Larcan MXD1V Digital Television Broadcast translator User Manual part 2

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1W VHF AMPLIFIER ASSEMBLY
5.0. Power Supply:
the power supply used in the amplifier is an International Series Linear. single output power supply. The pan
number is H824-1.2-A which is an adiustable 24VDC with a 1,2A rating. The range of the adjustment is about
£10%, It is adaptable to various AC voltage inputs by changing the iumpering on the primary side of the
transformer. The choices are: 110/120/220/230l240 VAC. In this application, its default setting is 120VAC.
7.0 BASIC MAINTENANCE
Please note that the following are basic maintenance guidelines and general information and not all may be
applicable to your particular equipment.
7.1 GENERAL
When the transmitter was installed and commissioned it was in proper operating condition. During final
tests, all circuits were checked for optimum adjustment to ensure both peak performance and
consen/ative operation of components, and test results were recorded for future reference.
Given reasonable care and attention the transmitter will provide efficient and reliable service for many
years.
Experience indicates that equipment which is regularly and carefully maintained is far less likely to be
subject to sudden failure than that which is operated continuously without regard to basic maintenance
requirements. It is therefore desirable that a detailed preventive maintenance program be established to
ensure that the original efficiency and picture quality is maintained throughout the life of the equipment.
Preventive maintenance techniques do not necessarily involve extenstve dismantling of the various
assemblies; on the contrary, this practice is to be discomaged unless a valid reason exists for doing so.
Preventive maintenance is more concerned with detailed physical inspection and the general observation
of the equipment during and after operation, to detect the presence of any abnormality which it not
corrected might later develop more serious proportions. resulting in operational failure.
in preparing any maintenance program, the frequency and scope of the inspections must be determined,
and to a great degree will be influenced by site location and the station's market parameters consequently
its hours of operation. equipment configuration. and technical personnel deployment, For example, is the
station on the air for 24 hours a day, are there main/standby transmitters, and are they attended or
unattended? In general. the following routines should term the basis at any maintenance program,
7.2 DAILY
At an attended site, the operator is afforded the opportunity to make daily or more frequent checks on the
equipment and thereby increase his/her familiarity with its operation. The "transmitter log" entries made
during these checks would include all meter readings, also any irregularity in performance. or in picture
quality. for later analysis. An unattended site where equipment is operated by remote control, and
monitored by telemetry and a high quality off-arr receiver or demodulator located within the primary
coverage area at the studio site. can also be continuously checked for performance by studio technical
personnel, using VITS or VBI test signals encoded into the video signal vertical blanking interval.
7.3 WEEKLY
It the site is unattended, and VITS or VBI test equipment is not available, many broadcasters schedule
PU599-94 rev 0: June 14, 2000 94-7 IW VHF Amplifier
1W VHF AMPLlFlEH ASSEMBLY
thetr operational tests and transmitter inspections to be periormed once a week during weekend hours,
such as lrom midnight Sunday to six AM Monday, depending on their market conditions,
ii there is an emergency alternator, it should be checked out completely, and run for at least an hour under
full load. The checking of this unit should include the condition oi its battery. its ease oi starting (and its
Winter starting enhancers such as block heater. battery warmer, iuel antifreeze). its engine oil level and
condition (see "Monthly" below), its radiator coolant condition and level; and its fuel tank should be topped
up, This simple check will serve as a reminder to order more iuel it necessary.
7.4 MONTHLY
In addition to the normal operational tests, thorough physical inspection oi every piece of equipment
should be made, with all power turned offt All surfaces should he dusted oil or wiped down. terminal
boards checked ior loose connections, and all components examined tor any evidence of overheating, Air
filter media should be inspected and replaced it necessary. High pressure air, not over 20 psi, may be
used with discretion to dislodge dust irom inaccessible places.
Change the engine oil and oil filter in the emergency alternator, if it has been operated longer than its
manuiacturer’s recommended time since this was last done. In the absence oi recommendations, don‘t
let it run more than about 100 hours between oil changes. When put into perspective, 100 hours is the
time logged by a vehicle running 6000 miles at 60 mph. Oil is cheap, when compared with engine parts.
7.5 SEMI-ANNUALLY and ANNUALLV
Check all external FtF connections ior tightness. Test the antenna and transmission line with a
transmission test set or network analyzer it one is available, to identify any potential problems with the
antenna or line. Inspect and clean contacts on all switches and contaciors; carefully redress contact
suriaces if pitted.
Change the engine oil in the emergency alternator to summer or winter grade, depending on the season.
Also inspect and ii necessary replace. its iuel filter and air filters.
inspection and maintenance (tighten all bolts, replace obstruction light bulbs) oi the tower, antenna, and
grounding system, should be conducted annually.
7.3 TRANSMITTER COOLING SYSTEM
Air iilter material supplied with some transmitter cabinets has been impregnated With a polyester coating.
which is designed to attract and hold very fine particles that may be in the air How. This air liltor material
should be inspected every month or ottener. and replaced when dirty. Frequency of inspection and
replacement, oi course, will depend on your particular local environmental conditions.
All cooling fans in the transmitter are Ftotronmor equivalent. and all are titted with sealed bearings
requiring no lubrication during the lifetime oi the motor.
puegeegza rev 0: June 14. 2000 94-8 1 w VHF Amplltler
7.7
1W VHF AMPLIFIER ASSEMBLY
STATIC L EQUIPMENT 0: Static vs. Sensitive devices...
Care must be taken at all times because this equipment contains static-sensitive CMOS and FET devices.
Here is a brief tutorial on static, particularly pertinent to CMOS and other MOS device handling:
1.
2.
It is important to avoid surroundings or situations in which static can be generated. The building
floor should have grounded conductive lloor coverings, or a grounded conductive mat placed on
the floor in front of the bench. Then. the bench itself should also have a grounded conductive mat
on which the equipment is placed. Anybody working on the equipment should wear either a
grounded wrist strap (preferably) or conductive overshoes. Vacuum cleaner tools should all be
conductive and grounded to avoid static from air motion. (Vacuum cleaners made for computer
servicing would be suitable). Soldering iron tips must be grounded, Use properly maintained
soldering equipment that has a three wire. grounding plug. verifying low path resistance between
ground and the tip with an ohmmeter every time this equipment is used.
The average person wearing rubber- soled shoes and walking across a woollen or synthetic carpet
or untreated vinyl tiled floor is able to generate voltages In excess of 15 to 20 kV Most MOS devices will
sulter puncture of the oxide insulating their gates. at 20 to 40 V. Many CMOS devices are fabricated with
built-in zeners which will clamp foreign voltages, but the amount of energy that must be dissipated may
easily exceed the rating of this protection. It is therefore prudent to assume that little or no static
protection exists in a CMOS device and therefore you must provide your own.
3.
A typical unprotected gate of a CMOS logic K) has an input capacitance of about 5 pF and can
self-immolate at 20 v, so the energy to destroy the IC' is given by the expression W= CVz /2 where
W is in watt-seconds, C is in larads and V‘ is in volts. One watt- -second is also known as a Joule
Substituting numeric quantities results in W: 5 x 10"? x 20 x 20 2- — 1 x 10' Joule per gate
Stored energy in the approximately 100 pF capacitance of the human body charged to 15 kV
becomes W— - 100 x 10" x 15000 x 15000 2— - 11 25 x 10‘3 Joule Eleven anda quarter mill/on
times more energy than is needed to destroy one gate input! Some of us may therefore be led to
conclude that a body can annihilate more than eleven million CMOS gate oxides all at once.
This is serious stuff. To avoid destroying CMOS devices, the human body must be grounded first.
That is the reason for all the "grounded surroundings" we suggest in paragraph 1. Don't forget.
though, that a circuit board has conductive metallic paths connecting into the CMOS parts, which
makes them all susceptible to mass devastation as easily as would be the destruction of any one
CMOS chip all by itself. Always ground yourself first, then the board.
Avoidance of static exposure of boards and CMOS devices is easier. Ensure that boards are
always kept in conductive bags or boxes when not in place in the equipment, and that spare
CMOS ICs are in conductive chip carriers or plugged into conductive foam. Be careful about this
point; many plastic foams can be coloured black, but may still be an insulator. Use your
ohmmeter to be sure.
Don‘t accept any devices whose pins are punched through aluminum foil into foam plastic.
People who don't know better have used this method for shipment and storage of devices, but it
cannot be depended upon, because many times the holes made in the loll by the device pins
become enlarged simply from the motion of pressing the pins into the foam, and won't make
contact any longer. When the device is withdrawn from the foam. the friction of the plastic against
the pin can generate enough charge to cause puncture and consequent failure of the CMOS gate
insulation.
identical statements to those made in the above paragraphs apply to RF power MOSFETs, and
although the gates of these devices might appear to be considerably more robust than those of
the average CMOS logic device, this is due only to the much greater gate area and consequently
greater input capacitance. The same order of magnitude of gate oxide breakdown voltage exists
for RF power FETs as for small CMOS devices, therefore use the same order of care in handling.
Fuses-94 rev 0: June 14, 2000 94-9 1w VHF Amplifier
1W VHF AMPLIFIER ASSEMBLY
7, Believe it or not, ordinary analog meters can also he ailected by static. Years ago, meters were
made wtth glass taceplates and had movements that were relatively insensitive, so were attected
little by stray static charges accumulating on the glass. Today, almost all meters are made with
clear plastic laceplates and many of these, such as the sensitive so uA ones we use, have
extremely compliant moving parts. thus can be easily caused to read incorrectly from a static
charge on their front surfaces. This charge can be readily generated by simply cleaning the meter
lace.
It is important that meter accuracy be maintained within reasonable tolerances, because you as a
broadcaster are responsible for ensuring that the transmitter complies with all regulations
pertinent to its operation, and the easiest way 01 tracking its perlormance is from its meter
readings.
It is recommended tor better accuracy that meter laces be given an anti-static treatment, either by
cleaning with an antistatic cleaning agent, or sprayed with an antistatic coating, or both.
Suitable antistatic chemicals should be available through your nearest electronics parts distributor,
and typically carry such names as "Zero Charge"from Tech Spray”, "Destaticizing Lens Cleaner"
lrom G»C"‘, and ”420Antistatic Screen Cleaner"lrom MG. Chemicals’t‘t Check them out, Similar
brands should also be available in most reputable computer shops or office supply stores
CAUTION: Antistatic cleaners or treatment chemicals must not contain organic solvents such as
acetone, MEK, methyl isobutyt ketone, benzene, toluene, xylene, ethyl cellosolve acetate, or many
or the chlorinated hydrocarbons including ethylene dichloride and 1, 1, 1 tn‘chloroethane, as these
solvents will etch or even dissolve most of the plastics used for meter face/slates.
Our meter supplier recommends and uses a harmless coating treatment which it keeps in stock
under its catalog number FS 681. This coating is otherwise known to the trade as ANSTACZ-M.
ANSTAC 2-M is made by Chemical Development Corp.
22 Portsmouth Fld
Amesbury MA 01913 U.S.A.
Phone (508) 388-2221.
7.8 FIELD REPLACEMENT OF FETs and SURFACE MOUNT COMPONENTS:
TOXIC MATERIALS WARNING“. Thermal management In certain RF devices In this equipment Is
accomplished through the use of Beryllium Oxide ceramic material. Beryllium Oxide Is a hard
white ceramic used as insulation for heatsinking of RF power semiconductors. Beryllium Oxide is
a POISON it taken Into the body. In case or accidental breakage, DO NOT INHALE THE
RESULTING BERYLLIUM DUST and AVOID GETTING BEHYLLIUM DUST IN YOUR MOUTH. DO
NOT LET BERYLLIUM DUST INTO YOUR BLOOD STREAM THROUGH CUTS OH OPEN WOUNDS !!
Seek and get IMMEDIATE medical attention if the dust enters your body in any manner. Avoid
cuts by wearing gloves while picking up the broken pieces. Be caretul - do not Inhale dust while
replacing or emptying vacuum cleaner IIIIer bags. and wash your hands thoroughly afterward.
Wash your hands thoroughly after replacing RF power devices. Dispose of detective HF power
devices only through approved toxic waste facilities.
It lot any reason it should become necessary to change a PET in the field, we strongly recommend
lolluwing the handling precautions outlined on the next Iew pages:
Any FET can be damaged by static discharge. It is therefore mandatory that static-tree handling
Fuses-94 rev 0: June 14, 2000 94-10 tw VHF Amplifier
1W VHF AMPLIFIER ASSEMBLY
techniques as discussed in lne ioregoing "static 1. equipment 0" tutorial should be routine, and that
soldering equipment must be suitable for Insulated gate MOSFET work, and must be properly maintained.
a) Keep FETs in their anti-static containers until ready to install The module and the technician
should both be canned/grounded. Observe the handling procedures discussed in Part 7 above.
Including the use ol antistatic bench coverings. conductive uvershoes, grounded wrist straps. etc.
b) The soldering iron tip MUST be at earth/ground potential at all times, that is. absolutely no AC
voltage must be available on the tip. Test with an ohmmeter each time the iron is used: the test
must indicate continuity from tip to ground. Special battery operated soldering irons are also
available to avoid any chance at AC voltage being present on the tip, but these are not satislactory
for RF FET work as they do not heat to sufficiently high temperatures. Use an accurately
controlled temperature regulated low voltage soldering iron. and set it for about 700° to 750°F.
7.9 FET Replacement Hints and Advice:
a) Remove the screws bolting the transistor to the heatsink. Some transistors are mounted on the
heatsink using clamping bridges to improve the devices' thermal transfer. In the PA module
remove the nuts holding the clamping bridge and FET to the heatsink. then salvage the clamping
bridge. nuts, and spring lookwashers tor later use.
b To minimize board damage. use a sharp "screwdriver" tip on the soldering iron. and carefully help
it along with a solder pick tool. working it under one tab first. then once that tab is free and FET
mounting screws have been removed. the FET can be rocked gently. allowing other tabs to be
easily unsoldered in turn. The detective FET can now be Iitted out. Flemove excess solder with
"no clean" tluxed copper braid wick.
0) Clean the FET heatsink area thoroughly with alcohol (CAUTION:- ALCOHOL VAPOUH IS
TOXIC), and inspect to ensure that there are no defects nor debris present and that all
old thermal compound has been completely removed. The board solder areas should
be tightly and uniformly pro-tinned.
d) Apply only enough heatsink thermal compound (supplied with the transmitter) to the new FET
base and to the heatsink, that will result in a thin uniform coating on the FET base and heatsink.
The metal should be faintly visible through the coating on both surtaces. Apply it sparingly; too
much compound is every bit as bad tor thermal transter as an insufficient amount would be. To
refresh your memory: thermal compound fills the tiny little tool marks left by the milling machine
on the heatsink surface. but only enough that no microscopic air spaces remain between FET and
heatsink. Heat transler depends partly on the distance through which the heat must travel irom
the FET to the heatsink; too much compound effectively adds more distance, which could result in
overheating.
e) Lightly pre~tin and gently bend the FET tabs upward slightly. so that the tabs and the circuit board
do not prevent the FET lrom making proper thermal contact with the heatsink.
i) Torque the screws evenly to 4.5 inch-pounds. This amount is recommended by the FET
manufacturer to allow for thermal expansion oi the device. 45 inch-pounds also will avoid the
possibility of stripping the threads in the heatsink, or breaking the screws
g) Solder each tab to the board in turn. using a solder-pick tool to hold each tab in contact with the
board while soldering; apply enough heat to ensure that the pre-tin solder on the boards flows.
and apply just enough new solder to give a "butt" lree joint. Set the bias resistances at their
highest values to get minimum start»up current (see step 'I" below). and then set the stage bias
currents as described in the applicable PA module. iPA2 (driver), or IPA1 section or this manual.
purses-94 rev 0: June 14, 2000 94-1 1 1W VHF Ampiirter
h)
1W VHF AMPLIFIER ASSEMBLY
Use eutectic tin-lead 63/37 solder (preferred. but if 63/37 is not available, 60/40 is acceptable).
Current manufacturing process at LARCAN uses AiM'“ (American Iron & Metal Company inc.)
63/37 solder containing a “no clean“ tlux which becomes inert during soldering, thorotore does not
require subsequent board cleaning. Other good brands are Kesler and Ersin Multicore: equivalent
63/37 or 60/40 “no clean“ tin-load solders also should be available from other vendors. It
"no-clean“ is unavailable. "FtMA" (Resin Mildly Activated) core solder can be used; carefully clean
the flux residue from the board with an environmentally lriendly board cleaning solvent. applied
sparingly.
Most commercially available alcohols are reasonable flux solvents that are harmless to circuit
boards, and are CFC tree and environment-friendly. Proprietary circuit board cleaning solvents
are available that also meet these objectives; check with your local electronics parts dealer.
PUBQQ»94 rev 0: June 14. 2000 94-12 1w VHF Amplifier
1 W VHF AMPLIFiER ASSEMBLY
Inexpensive cotton swabs (available in drug stores or supermarkets) can be used for wiping the solvent
over the area to be cleaned, then a stiff bristle brush (an old toothbrush) can be used to scrub if
necessary. Use the swabs for mapping up the residue. Clean the board thoroughly. then inspect and
clean it again: don‘t merely rearrange the residue. Be careful - do not allow solvent to run under power
transistors where it can dilute the healsmk compound.
CAUTION: VAPOUHS FROM ALCOHOLS AND OTHER SOL VENTS ARE TOXIC AND
FLAMMABLE... DO NOT INHALE! fF YOUAREA SMOKER, DO NOT SMOKE WHILE USING
FLAMMABLE SOLVENT 5! USE ALL SOLVENTS ONLY IN A PROPERLY VENTILATED
LOCATION!
i) Finally. it you have not already done so, set the bias potentiometers for the stage to maximum
resistance so that when power is applied. the FET will start at its lowest current. Then set the bias
as described in the RF PA, VisualNision Driver. and IPA FtF amplifier sections of this manual.
We mentioned this procedure during step i above as well. because some circumstances may
make it simpler to set the bias in a High Band PA before repIaCing L9. When L9 is in place, each
half of the stage will need to be adjusted concurrently with a bias short on the opposite side (to
turn off the stde not being set). otherwise the DC path through L9 makes the procedure
impossible. This is explained in the applicable PA. Visual Driver. or IPA section of the manual
7.1.1 Surface-mount Components Hlnts and Advice:
Failures of small surface mounted resistors on boards where they were companion to other components
having leads, were traced to mechanical overstress of their end caps as a result of the soldering
procedure to the component. Our manufacturing procedure has since been altered to fix this problem,
and despite our embarrassment. we think it is important that you should know about it. For your
information:
1. It is critical that surface mount components are soldered onto a clean flat surface. Use a suction
device followed by lluxed braid wick material to ensure that all old solder is removed from pads of
the board.
2. It this is not possible due to the presence of other components. try to clean at least one of the
pads so it is flat (don‘t solder this end yet). then solder the other (solder-laden) pad FIRST.
pressing the component down into the puddle of solder. (Plain wooden toothpicks will serve well
as tools to apply pressure to components while soldering themr The remaining flat pad then can
be soldered.
To ensure minimum stress on any SM component. always be certain that the component is laying
flat in contact with the board before soldering except as above when it is necessary to melt the
solder on a pad lirst. and never Iorce ll unless both ends 0! the component are free to move.
at If all the pads are loaded with solder, it will be necessary to heat all terminals 01 the component
simultaneously. Check with your local electronic parts dealer for special soldering iron tips and/or
other attachments (in addition to toothpicks) that will aid in surface-mount work.
4. Always keep the tip of your iron clean and freshly tinned (wettatfl. for maximum heat transfer.
mass-94 rev 0: June 14. 2000 94—1 3 1W VHF Amplifier
1W VHF AMPLIFIER ASSEMBLY
7.1.2 REPLACEMENT PARTS
All component parts in the transmitter are available lrom:
LAHCAN Inc, 228 Ambassador Drive, Mississauga, Ontario. Canada L5T 2.12;
Phone (905)-5s4-9222, or FAX (905)-564-9244, during and after normal working hours.
To expedite delivery of your order. especially if you call after hours and get our answering service. please
leave a number where we can return your call, and please identity the pans requested as specifically and
completely as possible.
Our Renewal Parts Department may be able to more quickly identify your requirement it the assembly
name and number where the part is used. and any applicable revision number lor that assembly. are
stated in addition to the parts symbol number, description, and its drawing and part number as listed.
Although LARCAN can supply any part when required, in many instances it may be more conveniently obtained
from a local source. Part numbers ot replaceable components used in LARCAN equipment are almost always
the catalog numbers Oi the various parts manufacturers, with the rare exception 0! proprietary items such as
tightly specified RF power FETs. crystals, or analog 50 M meters. If your local dealer or distributor should
encounter problems and you require lurther inicrmation. please feel free to call upon anyone in our customer
service department at the telephone number given above. We have assumed that reliable dealers of electronic
components are located in or near your station market area. and that they maintain adequate stocks of
"commodity“ items such as resistors and capacitors. We have turther assumed that you prefer to obtain most
non-proprietary replacement pans from your local dealer, therefore we have listed very tew such commodity
items here, but we believe the tollowing information might be useful to you during your spares requirements
planning:
Capacitors: Generally. most ceramic or film capacitors are reliable. and "5% spares" (1 spare for each
20 identical parts. and 1 each it less than 20) will be lound to be a satisfactow inventory level. This
includes ceramic. polystyrene. polyester. polycarbonate, polypropylene, and (usually) solid electrolyte
tantalums.
Reliability notwithstanding, it is worth the trouble to know exactly what is inside your replacement
capacitors. Use a bridge if available. to measure their capacitance (especially tor electrolytics). stray
inductance, and ESR (equivalent series resistance). Measure leakage current at rated voltage.
Aluminum electrolytics require iurther consideration. When you consider aluminum electrolytics. usually
you will need to consider their operating temperature as well:
The transmitter cooling system was designed to provide worst-case internal temperatures no higher than
60°C. in all modules oi the transmitter. This cooling is based on 45°C maximum ambient air temperature
and normal air llow through the intakes ot the transmitter cabinet.
Most capacitor vendors state that 60°C or lower operating temperatures can be expected to give service
lifetimes lor their aluminum electrolytic capacitors of ten years or longer. but as their operating
temperature increases to the specified maximum at 85°C. the specified service lifetime decreases to a
mere 1000 hours.
Vou may therefore wish to increase your spares level for aluminum electrolytic capacitors It site ambient
temperatures are consistently higher than 40°C. because it cooling air flow becomes restricted due to tiller
saturation, it is entirely possible for on-board temperatures to reach or exceed 85°C. This is why your
maintenance program MUST include the regular inspection and replacement of litter media.
PU899-94 rev 0: June 14. 2000 94-14 1 W VHF Amplifier
1W VHF AMPLIFIER ASSEMBLY
Resistors: Experience has shown that a spares stock to the 5% spares level (1 spare for each 20 of the
same thing, and 1 of each when less than 20} for each value and size oi resistor. is usually sufficient.
Incrdentally, when a molded carbon composition resistor (as specified on LARCAN drawings 3R152,
3Ft77. 3R78, or 3R79) such as those made by OhmiteW or Allen-Bradley“, is used in an RF circuit, it is
not necessarily good practice to make substitution without knowing exactly what the replacement resistor
is: in the past. certain makes of FILM resistors have been touted as replacements for molded composrtion,
but unless the resistors are specifically matte to be non-inductive, they may be unsuitable because some
film resistors are laser-trimmed on a lathe to final value. The resulting helix has significant inductance
which can make the resistor unsatisfactory for use in VHF circuits.
It is worth the trouble to know exactly what is inside your replacement components, Use an RF bridge if
available, to measure any stray inductance and/or capacitance assocrated with your replacement
reslstorst
Spare Parts: The list on the following pages began as computer output listings "STS1OB, STSSOB, etc,"
from our database used to compile the parts list data for each Section of the manual. and the computer
has classified recommended spare parts and suggested their quantities, by pan number. Because the
manual is wrilten to apply to the entire low powered basrc series of transmitters, we have made a
composite suggested spares list by simply combining the computer's Low Band and High Band
recommendations
We suggest that the parts lists in each Section booklet comprising the manual should be thoroughly and
rigorously scrutinized. with the intention of taking your specific local conditions, and your usual dealers or
suppliers inventories and order turnaround times into account, before commitment to a sizable inventory
of replacement parts.
7.1.3 SPARE PARTS RECOMMENDATIONS:
Although it is our sincere hope that they will never be found necessary, it is recommended that a minimum
spares stock of the lollowmg items be kept on hand,
Assembly No. Description
4002180G1&(32 IW VHF AMPLIFIER
Where used Part No. Description Quantity
400218061&2 MDL-l FUSE 1A. 250VAC, SLOW BLOW 2 EA
10A1453GS MHW6185 IC AMP 1 EA
8.0 PARTS LlST (see the following pages):
PUBQQ-Qd rev 0: June 14, 2000 94-15 1 w VHF Amplifier

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