Elettronika S r l TXUP5000 TXUP5000 5 kW Analog TV Transmitter User Manual APT120A AUTV 5000LD Rev0 Date221003 p65

Elettronika S.r.l. TXUP5000 5 kW Analog TV Transmitter APT120A AUTV 5000LD Rev0 Date221003 p65

Contents

User Manual Part 2

49_______________________________________________________________________________________________Section 1 - InformationContents:1.1 Description1.2 Technical characteristics
501.1 DESCRIPTIONThe AUTV/1500LD is an amplifier operating into Band IV-V for common amplification process of the Visionand Sound carriers.The amplifier has been designed to offer to the customer high performances, high reliability and greatersimplicity in his operation and maintenance procedures.The amplifiers modules employ all solid state LDMOS technology in order to obtain high gain, wide-band performances, very good linearity, reliability and high efficiency.The equipment design allows the soft degradation (RF power loss) for several transistor faulty: in fact theoutput combiner uses RF power resistors for unbalancing power dissipation. The unit is enclosed in a cabinetfor 19- 6U rackmounting.AUTV/1500LDLDMOS - UHF TV AMPLIFIER
511.2 TECHNICAL CHARACTERISTICSRFFrequency range 470 - 860MHzOutput power 1300W PEPVideo/Sound power ratio 10/1Out stage technology Solid State LDMOSVision-Sound amplification CommonI.M.D. (-8, -10, -16dB) Better than -54dBStandards G, K, NSpurious and harmonics level In compliance with CCIR rec.RF Output impedance 50WRF Output connector 7/16GENERALPower supply 230Vac, ±10%, 50/60Hz400Vac 3P+N (on request)Power consumption 3400VA at black levelRS232 Socket DB9 Connector (on front panel)RS485 Socket DB9 Connector (on rear panel)Telemeasuring socket DB9 Connector (on rear panel)AGC Socket DB9 Connector (on rear panel)Power factor > = 0.9Ambient temperature -5° to +45°CRelative humidity 20% - 90%Altitude Up to 2.500 metersCooling Forced airCabinet Rack 19-6UDimensions 760x263x266mmWeight 70kgPROTECTION THR.FWD Power 1500WREF Power 150WUnbalacing 350WTemperature 75°CIDC 25AVDC Min 10V - Max 33,5V
52This page is intentionally blank
53_______________________________________________________________________________________________Section 2 - InstallationContents:2.1 Operating environment2.2 Preliminary operations2.3 Telemeasuring socket connections2.4 RS232, RS485 and AGC socket connections2.5 Preventive maintenance- Front panel- Rear panel
542.1 OPERATING ENVIRONMENTYou can install the apparatus in a standard component rack or on a suitable surface such as a bench or desk.In any case, the area should be as clean and well-ventilated as possible. Always allow for at least 2 cm ofclearance under the unit for ventilation. If you set the apparatus on a flat surface, install spacers on the bottomcover plate. If you install the apparatus in a rack, provide adequate clearance above and below. Do not locatethe apparatus directly above a hot piece of equipment.2.2 PRELIMINARY OPERATIONSCorrect installation of the equipment is important for maximum performance and reliability. Antenna and earthconnections must be installed with the greatest care. The equipment adjustment isnt need, because the unit iscompletely adjusted by our technical staff. This is the installation procedure:1. connect the power supply cable of the exciter to the auxiliary socket on the rear panel of the amplifier;2. connect the power supply cable of the amplifier to the electric network (230VAC). If there is the IsolatorTransformer, the amplifier is provided with cable and plug;3. connect the exciter / antenna cables respectively to the RF IN and RF OUT on the rear panel of theamplifier.WARNING!!!FOR ELECTRICAL SAFETY REASONS AND IN ORDER TO KEEPTHE APPARATUS SAFE, THE GROUND TERMINAL OF THEAPPARATUS MUST BE CONNECTED TO THE EXISTING GROUND-ING SYSTEM AND NOT BY USING THE SHIELD OF THE OUTPUTCOAXIAL CABLE.132Three-Phase cablingMonophase cabling
55When the apparatus is put within a combined system it is directly connected to the input splitting and outputcombining systems.Before fully powering the apparatus, check that the output connections of the coaxial cable to the antennasystem are working.In order to this it is possible to check the indication of the reflected power at low power levels. Only if theSWR indication on the display is 0, the output power can be slowly increased. At maximum output power,some watts might be shown as reflected power.2.3 TELEMEASURING SOCKET CONNECTIONSDB9 Socket2.4 RS232, RS485 AND AGC SOCKET CONNECTIONSPIN N° SIGNAL TYPE IN / OUT FUNCTION1 Analog Output FWD Power2 Analog Output REF Power3 Digital Output Temperature4 Digital Input Interlock5GND - -6 - 7 Digital Output Free contact (closed when alarm)8 Digital Input 0V = ON5V = Normal9 Digital Input 0V = OFF5V = NormalPIN 1234 56789FUNCTIONS -TxDRxD-GND----RS232 - DB9 SocketPIN 1234 56789FUNCTIONS -Rx-Rx+5VGND-Tx-Tx+-RS485 - DB9 Socket
56AGC - DB9 SocketPIN N° SIGNAL TYPE IN / OUT FUNCTION1GND - -2 Digital Output 0V = Normal5V = AGC Alarm3 Digital Output 0V = Normal5V = AGC Alarm8 Analog Output FWD Power9 Analog Output FWD Power2.5 PREVENTIVE MAINTENANCETo ensure maximum performance and minimum repair trouble, we strongly recommend you to follow thebelow stated headlines for preventive maintenance:1. check antenna installation and ground connection at regular intervals;2. keep your apparatus clean and dry externally: this will ensure continuous functioning of the front panelcontrols;3. if the apparatus has not been used for a long period of time combined with exposure to extreme environ-mental conditions, open the unit and make a visual inspection.Remove salt, water or ice with a moist cloth before turning the apparatus on. Check that the cooling fans arerunning freely.4. for general maintenance and top performance, call an authorized service technician to give the apparatusand the complete antenna/earth connection installation a general check every 12-18 months;5. check at regular intervals that the air intake located on the front panel is free of dust. If there is visible dust,remove it by means of a soft brush.
57Front panel123456DESCRIPTION1LCD Display2 Function keys3 Status LEDs4 RF Monitor connector5 Main switch6 RS232 Socket
58Rear panel123456987DESCRIPTION1 Breaker2 Power supply socket3 Auxiliary socket4Fuse5 RS485 Socket6 AGC Socket7 Telemeasure socket8 RF Input connector9 RF Output connector
59_______________________________________________________________________________________________Section 3 - OperationContents:3.1 Control board and display description3.2 Operation3.3 Display3.4 Menu
603.1 OPERATIONAt startup, after intro image, the display shows the main screen, showing the RF powers as in Figure 1:The user may turn on and off the amplifier by means of the switch on the front panel. The control board turnson all the power supplies, the exciter, if any, and the cooling fans. While the amplifier is working, the micro-controller monitors continuously the most important parameters: power supply voltages, absorbed currents,temperature, forward and reflected power, unbalances, if any. Each signal is associated to a maximum thresholdbeyond which the amplifier is immediately put in protection status by turning off one or more power supply,depending on the failed block. In order to prevent a temporary problem to trigger a definitive protectionstatus, the failed block is turned on again for up to five times. If it goes beyond the protection threshold formore than five times, it is declared as FAILED and will no longer be turned on. In this case the amplifier willhave to be turned off manually by means of the switch on the front panel, then turned on again after performingthe needed maintenance. On the front panel there are also three LEDs labelled ON, REMOTE and ALARM.Their meanings are explained below.Figure 1: Main screenLED COLOUR MEANING MEANING WHEN BLINKINGON Green The amplifier is onThe amplifier has been turned onlocally but it has been turned off byremoteREMOTE Yellow Remote control isenabled It ne ve r blinksALARM Red Alarm status It never blinksTable 1: Meanings of the three LEDs on the front panel1 Screenshots in this manual are indicative and they refers to a TV amplifier, so they can be different from those on your equipment.
613.2 DISPLAYThe control board is provided with a modern 128x64 pixels graphic display with blue backlight. Normally italways shows a title bar (on the top line) and a status bar (on the bottom line).The title bar, see Figure 2, shows the name of the amplifier (TV Amplifier or FM Amplifier) and the currenttime.Figure 2: Title barFigure 3: Status BarThe status bar indicates the forward and reflected power and the temperature. It also contains two symbolsfor the interlock (lock) and a generic alarm (bell).The bell symbol is displayed in case of alarm. It blinks if there has been an alarm which has ended but has notyet been seen by the user. It stops blinking once the alarm Log has been checked.The interlock symbol is displayed only when the check for this alarm is enabled. It may be either a close lock,see Figure 3, when there is no alarm (close interlock chain) or an open lock in case of alarm (open interlockchain).Since the status bar is always on the display, regardless of the displayed screen, the user may monitor at anymoment the most important parameters and the presence of alarms, if any, while moving between differentscreens.3.3 MENUThe user may see or modify locally some configuration parameters of the apparatus by means of the four keyson the front panel. All screens are made up by hierarchical menus and the user may move between them in asimple and intuitive way.To see the main menu its sufficient to press ESC key (see Figure 4).
62Figure 4: Main menuThe display only shows three items, but the whole menu can be scrolled by means of the UP and DOWNarrow keys. Any item can be chosen by selecting it and pressing the RET key. Menu entries with arrow on theright open sub-menus when chosen. Thus there is a hierarchical structure as in Figure 5. To go back froma sub-menu to the previous menu, press the ESC key. If the ESC key is pressed in the main menu, the mainpowers screen is accessed.Figure 5: Hierarchical menu structureAll menu items are described in detail below.RF PowersPower SuppliesLog/Alarms >Working Timer >ThresholdsSettings >ExitView Log/AlarmsClear Log/AlarmsLog ModeView TimerTimer ResetExitRMS/PeakDate/TimeDisplayFrequencySlave AddressRemoteInterlockReleaseSerial NumberExitBacklightContrastScreensaverExitExit
63- RF PowersThis is the main screen showing the RF powers of the amplifier: forward power, reflected power, unbalances,if any. For forward power a level bar is displayed. See example in Figure 1.- Power SupplyThis screen shows all the signals coming from the power supply. To check a different power supply press theUP (or DOWN) key to see the next (or previous) one. For each power supply, the two voltages, the twoabsorbed currents and the status (ON or OFF) are shown.Figure 6: Power supply screen- Log/AlarmsThe control board is provided with an external EEPROM and a clock. Any alarm or switching event is savedinto an event log stored inside the EEPROM and associated to the time at which it occurred. The Log/Alarmssub-menu allows to manage this log.It is possible to see the events stored in the log by selecting Log/Alarms View Log/Alarms. All eventscan be scrolled by pressing the UP and DOWN keys. The event shown in Figure 7 is the turning on of theamplifier by means of the local switch. Each event is associated to the date and time at which it occurred andto a description.Figure 7: Event stored in the log
64In case of alarm on a parameter, the value of the parameter which caused the alarm is saved into the log. Incase of alarm still existing after five turning-on attempts, the parameter is marked as FAILED. Table 2 is thelist of all the events which can be logged.Table 2: Events managed and logged by the control boardThe log may be completely deleted by selecting Log/Alarms Clear Log/Alarms.Amplifier can store in the log details about alarms and generic events. You can change this behaviour selectingLog/Alarms Log/Mode menu item.- Working TimerThe control board has a working timer which is always enabled while the amplifier is working (i. e. there is atleast one power supply working). The menu entry Working Timer View Timer allows to check the hoursfor which the timer has been enabled. Working Timer Timer Reset resets the timer.- ThresholdsThis is a screen showing the alarm threshold of each and all signals monitored by the control board. The listcan be scrolled by means of the UP and DOWN keys.EVENT DESCRIPTIONLocal ON Amplifier turned on by means of the local switchLocal OFF Amplifier turned off by means of the local switchRemote ON Amplifier turned on remotelyRemote OFF Amplifier turned off remotelyInterlock opened Interlock chain openedInterlock closed Interlock chain closedPower Supply ON Power supply onFwd Pwr xxxxW Alarm for forward powerRef Pwr xxxxW Alarm for reflected powerUnbY xxxxW Unbalancing alarmPwr Sup x: V1 xx.xV Power supply voltage alarmI1 xx.xA Power supply current alarmPwr Sup x: OVERVOLT Power supply overvoltage alarmPwr Sup x: OVERTEMP Power supply overtemperature alarm
65- RMS/PeakThe control board can monitor both the RMS and peak powers. The menu entry Settings RMS/Peakallows to choose the power to be displayed and monitored.- Date/TimeThis screen allows to set the current date and time. The setting is changed by pressing the arrow keys, thenpressing the RET key to move to the following setting and eventually save the changes. To go back to theprevious menu and discard any change made, press the ESC key. Figure 8 shows an example of this screen.Figure 8: Date and time setting screen- DisplayThe menu entry Settings Display allows to change some settings of the display, such has back light,contrast and screensaver. The back light and the contrast are set by means of the UP and DOWN arrowkeys. The changes made are saved by pressing the RET key or discarded pressing the ESC key. Figure 9shows the contrast screen.With Settings Display Screensaver you can set an interval time after which display backlight isturned off. When display backlight is off, press any key to switch it on.Figure 9: Display contrast setting screen
66- Frequency (only for some Amplifiers)The forward and reflected RF power is measured by means of a directional coupler. In order to compensatefor the effect due to the sampling made by the coupler, it is possible to set the frequency by means of the menuentry Settings Frequency. The setting can be changed by pressing the arrow keys. The changes madeare saved by pressing the RET key or discarded pressing the ESC key. In a TV Amplifier, set the videocarrier frequency.- Slave AddressThe amplifier may be used either in stand-alone mode or as slave of a master within a multiple transmitter. Inthe latter case an unique address for each amplifier has to be specified, in order for all of them to communicatewith the master on the same RS485 bus. The menu entry Settings Slave Address allows to choose thestand-alone mode or set a slave address by means of the UP and DOWN arrow keys. The changes made aresaved by pressing the RET key or discarded pressing the ESC key. This screen is shown in Figure 10.Figure 10:Slave address setting screen- RemoteThe amplifier may be controlled either locally, by means of the keys and display, or remotely. There are threepossibilities for remote control:- using a direct serial connection between amplifier RS232 connector and a PC RS232;- using the remote control device manufactured by Elettronika S.r.l. (RCU), on the RS485 bus;- using a general-purpose control system connected to telemeasures.You can enable / disable remote control choosing menu item Settings Remote. When remote controlis enabled, the yellow REMOTE LED on the front panel is lit.- InterlockOne of the pins of the telemeasure connector, located on the rear panel, is for the interlock alarm. It is an inputline which turns off the amplifier in case of alarm. The interlock check can be enabled or disabled using menu
67item Settings Interlock. When it is enabled, the status bar shows the lock symbol (see Figure 3),which is close if the interlock chain is closed (no alarm) or open if it is open (alarm).- Firmware ReleaseThe menu entry Settings Firmware Release allows to display the firmware version number and thehardware release of the amplifier.- Serial NumberThe menu entry Settings Serial Number allows to display the serial number of the apparatus.
68This page is intentionally blank
69_______________________________________________________________________________________________Section 4 - DiagramContents:- Cable diagram- AUTV/1500LD Component layout- RF Section Block Diagram- MTF0070BR0 Amplifier module - Component list- SCH0192AR0 (200W UHF LDMOS Amplifier module)- SCH0223AR1 (Control board and display)- SCH0221AR1 (Amplifier interface)- SCH0215AR0 (Mains distribution board)- E0026 (1kW 32Vdc Switching power supply)
70
71
72
73Part Name Code Description Qty00001 0W 1206 SMD RESISTOR 201041D 1nF 1206 2% SMD CAPACITOR 200221B 75W 1206 1% SMD RESISTOR 203207 HSMS-2802*L31 DIODE 2SCH0192AR0 200W UHF LDMOS AMPLIFIER MODULE 9SCH0221AR0 AMPLIFIER INTERFACE 1SCH0248AR0 8 WAY WILKINSON 1SCH0249AR0 4 WAY WILKINSON Dx 1SCH0250AR0 4 WAY WILKINSON Sx 1SCH0251AR0 2 WAY WILKINSON 1SCH0252AR0 1500W UHF INPUT COUPLER 1PN1091A C.S. PN1091AR3 OUTPUT DIRECTIONAL COUPLER 102402 7/16 FEMALE CONNECTOR cod. 0142 102512 J01151A0531 SMA SOCKET WITHOUT BAT. 101400 2499-003-X5U0-102M FEED-THROUGH CAPACITOR 1401408 5000PF FEED-THROUGH CAPACITOR 2DET0726 DET0726R2 SIDE x 1500W UHF AMP. MOD. 2DET0727 DET0727R1 INTERNAL FRONT SIDE x AMP. MOD. 1DET0728 DET0728R4 INTERNAL SIDE x AMP. MOD. 2DET0729 DET0729R2 FRONT SIDE x AMP. MOD. 1DET0730 DET0730R2 REAR SIDE x AMP. MOD. 1DET0732 DET0732R1 CONNECTIONS SUPPORT BOARD 1DET0734 DET0734R0 COVER x AMPLIFIER MODULE P. 2634 1DET0736 DET0736R5 HEATSINK x AMPLIFIER MODULE 1DET0807 DET0807R3 SCREEN DIR. COUPLER MODULE 1DET0810 DET0810R0 PART. x DIRECTIONAL COUPLER 1DET0811 DET0811R1 COVER x DIRECTIONAL COUPLER 1DET0812 DET0812R1 TEFLON RING x DIRECTIONAL COUPLER 1DET0819 DET0819R0 SPESS. x INPUT DIR. COUPLER 1DET0828 DET0828R0 COVER x AMPLIFIER MODULE P. 2644 1DET0839 DET0839R2 DIRECTIONAL COUPLER 108502 RG316 50W CABLE 3,0008527 HF-85 ENDIFORM CABLE 0,20Component list MTF0070BR0 Amplifier module
74This page is intentionally blank
75Part Name Code Description QtyDET0516 DET0516R0 SUPPORTO PRESE ZN 1E0026 ALIM. SWITCHING 1kW 32VDC mod. PBIT2129 3V0958 ACCESSORIO GUIDA DIN ELECO E205 2V0962 MORSETTIERA/GIUNZIONE ELECO E806 1Z0081B TAV... SUPPORTO INT. MAG. QUADRIPOL. 2Z0673 TAV. 1199 CHIUS. CONT. PROF. 775 ZN 2MTF0070BR0 MOD. AMPLIFICATORE 1500W LDMOS UHF 102830 PRESA VDE 10A cod. PX675 A63 102876 PRESA VOLANTE ILME 16A PENTAPOLARE 3mt 102877 SPINA A PANNELLO ILME 16A PENTAPOLARE 107524A INTERR. NERI I3910 107515 INTER. AUTOM. 4*16A 4.5KA 23902 107541 PORTAFUS. 10A PANN. cod. P1820 307925 PROTEZIONE IN GOMMA OVC PG 075 108500 CAVO RG174 50 Ohm 1,40FUS1A FUSIBILI 1A 5x20 RITARDATI ST520210 1FUS5A FUSIBILI 5A 5x20 RITARDATI ST520250 1PAN0074 PAN0074AR0 PANN. 6U AMPLIFICATORE LDMOS 105553B KIT MANIGLIE 5-6U cod. 235.013 2Z0021 TAV. 635/A TOND. OTT. x INT. MAGNET. 207605B VENTOLA D2E097-BI56-48 207605A COND. 2uF 202228 GE 15145 D/60 NF A VITONE 102699 CONNETTORE cod. 534-2301 FEMM. 10 VIE 902695 CONNETTORE DB9F x CAVO 525-2810 300664 SENSORE TERMICO LM 35DT 1SCH0223AR1 SCHEDA CONTROLLO AMPLIFICATORI PBOX2003 1SCH0215AR0 SCHEDA DISTRIBUZIONE RETE 1CON0178 CON0178R2 POSTERIORE 1500W LDMOS UHF 1CON0179 CON0179R1 LATERALE 1500W LDMOS UHF 2FUS3A FUSIB. 3.15A 5x20 RITAR. ST520231 102502 J01150A0041 SMA x RG58/c 107605F GRIGLIA 09485-2-4039 408503 CABLE RG303 50 Ohm 1,20DET0771 DET0771R0 CANALINA COPERTURA CAVI 1DET0772 DET0772R0 BARRETTA FISSAGGIO VENTOLE 1Component list APT117B - AUTV/1500LD
76This page is intentionally blank
77200W 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
78CALIBRATION 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
79- 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
80capacitive 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.
81Component layout SCH0192AR0
82
83COMPONENT 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
84REF. 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
85REF. 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
86Picture 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. There are managed by amodern and powerful 16 bit micro-controller (MB90F543), made by Fujitsu, which is the main part of theboard.Picture 1 shows the block diagram.
87It 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 from which the +5V voltage powering the most of thechips (micro-controller, operational amplifiers, display, etc.) is derived by means of a switching converter (seeIC19). A +12Vdc voltage is obtained from it as well, by means of a linear conversion provided by theintegrated circuit IC8. From this, a -12Vdc voltage is obtained by means of the integrated circuit IC5. The-12V voltage is also 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 connected to the power supply powering the RF amplifier modules. Thenumber of power supply used changes depending on the amplifier, up to four power supply. They are connectedin the order shown in Table 1 below. Remaining connectors, if any, are left unused.Table 1: Interface connectors for the power supplyThrough this connection, each power supply provides the two levels of voltage and current acquired by themicro-controller by means of an internal ADC. Besides the connectors allow the control board to turn on oroff the individual power supply (for instance when an alarm occurs). The used power supply are protectedCONNECTOR POWER SUPPLY N°J1 1J6 2J8 3J12 4
88agaimst voltage surges or temperature increases. If one of these events occurs, the power supply is switchedoff and the event is signalled to the micro-controller through the connection with the control board.RF AMPLIFICATIONThe J3 connector interfaces the control board with the RF amplification section. Through this connector themicro-controller acquires the sample of forward and reflected power, unbalancing (if any), and temperatureof the critic amplification area. It also allows to inhibit the transistors in case of reflected power alarm, bymeans of a 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 as 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 for connection to the RemoteControl Unit (RCU) made by Elettronika S.r.l. This unit allows to monitor and control the remote transmitterfrom any site 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
89TELEMEASURESThe 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 correspondende 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 refers to theposition of the micro-controller on the board).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(usually high, active when low)9 8 Digital Input Turning-off control(usually high, active when low)Table 3: Description of the telemeasures connectorThe input stage of the digital controls has an internal pull-up towards the 5V power supply voltage. To use thislines 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 switched open again (impulse controls).The interlock pin may be used as protection so that the amplifier is switched off the digital input level is low. Itis possible to use several serially connected switches to make an interlock chain. Usually all switches areclosed and the interlock level is low, thus the amplifier is on. If even only one of the switches is opened, 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 connector, RMS power is selected. Otherwise, if there are two jumpers on pins 2 and 3 of the same connectors, peak poweris selected.
90Picture 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 connectors 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 stronglyincreases the output level due to the AGC, thus damaging the amplification stages, the connector is providedwith two digital output lines called AGC Alarm. Under alarm conditions, this lines are brought by the micro-controller at 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 protection for interlock alarm is activated for the amplifier, which is switched off. Note that incase the interlock protection is 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 (seeuser manual).Picure 2 shows a usage for the digital input signals to turn on and off the amplifier and for the interlock alarm.
91Table 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 is used. The connector is DCE type and the pin used are shown in Table 5.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
92FIRMWARE UPDATEThe micro-controller MB90F543 is provided with a built-in Flash memory containing the firmware. Thefirmware can be updated to later versions without removing the apparatus from the rack and/or replacing thechip.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 of the PC and choose the update fileby pressing 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. Picture 3 shows this window while a firmware is being updated.Picture 3: The EKAFlash window while updating a firmware
93
94
95
96
97
98
99
100
101COMPONENT 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
102Part 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

Navigation menu