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
- 1. User Manual Part 1
- 2. User Manual Part 2
- 3. User Manual Part 3
User Manual Part 2
_______________________________________________________________________________________________ Section 1 - Information Contents: 1.1 Description 1.2 Technical characteristics 49 AUTV/1500LD LDMOS - UHF TV AMPLIFIER 1.1 DESCRIPTION The AUTV/1500LD is an amplifier operating into Band IV-V for common amplification process of the Vision and Sound carriers. The amplifier has been designed to offer to the customer high performances, high reliability and greater simplicity in his operation and maintenance procedures. The amplifiers modules employ all solid state LDMOS technology in order to obtain high gain, wideband performances, very good linearity, reliability and high efficiency. The equipment design allows the soft degradation (RF power loss) for several transistor faulty: in fact the output combiner uses RF power resistors for unbalancing power dissipation. The unit is enclosed in a cabinet for 19- 6U rackmounting. 50 1.2 TECHNICAL CHARACTERISTICS RF GENERAL PROTECTION THR. Frequency range Output power Video/Sound power ratio Out stage technology Vision-Sound amplification I.M.D. (-8, -10, -16dB) Standards Spurious and harmonics level RF Output impedance RF Output connector 470 - 860MHz 1300W PEP 10/1 Solid State LDMOS Common Better than -54dB G, K, N In compliance with CCIR rec. 50W 7/16 Power supply Power consumption RS232 Socket RS485 Socket Telemeasuring socket AGC Socket Power factor Ambient temperature Relative humidity Altitude Cooling Cabinet Dimensions Weight 230Vac, ±10%, 50/60Hz 400Vac 3P+N (on request) 3400VA at black level DB9 Connector (on front panel) DB9 Connector (on rear panel) DB9 Connector (on rear panel) DB9 Connector (on rear panel) > = 0.9 -5° to +45°C 20% - 90% Up to 2.500 meters Forced air Rack 19-6U 760x263x266mm 70kg FWD Power REF Power Unbalacing Temperature IDC VDC 1500W 150W 350W 75°C 25A Min 10V - Max 33,5V 51 This page is intentionally blank 52 _______________________________________________________________________________________________ Section 2 - Installation Contents: 2.1 Operating environment 2.2 Preliminary operations 2.3 Telemeasuring socket connections 2.4 RS232, RS485 and AGC socket connections 2.5 Preventive maintenance - Front panel - Rear panel 53 2.1 OPERATING ENVIRONMENT You 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 of clearance under the unit for ventilation. If you set the apparatus on a flat surface, install spacers on the bottom cover plate. If you install the apparatus in a rack, provide adequate clearance above and below. Do not locate the apparatus directly above a hot piece of equipment. 2.2 PRELIMINARY OPERATIONS Correct installation of the equipment is important for maximum performance and reliability. Antenna and earth connections must be installed with the greatest care. The equipment adjustment isnt need, because the unit is completely 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 Isolator Transformer, 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 the amplifier. Monophase cabling Three-Phase cabling WARNING!!! FOR ELECTRICAL SAFETY REASONS AND IN ORDER TO KEEP THE APPARATUS SAFE, THE GROUND TERMINAL OF THE APPARATUS MUST BE CONNECTED TO THE EXISTING GROUNDING SYSTEM AND NOT BY USING THE SHIELD OF THE OUTPUT COAXIAL CABLE. 54 When the apparatus is put within a combined system it is directly connected to the input splitting and output combining systems. Before fully powering the apparatus, check that the output connections of the coaxial cable to the antenna system are working. In order to this it is possible to check the indication of the reflected power at low power levels. Only if the SWR 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 CONNECTIONS PIN N° DB9 Socket SIGNAL TYPE IN / OUT FUNCTION Analog Output FWD Power Analog Output REF Power Digital Output Temperature Digital Input GND 6-7 Digital Output Free contact (closed when alarm) Digital Input 0V = ON 5V = Normal Digital Input 0V = OFF 5V = Normal Interlock 2.4 RS232, RS485 AND AGC SOCKET CONNECTIONS PIN FUNCTIONS TxD RxD GND RS232 - DB9 Socket PIN FUNCTIONS Rx- Rx+ 5V GND Tx- Tx+ RS485 - DB9 Socket 55 PIN N° SIGNAL TYPE IN / OUT FUNCTION GND Digital Output 0V = Normal 5V = AGC Alarm Digital Output 0V = Normal 5V = AGC Alarm Analog Output FWD Power Analog Output FWD Power AGC - DB9 Socket 2.5 PREVENTIVE MAINTENANCE To ensure maximum performance and minimum repair trouble, we strongly recommend you to follow the below 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 panel controls; 3. if the apparatus has not been used for a long period of time combined with exposure to extreme environmental 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 are running freely. 4. for general maintenance and top performance, call an authorized service technician to give the apparatus and 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. 56 Front panel LCD Display Function keys Status LEDs RF Monitor connector Main switch RS232 Socket DESCRIPTION 57 Rear panel DESCRIPTION 58 Breaker Power supply socket Auxiliary socket Fuse RS485 Socket AGC Socket Telemeasure socket RF Input connector RF Output connector _______________________________________________________________________________________________ Section 3 - Operation Contents: 3.1 Control board and display description 3.2 Operation 3.3 Display 3.4 Menu 59 3.1 OPERATION At startup, after intro image, the display shows the main screen, showing the RF powers as in Figure 1: Figure 1: Main screen The user may turn on and off the amplifier by means of the switch on the front panel. The control board turns on all the power supplies, the exciter, if any, and the cooling fans. While the amplifier is working, the microcontroller 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 threshold beyond 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 protection status, the failed block is turned on again for up to five times. If it goes beyond the protection threshold for more than five times, it is declared as FAILED and will no longer be turned on. In this case the amplifier will have to be turned off manually by means of the switch on the front panel, then turned on again after performing the needed maintenance. On the front panel there are also three LEDs labelled ON, REMOTE and ALARM. Their meanings are explained below. LED COLOUR MEANING MEANING WHEN BLINKING The amplifier has been turned on locally but it has been turned off by remote ON Green The amplifier is on REMOTE Yellow Re mo te c o ntro l i s It never blinks enabled ALARM Red Alarm status It never blinks Table 1: Meanings of the three LEDs on the front panel Screenshots in this manual are indicative and they refers to a TV amplifier, so they can be different from those on your equipment. 60 3.2 DISPLAY The control board is provided with a modern 128x64 pixels graphic display with blue backlight. Normally it always 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 current time. Figure 2: Title bar The status bar indicates the forward and reflected power and the temperature. It also contains two symbols for the interlock (lock) and a generic alarm (bell). Figure 3: Status Bar The bell symbol is displayed in case of alarm. It blinks if there has been an alarm which has ended but has not yet 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 interlock chain). Since the status bar is always on the display, regardless of the displayed screen, the user may monitor at any moment the most important parameters and the presence of alarms, if any, while moving between different screens. 3.3 MENU The user may see or modify locally some configuration parameters of the apparatus by means of the four keys on the front panel. All screens are made up by hierarchical menus and the user may move between them in a simple and intuitive way. To see the main menu its sufficient to press ESC key (see Figure 4). 61 Figure 4: Main menu The display only shows three items, but the whole menu can be scrolled by means of the UP and DOWN arrow keys. Any item can be chosen by selecting it and pressing the RET key. Menu entries with arrow on the right open sub-menus when chosen. Thus there is a hierarchical structure as in Figure 5. To go back from a sub-menu to the previous menu, press the ESC key. If the ESC key is pressed in the main menu, the main powers screen is accessed. View Log/Alarms Clear Log/Alarms Log Mode Exit View Timer RF Powers Timer Reset Power Supplies Exit Backlight Contrast Screensaver Exit Log/Alarms > Working Timer > Thresholds RMS/Peak Settings > Date/Time Exit Display Frequency Slave Address Remote Interlock Release Serial Number Exit Figure 5: Hierarchical menu structure All menu items are described in detail below. 62 - RF Powers This 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 Supply This screen shows all the signals coming from the power supply. To check a different power supply press the UP (or DOWN) key to see the next (or previous) one. For each power supply, the two voltages, the two absorbed currents and the status (ON or OFF) are shown. - Log/Alarms Figure 6: Power supply screen The control board is provided with an external EEPROM and a clock. Any alarm or switching event is saved into an event log stored inside the EEPROM and associated to the time at which it occurred. The Log/Alarms sub-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 events can be scrolled by pressing the UP and DOWN keys. The event shown in Figure 7 is the turning on of the amplifier by means of the local switch. Each event is associated to the date and time at which it occurred and to a description. Figure 7: Event stored in the log 63 In case of alarm on a parameter, the value of the parameter which caused the alarm is saved into the log. In case of alarm still existing after five turning-on attempts, the parameter is marked as FAILED. Table 2 is the list of all the events which can be logged. EVENT DESCRIPTION Local ON Amplifier turned on by means of the local switch Local OFF Amplifier turned off by means of the local switch Remote ON Amplifier turned on remotely Remote OFF Amplifier turned off remotely Interlock opened Interlock chain opened Interlock closed Interlock chain closed Power Supply ON Power supply on Fwd Pwr xxxxW Alarm for forward power Ref Pwr xxxxW Alarm for reflected power UnbY xxxxW Unbalancing alarm Pwr Sup x: V1 xx.xV Power supply voltage alarm I1 xx.xA Power supply current alarm Pwr Sup x: OVERVOLT Power supply overvoltage alarm Pwr Sup x: OVERTEMP Power supply overtemperature alarm Table 2: Events managed and logged by the control board The 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 selecting Log/Alarms Log/Mode menu item. - Working Timer The control board has a working timer which is always enabled while the amplifier is working (i. e. there is at least one power supply working). The menu entry Working Timer View Timer allows to check the hours for which the timer has been enabled. Working Timer Timer Reset resets the timer. - Thresholds This is a screen showing the alarm threshold of each and all signals monitored by the control board. The list can be scrolled by means of the UP and DOWN keys. 64 - RMS/Peak The control board can monitor both the RMS and peak powers. The menu entry Settings allows to choose the power to be displayed and monitored. RMS/Peak - Date/Time This screen allows to set the current date and time. The setting is changed by pressing the arrow keys, then pressing the RET key to move to the following setting and eventually save the changes. To go back to the previous 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 - Display The 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 arrow keys. The changes made are saved by pressing the RET key or discarded pressing the ESC key. Figure 9 shows the contrast screen. With Settings Display Screensaver you can set an interval time after which display backlight is turned off. When display backlight is off, press any key to switch it on. Figure 9: Display contrast setting screen 65 - Frequency (only for some Amplifiers) The forward and reflected RF power is measured by means of a directional coupler. In order to compensate for the effect due to the sampling made by the coupler, it is possible to set the frequency by means of the menu entry Settings Frequency. The setting can be changed by pressing the arrow keys. The changes made are saved by pressing the RET key or discarded pressing the ESC key. In a TV Amplifier, set the video carrier frequency. - Slave Address The amplifier may be used either in stand-alone mode or as slave of a master within a multiple transmitter. In the latter case an unique address for each amplifier has to be specified, in order for all of them to communicate with the master on the same RS485 bus. The menu entry Settings Slave Address allows to choose the stand-alone mode or set a slave address by means of the UP and DOWN arrow keys. The changes made are saved by pressing the RET key or discarded pressing the ESC key. This screen is shown in Figure 10. Figure 10:Slave address setting screen - Remote The amplifier may be controlled either locally, by means of the keys and display, or remotely. There are three possibilities 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 control is enabled, the yellow REMOTE LED on the front panel is lit. - Interlock One of the pins of the telemeasure connector, located on the rear panel, is for the interlock alarm. It is an input line which turns off the amplifier in case of alarm. The interlock check can be enabled or disabled using menu 66 item 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 Release The menu entry Settings Firmware Release allows to display the firmware version number and the hardware release of the amplifier. - Serial Number The menu entry Settings Serial Number allows to display the serial number of the apparatus. 67 This page is intentionally blank 68 _______________________________________________________________________________________________ Section 4 - Diagram Contents: - 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) 69 70 71 72 Component list MTF0070BR0 Amplifier module Part Name Code Description Qty 00001 01041D 00221B 03207 SCH0192AR0 SCH0221AR0 SCH0248AR0 SCH0249AR0 SCH0250AR0 SCH0251AR0 SCH0252AR0 PN1091A 02402 02512 01400 01408 DET0726 DET0727 DET0728 DET0729 DET0730 DET0732 DET0734 DET0736 DET0807 DET0810 DET0811 DET0812 DET0819 DET0828 DET0839 08502 08527 0W 1206 SMD RESISTOR 1nF 1206 2% SMD CAPACITOR 75W 1206 1% SMD RESISTOR HSMS-2802*L31 DIODE 200W UHF LDMOS AMPLIFIER MODULE AMPLIFIER INTERFACE 8 WAY WILKINSON 4 WAY WILKINSON Dx 4 WAY WILKINSON Sx 2 WAY WILKINSON 1500W UHF INPUT COUPLER C.S. PN1091AR3 OUTPUT DIRECTIONAL COUPLER 1 7/16 FEMALE CONNECTOR cod. 0142 J01151A0531 SMA SOCKET WITHOUT BAT. 2499-003-X5U0-102M FEED-THROUGH CAPACITOR 14 5000PF FEED-THROUGH CAPACITOR DET0726R2 SIDE x 1500W UHF AMP. MOD. DET0727R1 INTERNAL FRONT SIDE x AMP. MOD. DET0728R4 INTERNAL SIDE x AMP. MOD. DET0729R2 FRONT SIDE x AMP. MOD. DET0730R2 REAR SIDE x AMP. MOD. DET0732R1 CONNECTIONS SUPPORT BOARD DET0734R0 COVER x AMPLIFIER MODULE P. 2634 DET0736R5 HEATSINK x AMPLIFIER MODULE DET0807R3 SCREEN DIR. COUPLER MODULE DET0810R0 PART. x DIRECTIONAL COUPLER DET0811R1 COVER x DIRECTIONAL COUPLER DET0812R1 TEFLON RING x DIRECTIONAL COUPLER 1 DET0819R0 SPESS. x INPUT DIR. COUPLER DET0828R0 COVER x AMPLIFIER MODULE P. 2644 DET0839R2 DIRECTIONAL COUPLER RG316 50W CABLE 3,00 HF-85 ENDIFORM CABLE 0,20 73 This page is intentionally blank 74 Component list APT117B - AUTV/1500LD Part Name Code Description Qty DET0516 E0026 V0958 V0962 Z0081B Z0673 MTF0070BR0 02830 02876 02877 07524A 07515 07541 07925 08500 FUS1A FUS5A PAN0074 05553B Z0021 07605B 07605A 02228 02699 02695 00664 SCH0223AR1 SCH0215AR0 CON0178 CON0179 FUS3A 02502 07605F 08503 DET0771 DET0772 DET0516R0 SUPPORTO PRESE ZN ALIM. SWITCHING 1kW 32VDC mod. PBIT2129 ACCESSORIO GUIDA DIN ELECO E205 MORSETTIERA/GIUNZIONE ELECO E806 TAV... SUPPORTO INT. MAG. QUADRIPOL. TAV. 1199 CHIUS. CONT. PROF. 775 ZN MOD. AMPLIFICATORE 1500W LDMOS UHF PRESA VDE 10A cod. PX675 A63 PRESA VOLANTE ILME 16A PENTAPOLARE 3mt SPINA A PANNELLO ILME 16A PENTAPOLARE INTERR. NERI I3910 INTER. AUTOM. 4*16A 4.5KA 23902 PORTAFUS. 10A PANN. cod. P1820 PROTEZIONE IN GOMMA OVC PG 075 CAVO RG174 50 Ohm FUSIBILI 1A 5x20 RITARDATI ST520210 FUSIBILI 5A 5x20 RITARDATI ST520250 PAN0074AR0 PANN. 6U AMPLIFICATORE LDMOS KIT MANIGLIE 5-6U cod. 235.013 TAV. 635/A TOND. OTT. x INT. MAGNET. VENTOLA D2E097-BI56-48 COND. 2uF GE 15145 D/60 NF A VITONE CONNETTORE cod. 534-2301 FEMM. 10 VIE CONNETTORE DB9F x CAVO 525-2810 SENSORE TERMICO LM 35DT SCHEDA CONTROLLO AMPLIFICATORI PBOX2003 SCHEDA DISTRIBUZIONE RETE CON0178R2 POSTERIORE 1500W LDMOS UHF CON0179R1 LATERALE 1500W LDMOS UHF FUSIB. 3.15A 5x20 RITAR. ST520231 J01150A0041 SMA x RG58/c GRIGLIA 09485-2-4039 CABLE RG303 50 Ohm DET0771R0 CANALINA COPERTURA CAVI DET0772R0 BARRETTA FISSAGGIO VENTOLE 1,40 1,20 75 This page is intentionally blank 76 200W UHF LDMOS AMPLIFIER MODULE SCH0192AR0 DESCRIPTION The RF module is an integrated TV linear amplifier designed for UHF band, this module employs push-pull LDMOS 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 is required for the channel change. The board includes RF section amplifier, bias circuit, protection circuit and matching 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 broadband UHF power transmitter. TECHNICAL CHARACTERISTICS Output power Input power Frequency Gain LDMOS Power supply LDMOS Bias current @+32V Vdc RF Input impedance RF Output impedance Input / Output return loss Drain efficiency Storage temperature range Dimensions (LxWxH) 300W max 15W max 470 - 860MHz > 13dB 32V ±2% 2A 50W 50W > = 15dB 47% @ 250W -50° to +150°C 165x95x29mm 77 - Curve response graphic Middle frequency 660MHz, span 500MHz, 2dB/div., reference to the arrow CALIBRATION PROCEDURE - Technical characteristics Power supply voltage Polarisation current Gain for low signal 32V (± 2%) 1.0 cold for each device (2A total), ± 0.1A Not less than 13dB in the 470-860MHz band (± 1dB) Compare to the typical curve eclosed - Adjustment procedure Polarisation current calibration Gain curve 32V stabilised power supply 10A amperometer Network analyser - Adjustment points description R7-R8 (Trimmers) 78 Adjust the current absorbed in stand-by (1.0A per device) - Calibration steps STEP 1. Close the input and the output of the module by connecting them to a 50W W dummy load and connect the spectrum analyser through a directive sample, in order to look for self-oscillation of the module, if any (anyway the module has been designed so that it would not self-oscillate even if totally decoupled, 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 check data: - 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 R24 resistors 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; Solder a wire - 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 red LEDs will immediately light up and the two RF transistors will be switched off at the same time: the polarisation current (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! Then disconnect the 32V power supply. STEP 4. Fastening of the LDMOS transistors: after properly cleaning the plate surface, smear a thin layer of silicone fat on the lower side of the flange of the MOSFETs, fasten them to the heat sink and solder the gate first, then the drain. Solder the two 13pF (ATC) chip capacitors and above them the two 1-5pF 79 capacitive trimmers, between the two pair of gates, as shown by the mounting plan. STEP 5. 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 device is integral and working correctly. STEP 7. Slowly turn the R7 trimmer until the MOSFET absorbs 1A, always checking that there are no self-oscillation; under this conditions it is possible to check by means of a digital tester that the voltage on the gate is about 5.2-5.4V. STEP 8. Repeat the previous step for the other section of the module, this time turnign R8 and checking that the indication of the current on the amperometer increases to 2A total (which includes the current of the other 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, act on the four trimmers C41-C41a and C42-C42a with the proper calibrator, inorder to flatten the curve as much 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 at worst 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 output connectors. These are mounted with a single 3mm screw and if it is not properly fastened it may be detached from the PCB by a movement of the connector once it has already been soldered to the path. 80 Component layout SCH0192AR0 81 82 COMPONENT LIST SCH0192AR0 REF. DESCRIPTION ELETTRONIKA CODE R1 R2 R3 R4 R5 R6 R7 R8 R9 R10 R11 R12 R13 R14 R15 R16 R17 R18 R19 R20 R21 R22 R23 R24 *R25 *R26 C1 C2 C3 C4 C5 C6 C7 C8 x 2 C9 x 2 C10 x 4 C11 x 4 C12 C13 C14 C15 C16 C17 2200W 1/4W 1206 SMD RESISTOR 2200W 1/4W 1206 SMD RESISTOR 2200W 1/4W 1206 SMD RESISTOR 2200W 1/4W 1206 SMD RESISTOR 1200W 1/4W 1206 SMD RESISTOR 1200W 1/4W 1206 SMD RESISTOR 50kW MULTITURNS PTH TRIMMER 50kW MULTITURNS PTH TRIMMER 1200W 1/4W 1206 SMD RESISTOR 1200W 1/4W 1206 SMD RESISTOR 18kW 1/4W 1206 SMD RESISTOR 18kW 1/4W 1206 SMD RESISTOR 680KW 1/4W 1206 SMD RESISTOR 0W 1/4W 1206 SMD RESISTOR 50W 30W 1512EBX SMD RESISTOR 50W 60W 4.7kW 1/4W 1206 SMD RESISTOR 4.7kW 1/4W 1206 SMD RESISTOR 3.9W 1/4W 1206 SMD RESISTOR 3.9W 1/4W 1206 SMD RESISTOR 3.9W 1/4W 1206 SMD RESISTOR 3.9W 1/4W 1206 SMD RESISTOR 1000W 1W 2512 SMD RESISTOR 1000W 1W 2512 SMD RESISTOR = R15 (da montare se si inverte lingresso) = R26 (da montare se si inverte luscita) 470uF 50V PTH ELECTROLYTIC CAPACITOR 470uF 50V PTH ELECTROLYTIC CAPACITOR 470uF 50V PTH ELECTROLYTIC CAPACITOR 100uF 50V PTH ELECTROLYTIC CAPACITOR 100uF 50V PTH ELECTROLYTIC CAPACITOR 1nF ATC 100B CAPACITOR OR EQUIVALENT 1nF ATC 100B CAPACITOR OR EQUIVALENT 2 x 100nF ATC CAPACITOR OR EQUIVALENT 2 x 100nF ATC CAPACITOR OR EQUIVALENT 4 x 100pF ATC 100B CAPACITOR OR EQUIVALENT 4 x 100pF ATC 100B CAPACITOR OR EQUIVALENT 100nF 1210 SMD CAPACITOR 100nF 1210 SMD CAPACITOR 100nF 1210 SMD CAPACITOR 1uF 35V SMD TANTALIUM CAPACITOR 1uF 35V SMD TANTALIUM CAPACITOR 100nF 1210 SMD CAPACITOR 00045A 00045A 00045A 00045A 00042A 00042A 00800 00800 00042A 00042A 00056B 00056B 00075A 00001 00416A 00432 00049A 00049A 00012A 00012A 00012A 00012A 00396 00396 Page 1/3 01807B 01807B 01807B 01795 01795 01145 01145 01065H 01065H 01135 01135 1065G 1065G 1065G 01613A 01613A 1065G 83 REF. DESCRIPTION ELETTRONIKA CODE C18 C19 C20 C21 C22 C23 C24 C25 C26 C27 C28 C29 C30 C31 C32 C33 C34 C35 C36 C37 C38 C39 C40 C41 x 2 C42 x 2 C43 C44 C45 C46 C47 C48 C49 C50 C51 C52 C53 C54 C55 C56 C57 C58 C59 T1 T2 B1 100nF 1210 SMD CAPACITOR 10uF 16V SMD TANTALIUM CAPACITOR 10uF 16V SMD TANTALIUM CAPACITOR 100nF 1210 SMD CAPACITOR 100nF 1210 SMD CAPACITOR 100nF 1210 SMD CAPACITOR 100nF 1210 SMD CAPACITOR 1nF ATC 100B CAPACITOR OR EQUIVALENT 1nF ATC 100B CAPACITOR OR EQUIVALENT 1nF ATC 100B CAPACITOR OR EQUIVALENT 1nF ATC 100B CAPACITOR OR EQUIVALENT 20pF ATC 100B CAPACITOR OR EQUIVALENT 20pF ATC 100B CAPACITOR OR EQUIVALENT 20pF ATC 100B CAPACITOR OR EQUIVALENT 20pF ATC 100B CAPACITOR OR EQUIVALENT 1.3pF ATC 100B CAPACITOR OR EQUIVALENT 1.3pF ATC 100B CAPACITOR OR EQUIVALENT 470pF ATC 100B CAPACITOR OR EQUIVALENT 470pF ATC 100B CAPACITOR OR EQUIVALENT 470pF ATC 100B CAPACITOR OR EQUIVALENT 470pF ATC 100B CAPACITOR OR EQUIVALENT 4.7pF ATC 100B CAPACITOR OR EQUIVALENT 4.7pF ATC 100B CAPACITOR OR EQUIVALENT 2 x 1¸5pF JOHANSON SMD TRIMMER 2 x 1¸5pF JOHANSON SMD TRIMMER 3.6pF ATC 100B CAPACITOR OR EQUIVALENT 3.6pF ATC 100B CAPACITOR OR EQUIVALENT 6.8pF ATC 100B CAPACITOR OR EQUIVALENT 6.8pF ATC 100B CAPACITOR OR EQUIVALENT 6.8pF ATC 100B CAPACITOR OR EQUIVALENT 6.8pF ATC 100B CAPACITOR OR EQUIVALENT 13pF ATC 100B CAPACITOR OR EQUIVALENT 13pF ATC 100B CAPACITOR OR EQUIVALENT 8.2pF ATC 100B CAPACITOR OR EQUIVALENT 8.2pF ATC 100B CAPACITOR OR EQUIVALENT 8.2pF ATC 100B CAPACITOR OR EQUIVALENT 8.2pF ATC 100B CAPACITOR OR EQUIVALENT 10pF ATC 100B CAPACITOR OR EQUIVALENT 10pF ATC 100B CAPACITOR OR EQUIVALENT 4.7pF ATC 100B CAPACITOR OR EQUIVALENT 4.7pF ATC 100B CAPACITOR OR EQUIVALENT 0.3pF ATC 100B CAPACITOR OR EQUIVALENT BLF861A RF LDMOS POWER TRANSISTOR BLF861A RF LDMOS POWER TRANSISTOR COAX 2:1 BALUN 1065G 01626A 01626A 1065G 1065G 1065G 1065G 01145 01145 01145 01145 01123 01123 01123 01123 01104 01104 01143 01143 01143 01143 01108 01108 1485 1485 01104B 01104B 01111 01111 01111 01111 01119A 01119A 01113 01113 01113 01113 01117 01117 01108 01108 01160 04034 04034 08491 84 Page 2/3 REF. DESCRIPTION ELETTRONIKA CODE B2 B3 B4 L1 L2 L3 L4 H1 H2 NTC1 NTC2 IC1 IC2 DZ1 DZ2 DZ3 DZ4 DL1 DL2 PN964AR3 COAX 2:1 BALUN COAX 4:1 BALUN COAX 4:1 BALUN 4 TURNS SILV. COP. WIRE 1.2mm WOUND ON OD 5mm 4 TURNS SILV. COP. WIRE 1.2mm WOUND ON OD 5mm ½ TURN COIL ½ TURN COIL HYBRID COUPLER 3dB 90° ANAREN HYBRID COUPLER 3dB 90° SAGE NTC 100KW PTH NTC 100KW PTH DG419DY DG419DY 15V SMD ZENER DIODE 15V SMD ZENER DIODE 6.8V SMD ZENER DIODE 6.8V SMD ZENER DIODE SMD LED DIODE - RED SMD LED DIODE - RED PCB Torretta 3x10 f/f Imballo velapack 200x125x50 08491 08492 08492 07684 07684 Page 3/3 05368 05369 00661 00661 04583 04583 03135 03135 03137 03137 03056 03056 0643K V0774 09983 85 CONTROL BOARD AND DISPLAY SCH0223AR1 DESCRIPTION The control board SCH0223AR1 manages the operational logic of the amplifier: switching on and off, power supply and fans, alarms and protections, remote control, human-machine interface. There are managed by a modern and powerful 16 bit micro-controller (MB90F543), made by Fujitsu, which is the main part of the board. Picture 1 shows the block diagram. Picture 1: Simplified block diagram of the control and display board 86 It 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 and keys) are interfaced. - Power Supply The board is powered with a continuous +24V voltage from which the +5V voltage powering the most of the chips (micro-controller, operational amplifiers, display, etc.) is derived by means of a switching converter (see IC19). A +12Vdc voltage is obtained from it as well, by means of a linear conversion provided by the integrated 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. - Connectors On the board SCH0223AR1 there are several connectors used as interfaces for the peripherals of the apparatus and the ports for external communication. POWER SUPPLY The connectors J1, J6, J8 e J12 are connected to the power supply powering the RF amplifier modules. The number of power supply used changes depending on the amplifier, up to four power supply. They are connected in the order shown in Table 1 below. Remaining connectors, if any, are left unused. CONNECTOR POWER SUPPLY N° J1 J6 J8 J12 Table 1: Interface connectors for the power supply Through this connection, each power supply provides the two levels 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 the individual power supply (for instance when an alarm occurs). The used power supply are protected 87 agaimst voltage surges or temperature increases. If one of these events occurs, the power supply is switched off and the event is signalled to the micro-controller through the connection with the control board. RF AMPLIFICATION The J3 connector interfaces the control board with the RF amplification section. Through this connector the micro-controller acquires the sample of forward and reflected power, unbalancing (if any), and temperature of the critic amplification area. It also allows to inhibit the transistors in case of reflected power alarm, by means 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 critic area. RS485 The J11 connector (10 pin socket) is directly wired to a DB9 female connector placed on the rear panel of the apparatus. This communication bus allows to connect the amplifier to the control (Amplifier Control) module of a high-power transmitter composed by several individual amplifiers. In this case, each amplifier and the Amplifier 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 Remote Control Unit (RCU) made by Elettronika S.r.l. This unit allows to monitor and control the remote transmitter from 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 rear panel, along with the description of the lines. PIN N° ON DB9 PIN N° ON J11 DESCRIPTION Not used Rx- Rx+ +5V GND Not used Tx- Tx+ Not used Table 2: Description of the RS485 connector For more details about the control system contact the distributor or the manufacturer. 88 TELEMEASURES The J9 telemeasure connector (10 pins socket) is directly wired on a DB9 female connector placed on the rear panel. There are input and output digital lines (TTL level) and analog output lines on this connector, which are 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 the rear panel, as well as the meaning of the various lines, is shown in table 3 below (the directions refers to the position of the micro-controller on the board). PIN N° ON DB9 PIN N° ON J9 TYPE DIRECTION Analog Output Forward power (*) Analog Output Reflected power (*) Analog Output Temperature Digital Input 6-7 2-4 Digital Output Digital Input Turning-on control (usually high, active when low) Digital Input Turning-off control (usually high, active when low) DESCRIPTION Interlock: 0V = Interlock Alarm 5V = Normal Ground Free Contact (closed when amplifier is in alarm) (*) 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 of JP1 and JP2 connector, RMS power is selected. Otherwise, if there are two jumpers on pins 2 and 3 of the same connectors, peak power is selected. Table 3: Description of the telemeasures connector The input stage of the digital controls has an internal pull-up towards the 5V power supply voltage. To use this lines it only takes setting a switch to close to earth, when closed, the relevant control (turning on or off) is enabled 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. It is possible to use several serially connected switches to make an interlock chain. Usually all switches are closed and the interlock level is low, thus the amplifier is on. If even only one of the switches is opened, the 89 level of the interlock signal becomes high (this line has a pull-up towards the +5V power supply voltage as well) and the protection for interlock alarm is activated for the amplifier, which is switched off. Note that in case 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 (see user manual). Picure 2 shows a usage for the digital input signals to turn on and off the amplifier and for the interlock alarm. Picture 2: Usage of the digital input signals of the telemeasures connector AGC / EXCITER The connector called J10, as the telemeasures connector and the RS485 bus, is wired to a DB9 female connector placed on the rear panel of the amplifier. This connectors allow the implementation of an automatic gain control between an exciter and the amplifier. A voltage signal related to the forward output power supplied by the amplifier is provided through two pins of the AGC connector. Connecting one of these to the relevant input pin of the exciter, this can pursuit a given voltage level, so that the output power is always constant. In order to avoid that, in case of an alarm decreasing the forward power, the exciter strongly increases the output level due to the AGC, thus damaging the amplification stages, the connector is provided with two digital output lines called AGC Alarm. Under alarm conditions, this lines are brought by the microcontroller 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 rear panel, along with the description of each pin (the direction of the pin is referred to the position of the microcontroller on the board). 90 PIN N° ON DB9 PIN N° ON J10 TYPE DIRECTION Digital Output AGC Alarm 0V = Alarm 5V = Normal Digital Output AGC Alarm 0V = Alarm 5V = Normal Not used Not used Not used Nout used Analog Output Forward power Analog Output Forward power DESCRIPTION Ground Table 4: Description of the AGC connector RS232 The DB9 female connector on the front panel is an external communication RS232 serial port, through which a PC can be connected directly to the amplifier in order to perform operations such as the remote control (by means 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 DESCRIPTION TxD RxD GND Table 5: Description of the RS232 connector MISCELLANEOUS The J2 (called AUX), J4, J5 and J17 connectors are not used and are there only for future updates. The SW1 dip-switches are partially used for the configuration of the correct mode for the micro-controller. The other switches are not used. It is important that the position of the dip-switches is left unchanged, because changing it may set a wrong mode for the micro-controller, affecting the work of the whole amplifier. For more information about this application contact the distributor of the manufacturer. 91 FIRMWARE UPDATE The micro-controller MB90F543 is provided with a built-in Flash memory containing the firmware. The firmware can be updated to later versions 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 cable DB9 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 file by 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 firmware begins on the EKAFlash window. Picture 3 shows this window while a firmware is being updated. Picture 3: The EKAFlash window while updating a firmware 92 93 94 95 96 97 98 99 100 COMPONENT LIST SCH0223AR1 Part Name/Number Description Qty. Comps. Page 1/2 BATT BH001RB 3093_90 CC 100nF-S 01065C 03093 03090 BATTERY HOLDER 01065C Y5V 1206 COND 46 CC 15pF-S 01088 CC 1nF-S 01096 CC 1uF100V-S 01760A 01088 SMD 1206 COND 01096 SMD 1206 COND 01760A Y5V 1206 COND 13 CC 47pF-S 01100 CE 100uF25V-S 01793B CE 10uF35V-S 01778A CE 1uF35V-S 01613A CE 220uF50V LOW ESR CE 22uF16V-S CE 47uF35V-S 01790A D 1N4148-S 03002 D 50WQ06FN D BAS85-S D BAT54S DIS MGLS12864T DL KA-3528SGC 03057 DL LEDG5 03060 DL LEDR5 03061 DL LEDY5 03054B IC 24LC64 04815 IC 78M12 4307B IC CD4051BM-S IC LM2596S-5.0 IC LM358M-S 04660 IC LM393-S 04639 IC LMC6482-S IC LMC6484-S 01100 SMD 1206 COND 01793B ELETTR SMD COND 01778A ELETTR SMD COND 01613A TANTALIUM ELETTR SMD CO 1799A ELETTR SMD COND LOW ESR 01780A ELETTR SMD COND 01790A ELETTR SMD COND 03002 SMD DIODE 03019A SMD DIODE SCHOTTKY 5,5A 03024 SMD DIODE SCHOTTKY 03199 SMD SCHOTTKY DIODE A-K T 03083A 128x64 DOT (BLUE-LED WH 03057 GREEN SMD LED DIODE 03060 GREEN LED DIODE 5mm 03061 RED LED DIODE 5mm 03054B YELLOW LED DIODE 5mm 04815 SMD INTEG CIRCUIT 04307B SMD VOLTAGE REGULATOR 04615 SMD INTEG CIRCUIT 04580 SMD INTEG CIRCUIT 04660 SMD INTEG CIRCUIT 04639 SMD INTEG CIRCUIT 04632 SMD INTEG CIRCUIT 04634 SMD INTEG CIRCUIT 19 IC M41T56 04611 IC MAX232-S 04804B IC MAX3080-S 04770 IC MAX942CSA-S IC MB90F543PF IC MPC100-450DI-TO IC TC7662BCOA 04758A IC ULN2003A 4870 IND 2u2H-S 05020A 04611 SMD INTEG CIRCUIT 04804B SMD INTEG CIRCUIT 04770 SMD INTEG CIRCUIT 04572 SMD INTEG CIRCUIT 04596 SMD INTEG CIRCUIT 04608 INTEG CIRCUIT 04758A SMD INTEG CIRCUIT 04870 SMD INTEG CIRCUIT 05020A INDUCTOR BATT1 C2, C7-10, C12, C16, C19, C21-27 C29, C31, C33, C37-40, C44-46, C49, C58-61, C63, C65-69, C74, C76, C78-81, C83-84, C87, C90 C13-15, C17 C3-6, C50-51, C53 C1, C18, C28, C36, C43, C54, C56-57, C62, C73, C77, C88-89 C42, C52 C11, C47 C20, C32 C70-72, C75, C82 C55, C64, C85-86 C34-35, C41, C48 C30 D1-2, D5-9 D23 D14-15 D3-4, D10-13, D16-22, D24-29 DIS1 DL2, DL5-10 DL1 DL4 DL3 IC17 IC8 IC7, IC14, IC23 IC19 IC3 IC2 IC24 IC1, IC4, IC6, IC9, IC13, IC18, IC25 IC20 IC21 IC22 IC10 IC11 IC16 IC5 IC12, IC15 L1 101 Part Name/Number Description Qty. Comps. IND MS85 10uH-S IND T100uH-1.8A 4958 J CON HD515V/05-4PVE J DB9_F-0° LT J FC-10P 02697-02699 J FC-16P 02701-02700 J PAN2 02739-40-41 J PAN8 02716 JU JUMP2 02739-02742 JU JUMP3 02707-02742 R 100K-1%-S 00065B R 100R-1%-S 00029D 04948 INDUCTOR 2,7 A 04958 TOROIDAL-STORAGE CHOKES 02881 + 02882 PANDUIT PCB CONN 02794 PCB CONNECTOR DB9 LONG T 02697+02699 PCB CONNECTOR POL 02701+02700 PCB CONNECTOR POL 02739+02740+02741 PCB CONNECTO 02716 PCB CONNECTOR 02739+02742 MASCHIO PAN2 02707+02742 MASCHIO PAN3 00065B RES 1/4W 1% SMD 1206 00029D RES 1/4W 1% SMD 1206 10 12 R 10K-1%-S 00053B 00053B RES 1/4W 1% SMD 1206 32 R 10R-S 00017A R 1206 NOT MOUNTED R 1K0-1%-S 00041B 00017A RES 1/4W 5% SMD 1206 NOT MOUNTED RES 1/4W 5% SMD 12 00041B RES 1/4W 1% SMD 1206 R 22K-1%-S 00057B 00057B RES 1/4W 1% SMD 1206 11 R 2K2-1%-S 00045B R 470K-S 00073A 00045B RES 1/4W 1% SMD 1206 00073A RES 1/4W 5% SMD 1206 11 R 470R-1%-S 00037B R 4K7-1%-S 00049B R 68K-1%-S 00063B R 820R-S 00040A R 8K2-1%-S 00052B RL 30.22.24 07569 RV 100K-3266X RV 10K-3266X 00807 SW SWITCH-8DIP T 06086 N 7630 7632 TR BC848 03457 TR BC856 03455 XTAL 32.768k-S 05146 XTAL 4MHz-S 05101A 00037B RES 1/4W 1% SMD 1206 00049B RES 1/4W 1% SMD 1206 00063B RES 1/4W 1% SMD 1206 00040A RES 1/4W 5% SMD 1206 00052B RES 1/4W 1% SMD 1206 07569 RELE 00814 VARIABLE RESISTOR 00807 VARIABLE RESISTOR 07530A PCB DIP SWITCH SMD 7630 7632 KTI06086 PULSANTE 2 03457 NPN SMD TRANSISTOR 03455 PNP SMD TRANSISTOR 05146 QUARTZ 05101A QUARTZ L2 L3 J14 J13 J1-2, J6, J8-12 J3 J5, J7, J15 J4 JP3 JP1-2 R65-66, R94-101 R24, R47, R58, R71, R75,R81, R83, R89, R103-105, R113 R7, R10, R12, R14-16, R22, R25, R27, R30, R33-34, R36, R38, R51, R62-64, R78-79, R84-85, R87-88, R92-93, R106-111 R68 R91 R17, R54, R59-60, R76-77, R86, R90 R9, R21, R26, R28-29, R37, R45, R48-50, R69 R52, R55, R61 R8, R23, R40, R42, R46, R57, R70 R74, R80, R102, R112 R11, R13, R39, R53, R56, R67 R18, R31, R43 R19-20, R32, R44 R35, R72-73, R82, R114-116 R41 RLY1-3 R1-4 R5-6 SW1 T1-4 TR1-2 TR3-4 XTAL2 XTAL1 102 Page 2/2
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