Elettronika S r l TXUP1000 1000 Watt Analog TV Broadcast Transmitter User Manual APT148B AUTV 1000LD Rev0 Date040305p65 p65

Elettronika S.r.l. 1000 Watt Analog TV Broadcast Transmitter APT148B AUTV 1000LD Rev0 Date040305p65 p65

Amplifier User Manual Part 2

31_______________________________________________________________________________________________Section 4 - DiagramContents:- Cable diagram- MTF0077AR0 Amplifier module - Component list- SCH0192AR0 (200W UHF LDMOS Amplifier module)- SCH0223AR1 (Control board and display)- SCH0259AR0 (RF Amplifier interface)- SCH0265AR0 (Mains distribution board)- SCH0288AR1 (Interface board)- E0012 (SP500-27-DE2 Switching power supply)
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33Part Name Code Description Qty Page 1/200441 TERMINAZIONE 50W 500W 32-1123-50-5 101400 C. PAS. 2499-003-X5U0-102M 1102402 7/16 FEMMINA ANIM. FILET. cod. 0142 1SCH0192AR0 SCHEDA AMPLIFIC. 200W UHF LDMOS PHILIPS 700424 TERMINAZIONE 50W 250W 32-1037-50-5 603207 DIODO HSMS-2802*L31 300028A 82W RESISTENZA SMD 1/4W 301041D 1nF COND, SMD 1206 2% 308527 CAVO HF-85 ENDIFORM 0,4008502 CAVO RG316 50W1,70CAV092 CAVO RG179 75W DA 10cm 8DET0732 DET0732R1 PIASTRINA SUPPORTO CONNESSIONI 1DET0959 DET0959R0 SPESSORE x PN1120A 102520 GE 65125 D/22 SMA A VIT. RG174/c 102512 J01151A0531 PRESA SMA SEN. BAT 1DET0868 DET0868R0 SPESS. ACC. DIR. ING. 1000W UHF 1PN1083A C.S. PN1083AR2 ACCOPPIATORE INGRES. 1500W 1PN1091A C.S. PN1091AR3 ACCOP. DIREZ. OUT 1500W UHF 1DET0839 DET0839R2 ACCOPPIATORE DIREZIONALE 1DET0810 DET0810R0 PART. x ACCOPPIATORE DIREZIONALE 100029D 100W RESISTENZA SMD 1206 1% 100221B 75W RESISTENZA SMD 1206 1% 201408 C. PAS. 5000PF 2DET0811 DET0811R1 CHIUS. x ACCOP. DIREZIONALE 1DET0812 DET0812R1 ANELLO IN TEFLON x ACCOP. DIR. 100001 0W REISTENZA SMD 1206 2PN1077A C.S. PN1077AR2 COMBINATORE 6VIE 1kW UHF 1PN1120A C.S. PN1120AR1 COMBINATORE 2VIE 1kW UHF 1PN1118A C.S. PN1118AR1 DIVISORE 2VIE 1kW UHF 1PN1066A C.S. PN1066AR3 DIVIS. 3VIE UHF 1kW DESTRO 1PN1080A C.S. PN1080AR2 DIVIS. 3VIE 1kW UHF SINIST. 1DET0960 DET0960R0 SPESSORE x PN1077A 1DET0961 DET0961R0 CHIUSURA MODULO RF 1kW UHF 100383 RESISTENZA SMD 1W 2512 100R 224/0272 1200395 560W RESISTENZA SMD 1W 224-0373 200399 220W RESISTENZA SMD 1W 224-0317 200403 270W RESISTENZA SMD 1W 2512 1% 12DET0901 DET0901R0 DISSIPATORE 1kW UHF 6 MOD. 1DET0902 DET0902R0 SPONDINA ANT. 1kW UHF 6 MOD. 1DET0903 DET0903R0 SPONDINA POST. 1kW UHF 6 MOD. 1DET0803 DET0803R1 SPOND. LATERALE 1kW IIIBd 1DET0905 DET0905R0 SPONDINA CENTR. 1kW UHF 6 MOD. 1DET0906 DET0906R0 SPONDINA LATER. SX 1kW UHF 6 MOD. 1DET0907 DET0907R0 SPONDINA PILOTA 1kW UHF 6 MOD. 1DET0908 DET0908R0 SPOND. WILKINSON 1kW UHF 6 MOD. 2Component list MTF0077AR0 Amplifier module
34Part Name Code Description Qty Page 2/208503A CABLE RG302 75W0,2008521 CAVO RG179 BU 75W0,54DET0904 DET0904R0 SPONDINA LAT. DX 1kW UHF 6 MOD. 1
35Part Name Code Description QtyAPT148A AMPLIFICATORE UHF 1000W LDMOS MEANWELL 106659 BANDPASS FILTER CL3N60C-AEE IV/VBd 1RO156F RACK 20U 565x1000 CON COPER. FORATO 1Z0500 TAV. 1081RF GUIDA RACK 3000W P. 2328 ZN 4DET0462 DET0462R0 BARRA x RACK SOSTEGNO PCAV ZN 4PAN0082 PAN0082R0 PANN. FRONT. 3U CON POLICARB. 2PAN0080 PAN0080R0 PANN. FRONT. 1U CON POLICARB. 1PAN0081 PAN0081R0 PANN. FRONT. 2U CON POLICARB. 2CSS5011 CAVO IN RG58 DA 1.5MT NM/NM 1CON0093 CON0093R3 POSTERIORE RACK 20U VR P. 2544 1CMS6006 CAVO 1/2 DA 1MT CONN. 7/16(M) BN203391 102502 J01150A0041 SMA x RG58/c 108504 CABLE RG58 50W102009 GE35145 D/60 BN (UG909/cxRG58) 107595 VENTOLE G2E160.AD01.21 107595A COND. 6uF VENTOLA G2E160.AD01.21 1Z0114 REGGI TUBO ARIA x 1kW P. 2058 TAV. 358/A ZN 1DET0434 DET0434R2 ANCORAGGIO FLANG. 7/8 CON RACK 1DET0564 DET0564R0 COLLARE FISS. EIA 7/8 1DET0565 DET0565R0 ANCORAGGIO COLL. EIA 7/8 102450 CONNECTOR EIA 7/8 FOR 1/2 cod. 9713 102458 INNER EIA 7/8 cod. 0135 108515A CABLE 1/2 LDF4-50A 50W102410 CONNECTOR 7/16 x 1/8 SP 10 CLX 160 107959B GRIGLIA x VENTOLA G2E160.AD01.21 107596 GRIGLIE VENTOLE LZ 201 1DET0609 DET0609R0 BARRETTA REGGI FILTRO 2R0031 CERNIERA PER SCURETTO LACCATA 2D0101 CHIAVE QUADRA MM8 E3-8-1 1D0100 CHIUSURA A COMPRESSIONE SE3-1010-045 2DET0671 DET0671R0 SPES. x CERNIERA REG. PORTIERA 2Component list APT148B - AUTV/1000LD
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37200W UHF LDMOS AMPLIFIER MODULE SCH0192AR0DESCRIPTIONThe RF module is an integrated TV linear amplifier designed for UHF band, this module employs push-pullLDMOS technology in order to achieve very good efficiency, high linearity and reliability.LDMOS transistors operate in AB class. It is a wideband amplifier over the full frequency, no adjustment isrequired for the channel change. The board includes RF section amplifier, bias circuit, protection circuit andmatching networks. A silver plated copper plate is brazed with PCB in order to obtain low thermal resistance.Providing a minimum of 200W Pk sync linear power, this module is the perfect amplifier for any broadbandUHF power transmitter.TECHNICAL CHARACTERISTICSOutput power 300W maxInput power 15W maxFrequency 470 - 860MHzGain > 13dBLDMOS Power supply 32V ±2%LDMOS Bias current @+32V Vdc 2ARF Input impedance 50WRF Output impedance 50WInput / Output return loss > = 15dBDrain efficiency 47% @ 250WStorage temperature range -50° to +150°CDimensions (LxWxH) 165x95x29mm
38CALIBRATION PROCEDURE- Technical characteristicsPower supply voltage 32V (± 2%)Polarisation current 1.0 cold for each device (2A total), ± 0.1AGain for low signal Not less than 13dB in the 470-860MHz band (± 1dB)Compare to the typical curve eclosed- Adjustment procedurePolarisation current calibration 32V stabilised power supply10A amperometerGain curve Network analyser- Adjustment points descriptionR7-R8 (Trimmers) Adjust the current absorbed in stand-by (1.0A per device)Middle frequency 660MHz, span 500MHz, 2dB/div., reference to the arrow- Curve response graphic
39- Calibration stepsSTEP 1. Close the input and the output of the module by connecting them to a 50WWWWW dummy loadand connect the spectrum analyser through a directive sample, in order to look for self-oscillation of themodule, if any (anyway the module has been designed so that it would not self-oscillate even if totally de-coupled, without any input or output load).STEP 2. Check the voltages of the polarisation circuits without assembling the transistors first:connect the 32V power supply to the proper turret by means of a fastening screw, then give power and checkdata:- the stabilised voltage on the zener diodes DZ1 and DZ2 is about 15V compared to the ground;- the stabilised voltage on the zener diodes DZ3 and DZ4 is about 6.8V compared to the ground;- the voltage on the pads to which the gates of the LDMOS transistors will be soldered (R23 and R24resistors side) changes from 0V to a maximum value of about 6V when moving the relevant trimmer (R7-R8).STEP 3. Check the work of the protections.- Set both trimmers so that there is a value of about 4.5V on the pads of the gates;- solder some wire to the pad between the two LEDs, next to the serigraphy of the input hybrid H1;- in order to check the work of the protections aboard, a power of about 4V has to be supplied to the wire,for example by touching with it the reophore of C23 or C24 which is not connected to ground; the two redLEDs will immediately light up and the two RF transistors will be switched off at the same time: the polarisationcurrent (2A) will decrease to 0 and of course the gain curve displayed by the spectrum analyser will decrease;- after this it is important to restore the position of the two trimmers for the minimum voltage! Thendisconnect the 32V power supply.STEP 4. Fastening of the LDMOS transistors: after properly cleaning the plate surface, smear a thinlayer of silicone fat on the lower side of the flange of the MOSFETs, fasten them to the heat sink and solderthe gate first, then the drain. Solder the two 13pF (ATC) chip capacitors and above them the two 1-5pFSolder a wire
40capacitive trimmers, between the two pair of gates, as shown by the mounting plan.STEP5. Connect serially a c.c. amperometer to the power supply, with scale starting from more than 5A(i.e. 10A).STEP 6. Power the module and check the MOSFET is not absorbing current; this means that the deviceis integral and working correctly.STEP 7. Slowly turn the R7 trimmer until the MOSFET absorbs 1A, always checking that there are noself-oscillation; under this conditions it is possible to check by means of a digital tester that the voltage on thegate is about 5.2-5.4V.STEP 8. Repeat the previous step for the other section of the module, this time turnign R8 and checkingthat the indication of the current on the amperometer increases to 2A total (which includes the current of theother device left on).STEP 9. Check the response curve of the module by means of the network analyser.STEP 10. Check the response curve for low signal with centre 660MHz and span 500MHz, 2dB/div.STEP 11. The curve should be similar to the one enclosed, with a tolerance of ± 0.5dB. To obtain this, acton the four trimmers C41-C41a and C42-C42a with the proper calibrator, inorder to flatten the curve asmuch as possible, especially at the edged of the band which represents the minimum values.STEP 12. Finally, check that the current in stand-by does not increase by more than 15÷20%, reaching atworst 2.3÷2.4A when the heat sink is hot and not ventilated.Note: when mounting-removing the PALLET on the heat sink, tightly fasten the screw of each all N input and outputconnectors. These are mounted with a single 3mm screw and if it is not properly fastened it may be detached from the PCBby a movement of the connector once it has already been soldered to the path.
41Component layout SCH0192AR0
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43COMPONENT LIST SCH0192AR0REF. DESCRIPTION ELETTRONIKA CODE Page 1/3R1 2200W 1/4W 1206 SMD RESISTOR 00045AR2 2200W 1/4W 1206 SMD RESISTOR 00045AR3 2200W 1/4W 1206 SMD RESISTOR 00045AR4 2200W 1/4W 1206 SMD RESISTOR 00045AR5 1200W 1/4W 1206 SMD RESISTOR 00042AR6 1200W 1/4W 1206 SMD RESISTOR 00042AR7 50kW MULTITURNS PTH TRIMMER 00800R8 50kW MULTITURNS PTH TRIMMER 00800R9 1200W 1/4W 1206 SMD RESISTOR 00042AR10 1200W 1/4W 1206 SMD RESISTOR 00042AR11 18kW 1/4W 1206 SMD RESISTOR 00056BR12 18kW 1/4W 1206 SMD RESISTOR 00056BR13 680KW 1/4W 1206 SMD RESISTOR 00075AR14 0W 1/4W 1206 SMD RESISTOR 00001R15 50W 30W 1512EBX SMD RESISTOR 00416AR16 50W 60W 00432R17 4.7kW 1/4W 1206 SMD RESISTOR 00049AR18 4.7kW 1/4W 1206 SMD RESISTOR 00049AR19 3.9W 1/4W 1206 SMD RESISTOR 00012AR20 3.9W 1/4W 1206 SMD RESISTOR 00012AR21 3.9W 1/4W 1206 SMD RESISTOR 00012AR22 3.9W 1/4W 1206 SMD RESISTOR 00012AR23 1000W 1W 2512 SMD RESISTOR 00396R24 1000W 1W 2512 SMD RESISTOR 00396*R25 = R15 (da montare se si inverte lingresso)*R26 = R26 (da montare se si inverte luscita)C1 470uF 50V PTH ELECTROLYTIC CAPACITOR 01807BC2 470uF 50V PTH ELECTROLYTIC CAPACITOR 01807BC3 470uF 50V PTH ELECTROLYTIC CAPACITOR 01807BC4 100uF 50V PTH ELECTROLYTIC CAPACITOR 01795C5 100uF 50V PTH ELECTROLYTIC CAPACITOR 01795C6 1nF ATC 100B CAPACITOR OR EQUIVALENT 01145C7 1nF ATC 100B CAPACITOR OR EQUIVALENT 01145C8 x 2 2 x 100nF ATC CAPACITOR OR EQUIVALENT 01065HC9 x 2 2 x 100nF ATC CAPACITOR OR EQUIVALENT 01065HC10 x 4 4 x 100pF ATC 100B CAPACITOR OR EQUIVALENT 01135C11 x 4 4 x 100pF ATC 100B CAPACITOR OR EQUIVALENT 01135C12 100nF 1210 SMD CAPACITOR 1065GC13 100nF 1210 SMD CAPACITOR 1065GC14 100nF 1210 SMD CAPACITOR 1065GC15 1uF 35V SMD TANTALIUM CAPACITOR 01613AC16 1uF 35V SMD TANTALIUM CAPACITOR 01613AC17 100nF 1210 SMD CAPACITOR 1065G
44REF. DESCRIPTION ELETTRONIKA CODE Page 2/3C18 100nF 1210 SMD CAPACITOR 1065GC19 10uF 16V SMD TANTALIUM CAPACITOR 01626AC20 10uF 16V SMD TANTALIUM CAPACITOR 01626AC21 100nF 1210 SMD CAPACITOR 1065GC22 100nF 1210 SMD CAPACITOR 1065GC23 100nF 1210 SMD CAPACITOR 1065GC24 100nF 1210 SMD CAPACITOR 1065GC25 1nF ATC 100B CAPACITOR OR EQUIVALENT 01145C26 1nF ATC 100B CAPACITOR OR EQUIVALENT 01145C27 1nF ATC 100B CAPACITOR OR EQUIVALENT 01145C28 1nF ATC 100B CAPACITOR OR EQUIVALENT 01145C29 20pF ATC 100B CAPACITOR OR EQUIVALENT 01123C30 20pF ATC 100B CAPACITOR OR EQUIVALENT 01123C31 20pF ATC 100B CAPACITOR OR EQUIVALENT 01123C32 20pF ATC 100B CAPACITOR OR EQUIVALENT 01123C33 1.3pF ATC 100B CAPACITOR OR EQUIVALENT 01104C34 1.3pF ATC 100B CAPACITOR OR EQUIVALENT 01104C35 470pF ATC 100B CAPACITOR OR EQUIVALENT 01143C36 470pF ATC 100B CAPACITOR OR EQUIVALENT 01143C37 470pF ATC 100B CAPACITOR OR EQUIVALENT 01143C38 470pF ATC 100B CAPACITOR OR EQUIVALENT 01143C39 4.7pF ATC 100B CAPACITOR OR EQUIVALENT 01108C40 4.7pF ATC 100B CAPACITOR OR EQUIVALENT 01108C41 x 2 2 x 1¸5pF JOHANSON SMD TRIMMER 1485C42 x 2 2 x 1¸5pF JOHANSON SMD TRIMMER 1485C43 3.6pF ATC 100B CAPACITOR OR EQUIVALENT 01104BC44 3.6pF ATC 100B CAPACITOR OR EQUIVALENT 01104BC45 6.8pF ATC 100B CAPACITOR OR EQUIVALENT 01111C46 6.8pF ATC 100B CAPACITOR OR EQUIVALENT 01111C47 6.8pF ATC 100B CAPACITOR OR EQUIVALENT 01111C48 6.8pF ATC 100B CAPACITOR OR EQUIVALENT 01111C49 13pF ATC 100B CAPACITOR OR EQUIVALENT 01119AC50 13pF ATC 100B CAPACITOR OR EQUIVALENT 01119AC51 8.2pF ATC 100B CAPACITOR OR EQUIVALENT 01113C52 8.2pF ATC 100B CAPACITOR OR EQUIVALENT 01113C53 8.2pF ATC 100B CAPACITOR OR EQUIVALENT 01113C54 8.2pF ATC 100B CAPACITOR OR EQUIVALENT 01113C55 10pF ATC 100B CAPACITOR OR EQUIVALENT 01117C56 10pF ATC 100B CAPACITOR OR EQUIVALENT 01117C57 4.7pF ATC 100B CAPACITOR OR EQUIVALENT 01108C58 4.7pF ATC 100B CAPACITOR OR EQUIVALENT 01108C59 0.3pF ATC 100B CAPACITOR OR EQUIVALENT 01160T1 BLF861A RF LDMOS POWER TRANSISTOR 04034T2 BLF861A RF LDMOS POWER TRANSISTOR 04034B1 COAX 2:1 BALUN 08491
45REF. DESCRIPTION ELETTRONIKA CODE Page 3/3B2 COAX 2:1 BALUN 08491B3 COAX 4:1 BALUN 08492B4 COAX 4:1 BALUN 08492L1 4 TURNS SILV. COP. WIRE 1.2mm WOUND ON OD 5mm 07684L2 4 TURNS SILV. COP. WIRE 1.2mm WOUND ON OD 5mm 07684L3 ½ TURN COILL4 ½ TURN COILH1 HYBRID COUPLER 3dB 90° ANAREN 05368H2 HYBRID COUPLER 3dB 90° SAGE 05369NTC1 NTC 100KW PTH 00661NTC2 NTC 100KW PTH 00661IC1 DG419DY 04583IC2 DG419DY 04583DZ1 15V SMD ZENER DIODE 03135DZ2 15V SMD ZENER DIODE 03135DZ3 6.8V SMD ZENER DIODE 03137DZ4 6.8V SMD ZENER DIODE 03137DL1 SMD LED DIODE - RED - 03056DL2 SMD LED DIODE - RED - 03056PN964AR3 PCB 0643KTorretta 3x10 f/f V0774Imballo velapack 200x125x50 09983
46Figure 1: Simplified block diagram of the control and display boardCONTROL BOARD AND DISPLAY SCH0223AR1DESCRIPTIONThe control board SCH0223AR1 manages the operational logic of the amplifier: switching on and off, powersupply and fans, alarms and protections, remote control, human-machine interface. All of that is performed bya modern and powerful 16 bit micro-controller, which is the main part of the board.Figure 1 shows the block diagram.
47It can be seen that the micro-controller is the heart of the control system, to which the various peripherals(power supply, serial ports, telemeasure socket, AGC port, RF amplifier module, ROM, clock, display andkeys) are interfaced.- Power SupplyThe board is powered with a continuous +24V voltage applied on the J14 connector. From that the +5Vvoltage, powering the most of the chips (micro-controller, operational amplifiers, display, etc.) is derived bymeans of a switching converter (see IC19). A +12Vdc voltage is obtained from it as well, by means of a linearconversion provided by the integrated circuit IC8. From this, a -12Vdc voltage is obtained by means of theintegrated circuit IC5. The -12V voltage is used to adjust the contrast of the display.- ConnectorsOn the board SCH0223AR1 there are several connectors used as interfaces for the peripherals of the apparatusand the ports for external communication.POWER SUPPLYThe connectors J1, J6, J8 e J12 are used to connect the power supply powering the RF modules. The numberof power supply used changes depending on the amplifier, up to eight power supply. They are connected inthe order shown in Table 1 below. Remaining connectors, if any, are left unconnected.Table 1: Interface connectors for the power supplyThrough this connection, each power supply provides the level of voltage and current acquired by the micro-controller by means of an internal ADC. Besides the connectors allow the control board to turn on or off theindividual power supply (for instance when an alarm occurs).CONNECTOR POWER SUPPLY N°J1 1 - 2J6 3 - 4J8 5 - 6J12 7 - 8
48RF AMPLIFICATIONThe J3 connector interfaces the control board with the RF amplification section. Through this connector themicro-controller acquires the forward and reflected powers, unbalancing (if any), and temperature of thecritic amplification area. It also allows to inhibit the transistors in case of reflected power alarm, by means ofa totally hardware, thus extremely fast protection.Depending on the apparatus, this connector may also allow to enable or disable the cooling fans of the criticarea.RS485The J11 connector (10 pin socket) is directly wired to a DB9 female connector placed on the rear panel of theapparatus. This communication bus allows to connect the amplifier to the control (Amplifier Control) moduleof a high-power transmitter composed by several individual amplifiers. In this case, each amplifier and theAmplifier Control are connected to the same 4-wires RS485 bus and each of them has a unique address(which can be set by means of the keys and the display) for correct communication.In case of single (stand-alone) amplifier, the RS485 connector can be used to interface to the Remote ControlUnit (RCU) made by Elettronika S.r.l. This unit allows to monitor and control the remote transmitter from anysite provided with PSTN or GSM1 phone connection.Table 2 shows the wiring between the J11 connector on the board and the DB9 female connector on the rearpanel, along with the description of the lines.1 For more details about the control system contact the distributor or the manufacturer.PIN N°ON DB9PIN N°ON J11 DESCRIPTION11 Not used23 Rx-35 Rx+47 +5V59 GND62 Not used74 Tx-86 Tx+98 Not usedTable 2: Description of the RS485 connector
49TELEMEASURESThe J9 telemeasure connector (10 pins socket) is directly wired on a DB9 female connector placed on therear panel. There are input and output digital lines (TTL level) and analog output lines on this connector, whichare used to monitor and control the amplifier by means of a general-purpose remote control system.The correspondence between the pins of the J9 connector on the board and the DB9 female connector on therear panel, as well as the meaning of the various lines, is shown in table 3 below (the directions are in respectto the micro-controller on the board).Table 3: Description of the telemeasures connectorThe input stage of the digital pins has an internal pull-up towards the 5V power supply voltage. To use theselines it only takes setting a switch to close to earth. When closed, the relevant control (turning on or off) isenabled and the switch may be open again (impulse controls).The interlock pin may be used as protection so that the amplifier is switched off when the digital input level islow. It is possible to use several serially connected switches to make an interlock chain. Usually all switchesare closed and the interlock level is low, thus the amplifier is on. If even only one of the switches is open, the(*)(*)(*) You can select by means of two jumpers on the board (JP1 and JP2) RMS or peak power. If there are two jumpers on pins 1 and 2 ofJP1 and JP2 connectors, RMS power is selected. Otherwise, if there are two jumpers on pins 2 and 3 of the same connectors, peak poweris selected.PIN N°ON DB9PIN N°ON J9 TYPE DIRECTION DESCRIPTION1 1 Analog Output Forward power2 3 Analog Output Reflected power3 5 Analog Output Temperature4 7 Digital InputInterlock:0V = Interlock Alarm5V = Normal59 - -Ground6-7 2-4 Digital Output Free Contact(closed when amplifier is in alarm)8 6 Digital Input Turning-on control(normally high, active when low)9 8 Digital Input Turning-off control(normally high, active when low)
50Figure 2: Usage of the digital input signals of the telemeasures connectorAGC / EXCITERThe connector called J10, as the telemeasures connector and the RS485 bus, is wired to a DB9 femaleconnector placed on the rear panel of the amplifier. This connector allow the implementation of an automaticgain control between an exciter and the amplifier. A voltage signal related to the forward output powersupplied by the amplifier is provided through two pins of the AGC connector. Connecting one of these to therelevant input pin of the exciter, this can pursuit a given voltage level, so that the output power is alwaysconstant. In order to avoid that, in case of an alarm decreasing the forward power, the exciter increases itsoutput level due to the AGC, thus damaging the amplification stages, the connector is provided with twodigital output lines called AGC Alarm. Under alarm conditions, this lines are brought by the micro-controllerat a low level, so that the exciter can stop the AGC.Table 4 shows the connection between the J10 connector on the board and the DB9 connector on the rearpanel, along with the description of each pin (the direction of the pin is referred to the position of the micro-controller on the board).level of the interlock signal becomes high (this line has a pull-up towards the +5V power supply voltage aswell) and the interlock protection activates switching off the amplifier. Note that in case the interlock protectionis not used, the pin 4 of the DB9 telemeasure connector and the earth pin (pin 5) must be short circuited.Otherwise it is possible to disable the monitoring of the interlock chain from menu (see user manual).Figure 2 shows a typical usage for the digital input signals to turn on and off the amplifier and for the interlockalarm.
51Table 4: Description of the AGC connectorRS232The DB9 female connector on the front panel is an external communication RS232 serial port, through whicha PC can be connected directly to the amplifier in order to perform operations such as the remote control (bymeans of an adequate software2) and the update of the microcontroller firmware.The used communication protocol is asynchronous, at a 19200bps speed, 1 start bit, 8 data bits, 1 stop bit,no parity. No hardware flow control is used. The connector is DCE type and the pin used are shown in Table5.PIN N° ON DB9 123456789DESCRIPTION -TxDRxD-GND----MISCELLANEOUSThe J2 (called AUX), J4, J5 and J17 connectors are not used and are there only for future updates. The SW1dip-switches are partially used for the configuration of the correct mode for the micro-controller. The otherswitches are not used. It is important that the position of the dip-switches is left unchanged, because changingit may set a wrong mode for the micro-controller, affecting the work of the whole amplifier.2 For more information about this application contact the distributor of the manufacturer.PIN N°ON DB9PIN N°ON J10 TYPE DIRECTION DESCRIPTION11- -Ground23DigitalOutputAGC Alarm0V = Alarm5V = Normal35DigitalOutputAGC Alarm0V = Alarm5V = Normal47- -Not used59 - -Not used62 - -Not used7 4 - - Nout used8 6 Analog Output Forward power9 8 Analog Output Forward powerTable 5: Description of the RS232 connector
52FIRMWARE UPDATEThe microcontroller is provided with a built-in Flash memory containing the firmware. The firmware can beupdated with a later version without removing the apparatus from the rack and/or replacing the chip.To upgrade it, connect a PC to the RS232 socket on the front panel of the apparatus by means of a cableDB9 male - DB9 female (pin-to-pin).Launch on the PC the EKAFlash application, select the serial port in use on the PC, choose the update file bypressing the ... key and click on Download button.Eventually, turn off the amplifier from the main switch and then turn it on again. The upgrade of the firmwarebegins on the EKAFlash window. Fifure 3 shows this window while a firmware is being updated.Figure 3: The EKAFlash window while updating a firmware
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61COMPONENT LIST SCH0223AR1Part Name/Number Description Qty. Comps. Page 1/2BATT BH001RB 3093_90 03093 03090 BATTERY HOLDER 1 BATT1CC 100nF-S 01065C 01065C Y5V 1206 COND 46 C2, C7-10, C12, C16, C19, C21-27C29, C31, C33, C37-40, C44-46,C49, C58-61, C63, C65-69, C74,C76, C78-81, C83-84, C87, C90CC 15pF-S 01088 01088 SMD 1206 COND 4 C13-15, C17CC 1nF-S 01096 01096 SMD 1206 COND 7 C3-6, C50-51, C53CC 1uF100V-S 01760A 01760A Y5V 1206 COND 13 C1, C18, C28, C36, C43, C54,C56-57, C62, C73, C77, C88-89CC 47pF-S 01100 01100 SMD 1206 COND 2 C42, C52CE 100uF25V-S 01793B 01793B ELETTR SMD COND 2 C11, C47CE 10uF35V-S 01778A 01778A ELETTR SMD COND 2 C20, C32CE 1uF35V-S 01613A 01613A TANTALIUM ELETTR SMD CO 5 C70-72, C75, C82CE 220uF50V LOW ESR 1799A ELETTR SMD COND LOW ESR 4 C55, C64, C85-86CE 22uF16V-S 01780A ELETTR SMD COND 4 C34-35, C41, C48CE 47uF35V-S 01790A 01790A ELETTR SMD COND 1 C30D 1N4148-S 03002 03002 SMD DIODE 7 D1-2, D5-9D 50WQ06FN 03019A SMD DIODE SCHOTTKY 5,5A 1 D23D BAS85-S 03024 SMD DIODE SCHOTTKY 2 D14-15D BAT54S 03199 SMD SCHOTTKY DIODE A-K T 19 D3-4, D10-13, D16-22, D24-29DIS MGLS12864T 03083A 128x64 DOT (BLUE-LED WH 1 DIS1DL KA-3528SGC 03057 03057 GREEN SMD LED DIODE 7 DL2, DL5-10DL LEDG5 03060 03060 GREEN LED DIODE 5mm 1 DL1DL LEDR5 03061 03061 RED LED DIODE 5mm 1 DL4DL LEDY5 03054B 03054B YELLOW LED DIODE 5mm 1 DL3IC 24LC64 04815 04815 SMD INTEG CIRCUIT 1 IC17IC 78M12 4307B 04307B SMD VOLTAGE REGULATOR 1 IC8IC CD4051BM-S 04615 SMD INTEG CIRCUIT 3 IC7, IC14, IC23IC LM2596S-5.0 04580 SMD INTEG CIRCUIT 1 IC19IC LM358M-S 04660 04660 SMD INTEG CIRCUIT 1 IC3IC LM393-S 04639 04639 SMD INTEG CIRCUIT 1 IC2IC LMC6482-S 04632 SMD INTEG CIRCUIT 1 IC24IC LMC6484-S 04634 SMD INTEG CIRCUIT 7 IC1, IC4, IC6, IC9, IC13, IC18,IC25IC M41T56 04611 04611 SMD INTEG CIRCUIT 1 IC20IC MAX232-S 04804B 04804B SMD INTEG CIRCUIT 1 IC21IC MAX3080-S 04770 04770 SMD INTEG CIRCUIT 1 IC22IC MAX942CSA-S 04572 SMD INTEG CIRCUIT 1 IC10IC MB90F543PF 04596 SMD INTEG CIRCUIT 1 IC11IC MPC100-450DI-TO 04608 INTEG CIRCUIT 1 IC16IC TC7662BCOA 04758A 04758A SMD INTEG CIRCUIT 1 IC5IC ULN2003A 4870 04870 SMD INTEG CIRCUIT 2 IC12, IC15IND 2u2H-S 05020A 05020A INDUCTOR 1 L1
62Part Name/Number Description Qty. Comps. Page 2/2IND MS85 10uH-S 04948 INDUCTOR 2,7 A 1 L2IND T100uH-1.8A 4958 04958 TOROIDAL-STORAGE CHOKES 1 L3J CON HD515V/05-4PVE 02881 + 02882 PANDUIT PCB CONN 1 J14J DB9_F-0° LT 02794 PCB CONNECTOR DB9 LONG T 1 J13J FC-10P 02697-02699 02697+02699 PCB CONNECTOR POL 8 J1-2, J6, J8-12J FC-16P 02701-02700 02701+02700 PCB CONNECTOR POL 1 J3J PAN2 02739-40-41 02739+02740+02741 PCB CONNECTO 3 J5, J7, J15J PAN8 02716 02716 PCB CONNECTOR 1 J4JU JUMP2 02739-02742 02739+02742 MASCHIO PAN2 1 JP3JU JUMP3 02707-02742 02707+02742 MASCHIO PAN3 2 JP1-2R 100K-1%-S 00065B 00065B RES 1/4W 1% SMD 1206 10 R65-66, R94-101R 100R-1%-S 00029D 00029D RES 1/4W 1% SMD 1206 12 R24, R47, R58, R71, R75,R81,R83, R89, R103-105, R113R 10K-1%-S 00053B 00053B RES 1/4W 1% SMD 1206 32 R7, R10, R12, R14-16, R22, R25,R27, R30, R33-34, R36, R38, R51,R62-64, R78-79, R84-85, R87-88,R92-93, R106-111R 10R-S 00017A 00017A RES 1/4W 5% SMD 1206 1 R68R 1206 NOT MOUNTED NOT MOUNTED RES 1/4W 5% SMD 12 1 R91R 1K0-1%-S 00041B 00041B RES 1/4W 1% SMD 1206 8 R17, R54, R59-60, R76-77, R86,R90R 22K-1%-S 00057B 00057B RES 1/4W 1% SMD 1206 11 R9, R21, R26, R28-29, R37, R45,R48-50, R69R 2K2-1%-S 00045B 00045B RES 1/4W 1% SMD 1206 3 R52, R55, R61R 470K-S 00073A 00073A RES 1/4W 5% SMD 1206 11 R8, R23, R40, R42, R46, R57, R70R74, R80, R102, R112R 470R-1%-S 00037B 00037B RES 1/4W 1% SMD 1206 6 R11, R13, R39, R53, R56, R67R 4K7-1%-S 00049B 00049B RES 1/4W 1% SMD 1206 3 R18, R31, R43R 68K-1%-S 00063B 00063B RES 1/4W 1% SMD 1206 4 R19-20, R32, R44R 820R-S 00040A 00040A RES 1/4W 5% SMD 1206 7 R35, R72-73, R82, R114-116R 8K2-1%-S 00052B 00052B RES 1/4W 1% SMD 1206 1 R41RL 30.22.24 07569 07569 RELE 3 RLY1-3RV 100K-3266X 00814 VARIABLE RESISTOR 4 R1-4RV 10K-3266X 00807 00807 VARIABLE RESISTOR 2 R5-6SW SWITCH-8DIP 07530A PCB DIP SWITCH SMD 1 SW1T 06086 N 7630 7632 7630 7632 KTI06086 PULSANTE 2 4 T1-4TR BC848 03457 03457 NPN SMD TRANSISTOR 2 TR1-2TR BC856 03455 03455 PNP SMD TRANSISTOR 2 TR3-4XTAL 32.768k-S 05146 05146 QUARTZ 1 XTAL2XTAL 4MHz-S 05101A 05101A QUARTZ 1 XTAL1
63RF AMPLIFIER INTERFACE SCH0259AR0Component layout SCH0259AR0COMPONENT LIST SCH0259AR0Part Name/Number Description Qty. Comps.CC 100nFAVX 01065A 01065A CERAMIC COND 4 C1, C3, C6, C8CE 100uF100V 01795B ELETT. COND. 1 C2CE 100uF50V 01795 01795 ELETT. COND. 1 C7CE 10uF35V-S 01778A 01778A ELETTR SMD COND 2 C4-5D 1N4007 03009 03009 DIODE 1 D4D 6CWQ10FN 03026 SMD DIODE SCHOTTKY 3,5A 3 D1-3IC LM317HV 04340A INTEG CIRCUIT 2 IC1-2J FC-16P 02701-02700 02701+02700 PCB CONNECTOR POL 1 J21J SCREWCONN2 02853 02853 PCB SCREW CONNECTOR 2 J11, J19J SCREWCONN3 02860 02860 PCB SCREW CONNECTOR 1 J20J TESTP1.3mm 07913 07913 TEST POINT 17 J1-10, J12-18JU JUMP2 02739-02742 02739+02742 MASCHIO PAN2 3 JP1-2, JP4JU JUMP3 02707-02742 02707+02742 MASCHIO PAN3 1 JP3R 0R33-1W-S 00380 RES 1W 5% SMD 2512 2 R1-2R 100K-S 00065A 00065A RES 1/4W 5% SMD 1206 1 R7R 220R-S 00033A 00033A RES 1/4W 5% SMD 1206 1 R4R 22K-S 00057A 00057A RES 1/4W 5% SMD 1206 1 R5R 270R-S 00034A 00034A RES 1/4W5% SMD 1206 1 R3R 4K7-S 00049A 00049A RES 1/4W 5% SMD 1206 1 R6TR BC856 03455 03455 PNP SMD TRANSISTOR 1 TR1
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65MAINS DISTRIBUTION BOARD SCH0265AR0Component layout SCH0265AR0COMPONENT LIST SCH0265AR0Part Name/Number Description Qty. Comps.CC 2nF2 2kV 01045A 01045A CERAMIC COND 2 C1-2CNV AC-DC ATC-12S E0037 AC DC CONVERTER 1 CNV1D 1N4148 03001 03001 DIODE 2 D1-2DL LEDG3 03053 03053 GREEN LED DIODE 3mm 1 DL1J CON HD515V/05-4PVE 02881 + 02882 PANDUIT PCB CONN 1 J2J CON HD515V/05-5PVE PANDUIT PCB CO 1 J1R 2K7 0046 0046 RES 1/4W 5% 1 R1RL 40.31.24 7567C RELE 2 RLY1-2
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67INTERFACE BOARD SCH0288AR1Component layout SCH0288AR1COMPONENT LIST SCH0288AR1Part Name/Number Description Qty. Comps.CC 1nF-S 01096 01096 SMD 1206 COND 16 C1-16DZ 5V1-S 03128 03128 SMD ZENER DIODE 8 DZ1-8J FC-10P 02697-02699 02697+02699 PCB CONNECTOR POL 4 J2-3, J6-7J FC-10P PCB FEMALE 02706 PCB FEMALE CONNECTOR POL 4 J1, J4-5, J8R 0R0-S 00001 00001 RES 1/4W 5% SMD 1206 16 R1, R8, R12, R15, R21, R23, R26R28, R33, R40, R44, R47, R53, R55,R58, R60R 10K-S 00053A 00053A RES 1/4W 5% SMD 1206 16 R3-6, R17-18, R31-32, R35-38,R49-50, R63-64R 1206 NOT MOUNTED NOT MOUNTED RES 1/4W 5% SMD 12 16 R2, R10, R14, R16, R19, R24, R29,R30, R34, R42, R46, R48, R51, R56,R61-62RV 3266W NOT MOUNT NOT MOUNTED VARIABLE RESISTOR 16 R7, R9, R11, R13, R20, R22, R25,R27, R39, R41, R43, R45, R52, R54,R57, R59TR BC847 03456 03456 NPN SMD TRANSISTOR 8 TR1-8
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69SPECIFICATIONMODEL SP -500-27 (E0012 Code) SP-500-48 (E0013 Code)DC Output Voltage 27Vdc 48VdcOutput Rated Current 18A 10AOutput Current Range 0-18A 0-10ARipple & Noise (p-p) 200mVp-p 240mVp-pDC Output Power 486W 480WEfficiency 87% 87%DC Voltage Adj. 24-30V 41-56VOver V. Protection 31V-36.5V 57.6V-67.2VInput Voltage Range 88-264VacInput Frequency 47-63HzPower Factor 0.95/100-240VacOverload Protection 105%-135%Type: Foldback current limitingRecovery: AutoOver Temp. Protection > =70°C Output ShutdownFan Control Temp. > =60°C Fan On < =50°C Fan OffWorking Temp., Humidity -10°C/+50°C, 20%-90% RHDimension 185x120x93Weight 1.8Kg.SP500-27-DI SWITCHING POWER SUPPLY E0012
70FEATURES- UHF 1kW analog TV output filter- 3 bandpass resonators and 2 notches- Foreshorten in-line combline structure- Iris couplings with fine bandwidth regulation- Phase regulation between bandpass and notches- 3D Electromagnetic CAD- Low loss (Typ. 0.35dB @ V.C. Ch. 69 G)- Compact and lightweightSPECIFICATIONS (Value referred to G Standard)Frequency Range 474 - 862MHz Selectivity > 35dB @ V.C. -5.5 / +11MHzMax Input Power 1kW Analog TV > 24dB @ V.C. -11 / +16.5MHzInsertion Loss < 0.40dB @ V.C. Ch. 69 Temperature Stability < 17kHz / K< 0.34dB @ V.C. Ch. 21 Connectors 7/16 FemaleReturn Loss > 28dB Weight (Approx) 5.8kgGroup Delay Variation < 25ns Operating temperature -10 to +50°CBandwidth 6 to 8MHzAVAILABLE OPTIONSA SMA Output Monitor Probe B SMB Output Monitor ProbeH EIA 7/8 Flange ConnectorsUHF BANDPASS FILTER CL3N60C Code 066591kW, 3 Sections + 2 Notches
71TECHNICAL DESCRIPTIONThe output filter mod. CL3NL15 is made up by a band-pass section with 3 resonators and two notchresonators. It may be adjusted on all channels of the YHF TV band (470 - 860MHz) and for any worldstandard (intercarrier 4.5 - 6.5MHz). The band-pass section is made up by the group of the three resonators,while the two separated resonators are the notches. The filter is symmetrical, as such any notch, upper orlower, can be chosen without any difference.The band width is adjusted by changing the insertion of the two post screws which are between the band-passresonators; when they are inserted, the band width is increased. To make this adjustment the bolt of each postscrew has to be loosened by means of a tubular wrench n° 19.The input and output couplings, which can be reached after removing the protection cups, can be adjustedtrough the coupling stubs put in correspondence to the connectors. The adjustment is made by means of a flatwrench n° 8, taking into consideration that the maximum coupling is obtained when the flat sides are parallelto the longer side of the filter, the minimum one when they are orthogonal.Finally, the symmetry of the response is given by the extrusion of the coupling stubs; these are set by looseningthe relevant clamps by means of a tubular wrench n° 16. Once these clamps are fastened, they also determinethe friction for the rotation of the couplings.The suggested calibration procedure is;1. Set the measurement instrument on- C.F. = (P.V. + P.A.)/2- SPAN = INTERCARRIER * 5 (Es. 27,5MHz std. B/G)- RESPONSE = 5dB/div.- ADAPTATION = 10dB/div.2. Set the coupling stubs of the couplers and the post screws according to the following extrusions, measuredfrom the edge to the body of the filter:C.F.(MHz)COUPLING STUB(mm)POST SCREW(mm)474 11 21666 28 20858 39 16
723. Tune the band-pass section on the desired channel and load input and output correctly until an optimalresponse is obtained. At this stage the tuning of the two notches must be kept distant from each other. Adjustthe band width to -27dB at the edges of the screen (es. std. B/G: BW (-27dB) = 27,5MHz). The input andoutput couplings may affect the tuning of the resonators, as such it takes adjusting them at the same time in littlesteps.4. Tune the two notches bringing them to the frequencies P.V.-INTERCARRIER and P.A.+INTERCARRIER.This will cause a variation in response and adaptation of the band-pass. Correct the response by acting on theband-pass tunings.5. Complete the calibration by acting alternately on the two sides according to this sequence: adjust thecoupling, re-tune the notch if it moved and then the band-pass tunings. Repeat these sequence in little stepstrying to improve the adaptation.6. Check the symmetry of the obtained response and if needed correct it as follows: if the lower notch is moremarked than the other, insert the coupling stubs, if it is less, extract them.7. Once the response symmetry is correct, complete the calibration as explained above.8. It is possible to obtain a particularly favourable response by slightly unbalancing the post screws from thenominal values, so that the post screw on the side of the lower-frequency notch is slightly more inserted thanthe one on the side of the higher-frequency one. The difference in adjustment should be about 1-2 mm and thebest adjustment will be made clear by the appearance of three very marked peaks in the adaptation curve.9. Once the calibration is completed, reposition the protection cups on the coupling adjustments.PRESCRIPT CALIBRATION VALUEMEASURE VALUEInsertion loss @ V.C. (dB) < -0.40 (typ. -0.34)Return Loss (from V.C. -0.75 to V.C. +0.25) (db) < -26Attenuation @ V.C. -INTERCARRIER < -40Attenuation @ V.C. +INTERCARRIER < -35
73SAMPLE FREQUENCY RESPONSE DIAGRAM

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