring section for pinout description). 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 AC IN – AC input to switching power supply. Switching power supply draws a maximum of 2 AAC at 110 VAC.
Technalogix Ltd. VIII-11Initial 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. 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. 5. Ensure that modulator or processor RF output level is turned down as far as possible. 6. 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). 7. 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). 8. Install the DB9 cables from each power amplifier enclosure to the combiner/filter enclosure. It does not matter which DB9 cable is used as they are both identical. 9. Install the RF cables between the power amplifiers and the combiner/filter enclosure. The cable labelled PA1 goes between PA1 and the PA1 input on the combiner/filter enclosure and the cable labelled PA2 goes between PA2 and the PA2 input on the combiner/filter enclosure. These cables are phase matched and must be hooked up on their respective power amplifiers. 10. There is no PSU external to PA’s. 11. Connect the transmitting antenna cable to the RF OUT N-type connector on the filter enclosure RF output.
IX-1 Section IX - Operating Procedure Assuming the previous installation instructions have been completed and cautions noted, and the TAV-1000 power amplifier is ready to receive a properly modulated video and audio signal, proceed with the following steps to place the system in operation. The TAV-1000 power amplifier has been factory aligned for channel frequency (per system specification), signal levels and optimum performance. 1. Do not apply RF drive signal to the power amplifier at this time. 2. Verify that all control and RF cables are tight and properly seated in or on the mating connector. 3. Plug the modulator or processor into AC mains (110Vac). 4. Plug the 5U combiner/filter enclosure into AC mains (110Vac). 5. On the combiner/filter enclosure switch AC rocker switch to “ON” position. 6. Verify that the combiner enclosure’s fan is on. 7. Plug the 5U power amplifier enclosures into 220V AC mains. 8. On the power amplifier, simultaneously switch the AC rocker switches to “on” position. 9. Verify that the power amplifier fans are all on. 10. Ensure that the modulator/processor is turned on and set up according to its instructions. Depress the POWER tactile button to turn the unit on. 11. The internal soft start circuitry will turn the bias voltages off until the power supply to the amplifier pallets is fully stable. The message on the LCD indicates when the soft start is running. Once complete, the Forward and Reflected Power and Power Supply readings will appear on the LCD in the filter and power amplifier enclosures. 12. After the soft start is complete, apply the RF drive signal (which still should be turned down) between the modulator or processor and the power amplifier RF In. This ensures that the RF drive signal is applied only after the power supply is stable and the bias voltages are applied to the amplifier.
IX-2 13. The TAV-1000 LCDs show the user the present status of the amplifiers. Adjust RF output power to desired level (see Important RF Power Notice in previous section). Verify that the FWD Power reads 800 to 1,000 Watts on the combiner/filter enclosure - depending on signal content. The system is set up for 1,000 watts peak visual power using the sync and blanking signal and should read 1,000 watts FWD Power on the LCD under this condition only. The output power level can be adjusted using the modulator or processor’s RF output level adjust. Keep in mind that the system will shut down should the forward RF output power level be exceeded. 14. Ideally, the RFL Power should read zero. However, should a high VSWR be detected, the system will automatically shut down and cycle as previously described. This is also a peak wattage reading. 15. Verify that the power supply reads approximately 30 Volts DC (see supplied final inspection sheet for factory settings of power supply levels) on the LCD of the power amplifier and power supply enclosures and 24Vdc on the combiner/filter enclosure. 16. Look at the transmitted output using a suitable monitor. The picture and sound quality should be clean and sharp. If the output picture and sound quality is unsatisfactory, check the input signals, connections to the antenna system, antenna and transmission line VSWR, and the physical condition of the antenna. If reception problems are encountered, and the quality of transmission is satisfactory, the difficulty is often with the receiving antenna or with obstructions in the path between the transmitter/translator and receiver.
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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