Technalogix TAU100 100 WATT UHF AMPLIFIER User Manual TAU 500 Cover Page

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POWER AMPLIFIER
NEW
ADVENTURES
IN
BROADCASTING
Technalogix
TAU-100
You’ve already unpacked it, haven’t you? You’ve unpacked it and
plugged it in and turned it on and fiddled with the knobs. No?
Okay, good. Please take a few minutes to read the manual and
familiarize yourself with your new Technalogix power amplifier.
We believe that this manual, and of course our equipment, should
be everything you need to get on the air with superb broadcast
quality video. We understand that a capable and confident user
will get the most out of our product and we have made every
attempt to educate readers of all technical levels. If there is
something that is not clear, or you require further information,
please do not hesitate to contact us and we’ll be glad to help out.
Technalogix Ltd.
#4, 8021 Edgar Industrial Place
Red Deer, Alberta, Canada
T4P 3R3
Phone: 403.347.5400
Fax: 403.347.7444
URL: www.technalogix.ca
Email: technical@technalogix.ca
sales@technalogix.ca
We truly appreciate that you have chosen us as your television
broadcast system supplier. Happy viewing.
Table of Contents
SECTION I- SAFEGUARDS ..............................................................................................I-1
SAFETY AND FIRST AID .....................................................................................................I-2
OPERATING SAFEGUARDS ................................................................................................I-3
SECTION II - WARRANTY ............................................................................................. II-1
SECTION III - OVERVIEW...............................................................................................III-1
STANDARD FEATURES .....................................................................................................III-1
PRINCIPLE OF OPERATION...............................................................................................III-2
BLOCK DIAGRAM ..............................................................................................................III-3
SPECIFICATIONS...............................................................................................................III-5
SECTION IV - RF COMPONENTS................................................................................ IV-1
AMPLIFIER PALLETS....................................................................................................... IV-1
SPLITTER /COMBINER ..................................................................................................... IV-4
DIRECTIONAL COUPLER ................................................................................................. IV-4
ISOLATOR ....................................................................................................................... IV-4
FILTER ............................................................................................................................ IV-4
SECTION V - POWER SUPPLY SECTION......................................................................V-1
SECTION VI - MONITOR AND CONTROL SYSTEM ....................................................... VI-1
CONTROL BOARD OVERVIEW (S ERIES II-H) ................................................................. VI-1
POWER SUPPLY COMPONENTS..................................................................................... VI-1
INTERFACE COMPONENTS ............................................................................................. VI-2
SIGNAL CONDITIONING COMPONENTS .......................................................................... VI-3
DISPLAY COMPONENTS ................................................................................................. VI-4
MICROCONTROLLER COMPONENTS............................................................................... VI-5
FAULT SHUTDOWN......................................................................................................... VI-6
REMOTE PORT ............................................................................................................... VI-7
BILL OF MATERIALS ....................................................................................................... VI-8
SCHEMATICS ................................................................................................................VI-10
SECTION VII - MECHANICAL SECTION .......................................................................VII-1
SECTION VIII - INSTALLATION ...................................................................................VIII-1
BUILDING RECOMMENDATIONS.....................................................................................VIII-1
HEATING AND COOLING REQUIREMENTS .....................................................................VIII-2
ELECTRICAL SERVICE RECOMMENDATIONS .................................................................VIII-3
ANTENNA AND TOWER RECOMMENDATIONS ................................................................VIII-4
SHELTER SECURITY ......................................................................................................VIII-5
UNPACKING AND INSPECTIO N .......................................................................................VIII-6
LOCATION AND FUNCTION OF CONTROLS AND CONNECTORS (TAU-100 P OWER
AMPLIFIERS)..................................................................................................................VIII-7
LOCATION AND FUNCTION OF CONTROLS AND CONNECTORS (POWER SUPPLY).......VIII-9
INITIAL HOOK UP.........................................................................................................VIII-11
SECTION IX - OPERATING PROCEDURE..................................................................... IX-1
SECTION X - MAINTENANCE AND TROUBLESHOOTING...............................................X-1
TROUBLESHOOTING ........................................................................................................X-2
Section I - Safeguards
General Safeguards
This section is written as a general guide to keep all 5 fingers on your hand and is intended for those
having previous knowledge and experience with these kinds of equipment. It is not intended to
contain a complete statement of all safety precautions, which should be observed by personnel using
this or other electronic equipment.
DOCUMENTATION - Read, retain and follow instructions before operating the equipment.
There is a lot of useful information in the manual, and besides, we spent a lot of time
writing it!
ENVIRONMENT - To reduce the risk of fire or electric shock, do not expose this equipment
to rain, moisture, or rye and sodas at the company Christmas party. Refer all servicing to
qualified service personnel.
SERVICING - Do not attempt to service this equipment yourself as opening or removing
covers can result in a warm tingly feeling and will void the warranty. Refer all servicing to
qualified service personnel.
I-1
Safety and First Aid
Personnel engaged in the installation, operation, maintenance, or servicing of electronic equipment
are exposed to the hazard of high voltage. It is imperative that all safety regulations and precautions
are consistently observed. Knowledge of first aid procedures is recommended. The following
information is presented as a reference only.
•
At all times, avoid placing any part of the body in series between ground and circuit points,
whether power is on or off.
•
Dangerous voltage may be present in equipment even though power is off. Do not open the
cabinet. Refer servicing to qualified service personnel.
•
It is the duty of all personnel to be prepared to give adequate emergency first aid treatment and
thereby prevent avoidable loss of life.
•
There are three principle degrees of burns, recognizable as follows:
• a first-degree burn reddens the skin.
• a second-degree burn blisters the skin.
• a third degree burn chars the flesh and frequently places the victim in a state of shock
accompanied by respiratory paralysis.
•
Respiratory paralysis can cause death by suffocation within seconds. It is imperative that the
approved methods of artificial respiration are initiated immediately and continue until the victim’s
breathing is normal.
•
A muscular spasm of unconsciousness may render the victim unable to break free of the electric
power. If this is the case, turn the power off immediately.
DO NOT TOUCH THE VICTIM OR YOU MAY SHARE THE SAME
PREDICAMENT.
•
If the power cannot be turned off immediately, very carefully loop a dry rope, article of clothing,
length of strong cloth or a rolled-up newspaper around the victim and pull the victim free of the
power source. Carefully avoid touching the victim or clothing.
•
Once free of the power source, the victim must be placed in a reclining position and covered
with a blanket or newspapers to keep warm. At the first opportunity, enlist help in
summoning a doctor. If a doctor cannot be summoned, transport the victim to the doctor or a
hospital. Be sure the victim is kept well covered and warm while awaiting professional
treatment.
I-2
Operating Safeguards
It is a known fact that our broadcast transmitters and translators enjoy 50-ohm load impedances.
So much so, that it is imperative you maintain 50-ohm impedances throughout your system. In
return, your equipment will provide you with maximum power transfer to the antenna and
decreased reflected power heading back towards the amplifier pallets, reducing the amount of
magic smoke that gets let out of the power amplifier. Before anything is turned on, ensure that
there is a 50-ohm path from the output of each stage to the input of the next, all the way to the
antenna.
In addition to maintaining proper 50-ohm impedances throughout the signal chain, it is also
important, whenever possible, to make sure the RF drive going to the input of the power amplifier
is removed before turning on or turning off the DC power supply. This is because all of the RF
transistors used in the individual amplifier pallets are fabricated with LDMOS (Laterally Diffused
Metal Oxide Semiconductor) technology. Nice and linear yes, but they do not like to make any RF
power when their supply voltages are not within a specific range. When you first turn your power
amplifier on or off, the DC power supply’s output voltage may take a while to stable out to a safe
operating voltage. Ten seconds wait before applying the RF drive will ensure no issues arise.
Our power amplifiers are designed to reliably generate a specific RF output power. Failing to
adhere to overdriven amplifier warnings can decrease the reliability of your system, and frankly,
makes our repair department busy and grumpy. If you need to transmit to a little larger coverage,
you are better off increasing antenna gain, and more importantly, antenna height above average
terrain. On TV and FM broadcast frequencies, insufficient antenna height puts an upper limit on
your range, regardless of power levels, as the distance from your antenna to the radio horizon is
limited.
I-3
Section II - Warranty
Our legalese is straightforward. It is simply designed to give you peace of mind and helps you resist
the temptation to have your electronics friend try to repair your Technalogix product.
Technalogix Ltd. products have been completely tested and found to meet specifications and be in
proper operating condition. They are warranted to be free from defects in materials and
workmanship for a period of one year from the date of shipment. If the system becomes damaged in
shipment and there are obvious signs of damage to the outside of the packaging, notify your courier
immediately before that courier walks out the door.
Technalogix Ltd. will not be liable for damages of whatever nature arising out of or in connection
with the equipment or its use thereof. Technalogix does not assume responsibility for injury or
damage resulting from the practices of untrained or unqualified personnel in the handling of this
equipment.
Technalogix Ltd. warranty does not include:
•
•
•
•
•
•
misuse, neglect or accident.
incorrect wiring and /or improper installation.
unauthorized repairs, modifications or use in violation of instructions issued by Technalogix.
incidental or consequential damages as a result of any defect.
reshipment cost or insurance of the unit or replacement units or parts.
acts of nature or terrorism.
Technalogix agrees, at our option, to remedy warranted defects or furnish a new part in exchange
for any part of a unit which, under normal installation, use and service, becomes defective. The user
will pay for transportation costs to and from the repair center.
II-1
To claim your rights under this warranty:
•
Contact Technalogix and describe the problem in as much detail as possible. See
troubleshooting section in this manual. If a solution cannot be found at this time, it may be
determined that the unit will have to be returned to Technalogix for repair, once a Return
Materials Authorization (RMA) number is provided.
•
Package equipment carefully for prepaid shipment to Technalogix. Include a written description
of the problem experienced, a copy of the original invoice establishing warranty status, and the
RMA.
Technalogix reserves the right to make revisions in current production of the equipment and
assumes no obligation to incorporate these changes in earlier models.
Shipping Address:
Technalogix Ltd.
ATTN: RMA#
#4, 8021 Edgar Industrial Place
Red Deer, Alberta, Canada
T4P 3R3
Ph: 403.347.5400
Made in Canada, returned for repairs
II-2
Section III - Overview
Standard Features
•
No sync compression to ensure power amplifier is digital compatible
•
Narrow output bandpass filter allows adjacent channel operation
•
Front panel Liquid Crystal Display (LCD) to monitor forward and reflected RF power, and DC
voltage
•
Microcontroller-based monitoring and control ensures amplifier will never be overdriven and high
VSWR will not damage amplifier
•
AC circuit breaker on back panel to eliminate replacement of fuses
•
RF/EMI filtering on AC entry plug
•
All aluminium enclosure maintains power amplifier’s light weight
•
3U-high enclosures for 25 and 100 watt power amplifiers reduce rack space
•
Simple design using commonly available parts ensures reliable operation
•
Predominate and third-order intermodulation distortion exceeds Industry Canada and FCC
specification.
III-1
Principle of Operation
The TAU-100 power amplifier supplies a 100 watt peak video signal with 10% aural power on any of the
UHF television channels 14 through 69. Please note that channel selection must be made at time of
order, as the transmitter or translator is calibrated and tested to the channel requested and is not field
tuneable. The TAU-100 power amplifier is a modular solid-state 100-watt broadcast amplifier utilizing
readily available RF components wherever possible, thus enhancing the serviceability of the
equipment.
The TAU-100 is comprised of a UHFTV-10 driver and UHFTV-150 final amplifier. The unique zero sync
compression technology ensures digital ready operation.
The TAU-100 features ultra linear amplification and individual channel RF output bandpass filtering.
The amplifier modules are stable for high reliability and long service life.
III-2
Block Diagram
The RF signal enters through the RF Input connector on the power amplifier enclosure from the
modulator or processor. It then passes through an RF attenuator to limit the output power level of
the power amplifier and to help buffer any transients that may come into the power amplifier. After
attenuation, the signal is amplified through the UHFTV-10 driver and UHFTV-150 T final pallets
before the signal passes through an isolator (circulator with load) and a bandpass filter. Finally, the
amplified signal passes through a dual directional coupler for monitoring purposes. After the
directional coupler, the signal exits the power amplifier enclosure before heading out to an antenna
for broadcast.
III-3
FILTER
UHFTV-10
UHFTV-150
DIRECTIONAL
COUPLER
CIRCULATOR
ATTENUATION
RF INPUT
RF OUT
A=+26dB min.
A=+12dB min.
A=-0.2dB typ.
A=-0.1dB
To Wattmeter
and Antenna
A=-0.3dB
50-OHM
TERMINATION
TAU-100 Block Diagram
Rev
ID
Date: May 24, 2005 Page: 1 of 1
Specifications
The following specifications were taken with a Technalogix modulator/processor. Should a different
modulator or processor be used, specifications could vary. For this reason, we recommend that any
different modulator/processor be shipped to Technalogix so the system can be matched and set up
optimally. In addition, the audio/video ratio the input to the power amplifier needs to be –10 dB in order
for the software and LCD readout to be accurate.
RF Characteristics
Frequency range
Frequency Response (one channel)
Frequency Stability
Selectivity
Minimum Input Level
Rated Visual Output Power
Rated Aural Output Power
IF Output Level
Input Impedance
Output Impedance
Harmonics
Predominant Intermodulation Distortion
+ 920 kHz
- 920 kHz
+ 2.66 MHz
- 2.66 MHz
+ 5.42 MHz
+ 7.16 MHz
any specified UHF Channel 14 to 69
±0.5 dB
±250 Hz
60 dB (adjacent channel)
0 dBmV
100 Watts
10% of peak visual power
+35 dBmV nominal
75 Ohms
50 Ohms
> 60 dB below rated power
dBc = decibels below visual carrier
> -50 dBc
> -50 dBc
> -50 dBc
> -50 dBc
> -50 dBc
> -50 dBc
3rd Order Intermodulation Distortion
+ 4.5 MHz
+ 9.0 MHz
All others
Spurious Emissions
> -60 dBc
> -60 dBc
> -60 dBc
> -60 dBc
NTSC Video Characteristics
Input Level to modulator (for 87.5% modulation)
Differential Phase (at 87.5% modulation)
Differential Gain (at 87.5% modulation)
Group Delay
Video Group Delay Pre-emphasis
K-Factor
Hum and Noise
III-5
1.0 VPP
±2 Degrees
2%
< ±40 nS
Conforms to IC/FCC specifications
1.9% for 2T Pulse
> 60 dB below rated power
Aural Characteristics
Input Level for 25 kHz Deviation
Frequency Response (Standard Pre-emphasis)
Harmonic Distortion (25 kHz Deviation)
Amplitude Modulation Noise
Frequency Modulation Noise
Intercarrier Stability
0.3 VPP
±1 dB
< 1% 50 Hz to 15 kHz
> 50 dB
> 60 dB
±250 Hz
Physical Characteristics
Power Requirements
100-130,210-230 vac, 50/60 Hz
Operating Temperature
Dimensions (power amplifier only)
0 - 50°C
W-19”,D -21 ¼”, H-5 ¼”, 3U-high
III-6
Section IV – RF Components
Amplifier Pallets
The UHFTV-10 pallet is a two stage ultra linear class-A linear pallet. It has a minimum gain of 38dB and
draws no more than 2.75Adc total drain current (the exact bias and drain currents of your system are
found in the spec sheet supplied with each manual). The quiescent and drain currents can be
measured on the UHFTV-10 pallet by measuring the voltage drop across the current sense resistor
found directly at the DC power supply lead input to the pallet. This resistance is 0.01-ohms, providing a
10mV per ampere ratio.
The UHFTV-150 pallet used in the driver and final amplification stages use LDMOS (Laterally Diffused
Metal Oxide Semiconductor) technology. LDMOS technology offers higher gain, efficiency and linearity
over standard MOSFET and Bipolar devices. LDMOS transistors have the added advantage of not
having BEO (Beryllium Oxide) in their construction. These pallets are split into (2) frequency bands
based on the channel ordered (channels 14-38 and channels 33 to 70). The UHFTV-150 amplifier
pallet have a typical gain of 14dB and draw no more than 16Adc (again, the exact bias and drain
currents of your system are found in the spec sheet supplied with each manual). Currents for these
pallets must be measured with an ammeter in series with the power supply lead. Temperature
compensated biasing helps ensure steady operating levels over wide temperature ranges.
Each of the amplifier pallets is connectorized. All amplifier pallets must have the transistor drain
voltages reach at least 26Vdc before the RF drive is applied.
IV-1
Isolator
The power amplifier pallets are protected in part by the isolator located in the filter enclosure. It is
actually made up of a circulator and 50-ohm dump resistor. The circulators’ specifications include an
insertion loss of less than 0.2dB with an isolation rating better than 20dB. Any reflected power gets
dumped into the flanged power resistor. This way, there is instantaneous protection due to the isolator
setup and long term protection due to the software.
Filter
The passive bandpass filter rejects spurious and harmonic output products and passes the UHF
channel RF output. The cavity resonator uses aperture coupling. Typical insertion loss is 0.3 dB to 0.6
dB depending on channel frequency. Average roll off is –33 dBc at a point 4.5 MHz below the peak
visual carrier frequency and –30 dBc 9.0 MHz above the peak visual carrier frequency. The filter is DC
grounded on both the input and output for additional lightning protection.
Directional Coupler
The Technalogix dual directional couplers provide DC voltages proportional to forward and reflected
RF power monitoring. These analog voltages are converted for processing using a 10-bit analog to
digital converter. The microcontroller system monitors power supply voltage, forward and reflected RF
power, amplifier module temperature, the input video signal and the “VIEW” display request button.
The LCD is based on the industry standard HD44780 controller and contains 4 lines with 20 characters
per line. The LCD communicates with serial-to-parallel latches on the monitor and control circuit board
and the latches communicate with the microcontroller via a custom serial interface.
IV-4
Section V – Power Supply
Switching AC-DC power supplies are used to power the amplifier pallets, the control circuits, and all of
the fans. There is (1) power supply used to generate the necessary current for the amplifier pallets, set
to 28.3 Vdc nominally.
The power supply is a Mean Well SP-500-27. This switching power supply is fully protected against
short circuit and output overload. Short circuit protection is a cycling type power limit. The internal AC
fuse is designed to blow only on a catastrophic failure in the unit – the fuse does not blow on overload
or short circuit. The thermal shutdown automatically recovers when the power supply chassis cools
down.
AC (115Vac) is fed into the enclosure via a filtered EMI AC entry. It is then current limited with a
resettable circuit breaker before passing through a rocker switch. This switch turns the AC on and off
to the switching power supply.
V-1
MEAN WELL
SWITCHING POWER SUPPLY
SP-500
SERIES
ISO-9001 CERTIFIED MANUFACTURER
.LOW COST, HIGH RELIABILITY
.COMPACT SIZE, LIGHT WEIGHT
.COOLING FAN ON/OFF AUTOMATICALLY
.100% FULL LOAD BURN-IN TEST
.BUILT IN REMOTE CONTRAL
.105 º C OUTPUT CAPACITOR
.INTERNATIONAL AC INPUT RANGE
.BUILT IN EMI FILTER, LOW RIPPLE NOISE
.HIGH EFFICIENCY, LOW WORKING TEMPERATURE
.BUILT IN PFC CIRCUIT
.SOFT-START CIRCUIT, LIMITING AC SURGE CURRENT
.SHORT CIRCUIT, OVERLOAD, OVER VOLTAGE, OVER TEMP. PROTECTED
MODEL
SP-500-12
SP-500-13.5
SP-500-15
SP-500-24
SP-500-27
SP-500-48
DC OUTPUT VOLTAGE
12V
13.5V
15V
24V
27V
48V
OUTPUT V. TOLERANCE
±1%
±1%
±1%
±1%
±1%
±1%
OUTPUT RATED CURRENT
40A
36A
32A
20A
18A
10A
OUTPUT CURRENT RANGE
0-40A
0-36A
0-32A
0-20A
0-18A
0-10A
240mVp-p
240mVp-p
240mVp-p
240mVp-p
200mVp-p
300mVp-p
LINE REGULATION
±0.5%
±0.5%
±0.5%
±0.5%
±0.5%
±0.5%
LOAD REGULATION
±0.5%
±0.5%
±0.5%
±0.5%
±0.5%
±0.5%
DC OUTPUT POWER
480W
486W
480W
480W
486W
480W
EFFICIENCY
84%
84%
83%
85.5%
86.5%
87%
10-13.2V
12-15V
13.5 -18V
20-26.4V
24-30V
41-56V
SPECIFICATION
RIPPLE & NOISE
DC VOLTAGE ADJ.
INPUT VOLTAGE RANGE
88~264VAC 47~63Hz; 124~370VDC
AC CURRENT
7A/115V 3.5A/230V
POWER FACTOR
0.95/100~240VAC
INRUSH CURRENT
18A/115V 36A/230V
LEAKAGE CURRENT
<3.5mA/240VAC
OVERLOAD PROTECTION
105%~135% TYPE:FOLDBACK CURRENT LIMITING RESET:AUTO RECOVERY
OVER VOLTAGE PROTECTION
13.8 ~16.2V
15.5 ~18.2V
18~21V
27.6 ~32.4V
31~36.5V
FAN CONTROL, O.T.P.
RTH1 or RTH2>=50 º C FAN ON, <=45 º C FAN OFF, >=70 º C OUTPUT SHUTDOWN
TEMP. COEFFICIENT
±0.03% / º C (0~50 º C)
SETUP, RISE, HOLD UP TIME
1.5s, 50ms, 20ms
VIBRATION
10~500Hz, 2G 10min./1cycle, PERIOD FOR 60min. EACH AXES
WITHSTAND VOLTAGE
I/P-O/P:3KVAC I/P-FG:1.5KVAC O/P-FG:0.5KVAC
ISOLATION RESISTANCE
I/P-O/P, I/P-FG, O/P-FG:500VDC / 100M Ohms
WORKING TEMP., HUMIDITY
-10 º C~+50 º C(REFER TO OUTPUT DERATING CURVE), 20%~90% RH
STORAGE TEMP., HUMIDITY
-20 º C~+85 º C, 10%~95% RH
DIMENSION
185*20*93mm CASE:910
WEIGHT
1.8Kgs
SAFETY STANDARDS
UL1950, TUV EN60950 APPROVED
EMC STANDARDS
CISPR22 (EN55022), IEC1000-4-2,3,4,5,6,8,11 IEC1000-3-2 VERIFICATION
NOTE :
57.6 ~67.2V
1.ALL PARAMETERS ARE SPECIFIED AT 230VAC INPUT, RATED LOAD, 25º C 70% RH. AMBIENT.
2.TOLERANCE GINCLUDE SET UP TOLERANCE, LINE REGULATION, LOAD REGULATION.
3.RIPPLE & NOISE ARE MEASURED AT 20MHz BY USING A 12" TWISTED PAIR TERMINATED WITH A 0.1uF & 47uF CAPACITOR.
4.LINE REGULATION IS MEASURED FROM LOW LINE TO HIGH LINE AT RATED LOAD.
5.LOAD REGULATION IS MEASURED FROM 0% TO 100% RATED LOAD.
6.C3,4,14,16,31,32,101,102 MUST BE REMOVED.
7.REFER TO OUTPUT DERATING CURVE VS INPUT VOLTAGE.
JUN.09.98
Section VI – Monitor and Control System
Control Board Overview (Series II-H)
The control printed circuit boards (PCB) are located at the front of each enclosure connected directly
to the back of the liquid crystal displays (LCD) and are identified as Series II-H PCBs. The main
purpose of the Series II-H PCB is to monitor the RF power and the DC supply voltages in the power
amplifier and filter enclosures and to monitor just the DC supply voltages in the power supply
enclosure. In all cases, a DC voltage proportional to the parameter being sampled is conditioned,
protected, buffered, and then run into an analog-to-digital converter (ADC) where software processes
the signal. The software processing determines if the parameters are within the predetermined safe
operating levels and displays the parameters on the LCD for monitoring purposes. The Series II-H PCB
can be broken apart into (5) main component areas: the power supply, interface, signal processing,
display, and microcontroller. Schematics are found later in this section.
Power Supply Components
There are (4) power supply voltages generated on the Series II-H PCB:
1.
2.
3.
4.
+5Vdc for all logic and general purpose PCB supply voltage.
+4Vdc for the LED backlighting on the LCD
-4Vdc for the contrast voltage required by the LCD
+8Vdc for the directional coupler supply
The +5Vdc is generated from a small switching power supply comprised of C1, C2, D2, L1, and U1.
This power supply accepts DC input voltages up to 40Vdc and outputs +5Vdc at up to 1Adc. This
voltage is always on, as the ON/OFF pin on U1 is hard-wired to the on configuration.
The +4Vdc is generated from a small switching power supply comprised of components C3, C4, D3, L2,
and U2. This power supply accepts DC input voltages up to 40Vdc and outputs +5Vdc at up to 1Adc.
The voltage then gets dropped down to +4Vdc through R1. This backlight voltage can be turned on
and off via the ON/OFF pin on U2. The PCB is setup in a manner that allows this voltage to be hardwired on all the time or controlled from the microcontroller through latch U11. This selection is made
with jumper J2.
The -4Vdc is generated using a switched capacitor voltage converter design, using components C6,
C7, R2, R3, U4, and VR1. U4 accepts +5Vdc from the general purpose +5Vdc supply and generates 4Vdc. This voltages then gets dropped across the voltage divider (R2, R3) to generate the contrast
voltage specific to the LCD that is installed in the system.
The +8Vdc required by the directional coupler is generated with a standard linear voltage regulator,
U3. C5 helps clean up any ripple or noise that might be on the output voltage.
VI-1
Interface Components
The interface section of the Series II-H PCB includes the front panel switch interfacing in addition to
the buzzer and carrier disable output circuits.
The (3) momentary switches found on the front panels of each enclosure are tied to the
microcontroller through an isolation stage to avoid any static discharge or noise on the switch
wiring from reaching the microcontroller. Optoisolators U5 and U6, in addition to components
R4…R15 create the necessary isolation to the sensitive microcontroller. By depressing any
momentary switch, a ground (0V) is applied to the input of the optoisolators. The optoisolators will,
in turn, output a ground (0V) to the microcontroller.
The membrane tactile switches found on the front panels of the enclosures operate in the following
manner with a depress:
POWER – When unit is plugged in, AC is supplied to the fan and switching power supply input,
but the amplifiers are still turned off. In order to turn the amplifiers on, wait ten seconds after
plugging the PA in and push in the “POWER” tactile button. The LCD will read “Soft Start Warm
Up, Please Wait”. After ten seconds the bias voltages will be turned on and you may then plug in
the RF drive. Depress for (1) second to turn on and (3) seconds to turn system off. In the case of
multiple enclosures, all POWER switches are tied together in each enclosure, so only one needs
to be depressed.
NAVIGATE – Turns on backlight to LCD and displays forward and reflected RF power and DC
supply voltage parameters. When power amplifier is first turned on, the LCD comes on
automatically and this information is displayed. Information is displayed for approximately 2
minutes before the backlight turns off and the display is cleared. This is set up so as not to burn
any pixels into the LCD from extended on time. In the case of multiple enclosures, the NAVIGATE
switches are individual to each enclosure.
SELECT – Turns on backlight to LCD and displays forward and reflected RF power and DC
supply voltage parameters. When power amplifier is first turned on, the LCD comes on
automatically and this information is displayed. Information is displayed for approximately 2
minutes before the backlight turns off and the display is cleared. This is set up so as not to burn
any pixels into the LCD from extended on time. In the case of multiple enclosures, the SELECT
switches are individual to each enclosure.
RESET – Tactile pushbutton resets the monitor and control system. The amplifier gets shut down
for under 0.5 seconds and comes back on with each depress of the reset button. At the same
time, all fault counters in the microcontroller software are reset and the LCD is reset in the same
manner as it is with a depress of the NAVIGATE button. Reset switches are individual to each
enclosure but may be tied together externally through the remote port, as explained later in this
section.
The buzzer control comes from pin 5 on microcontroller U14. The control signal turns on the base
of transistor Q1, which allows current to flow through the single tone magnetic buzzer. Jumper J4
VI-2
simply turns off the buzzer.
The carrier disable circuit simply applies a shutdown voltage to the driver pallet in the system. The
U14 generates the signal out of pin 21 and controls relay Q2 through R17. When Q2 is turned off,
the shutdown voltage to the driver is floating and the carrier is on. During a fault condition, when
Q2 is turned on, the shutdown voltage is applied to the carrier disable on the driver.
VI-3
Signal Conditioning Components
The signal processing section of the Series II-H PCBs is used to buffer potentially noisy or
damaging signals from the ADC. Power supply samples and forward and reflected power from a
directional coupler are then digitized.
Firstly, all analog signals are protected with a resettable fuse and transient voltage suppressor
(TVS) combination. These components ensure that voltages above the Vbr breakdown voltage of
the TVS get clamped and do not pass farther down the circuit. After this protection stage, the
analog voltages get dropped with voltage dividers to safe levels for the buffers and ADC. For
example, a 28Vdc power supply sample gets dropped to a level below the +5Vdc supply voltage of
the ADC. After the voltage dividers, the analog signals get buffered with U7 and U8, configured as
unity gain voltage followers. Finally, after some further decoupling capacitors and filters, the analog
signals get digitized by the 8-channel, 10-bit ADC (U10) and sent to the microcontroller through a
serial interface.
In the power amplifier and filter enclosures, there are (3) analog voltages that get conditioned and
processed: DC power supply sample, forward RF power, and reflected RF power. Specifically, the
components for the power amplifier and filter enclosure conditioning are as follows:
DC power supply sample – J7 (pin8), F9, D11, R32, R33, U8, C33, C34, C35, and U10.
Forward RF power – J7 (pin7), F8, D10, R30, R31, U8, C29, C30, C31, and U10.
Reflected RF power – J7 (pin6), F7, D9, R28, R29, U8, C26, C27, C28, AND U10.
In the power supply enclosure, there are (2) power supplies, but they are both paralleled together.
Hence, only (1) analog voltage is conditioned and processed for the LCD. Specifically, the
components for the power supply sample are as follows:
DC power supply sample- J7 (pin8), F9, D11, R32, R33, U8, C33, C34, C35, and U10.
VI-4
Display Components
The display section of the Series II-H PCB is comprised of the LCD and the components that make
up the data bus to send the data from the microcontroller to the LCD.
Specifically, the LCD is an alphanumeric 20X4 display that uses the industry standard 44780
controller and a parallel interface for data communications. Firstly, the microcontroller sends out
the data to be displayed via a serial bus where the signals are latched with U11 and U12 and
converted to a parallel data stream. The parallel data then transfers directly to the LCD through
connector J8. J8 also carriers the power supply for the LCD.
VI-5
Microcontroller Components
The heart of the monitor and control system found in Series II-H PCBs is microcontroller U14. This
microcontroller analyzes all RF power levels and voltages to ensure that all operating parameters
are within their predetermined safe operating levels. If a fault is found, appropriate action is taken
to help protect the system from damage, which may include turning the RF carriers off. A full
description of all faults and their respective actions is found later in this section.
The power supply for the microcontroller is monitored closely via supervisor U13. Should the +5Vdc
supply drop below +4.5Vdc, a microcontroller reset is generated to ensure there are no brown out
conditions that may latch the microcontroller up to an unknown state. The front panel Reset
momentary switch is also tied to this line after optoisolation. The microcontroller is run off of a
4.000MHz clock source, generated by ceramic resonator CR1. If the software is running, LED D12
will be lit. Finally, U15 stores all characters for the LCD to minimize the overhead required for the
microcontroller, and also stores the current state of the power ON/OFF of the system. This is to
ensure that, in the event of a power outage, the system returns to the exact state is was before
power was interrupted.
VI-6
Fault Shutdowns
On the LCD (Liquid Crystal Display) the following messages may appear:
If you see this message, the system will:
- shut amp down for 1 minute
- automatically turn amp on after 1 minute and check again for overdriven amplifier
- come back to the same power level that it was set
If you see this message, the system will:
- shut amp down for 5 minutes
- automatically turn amp on after 5 minutes and check again for high VSWR
- come back to the same power level that it was set
VI-7
Remote Port
The remote port allows external control of the transmission system via the DB25 connector on each
enclosure. All functions on the remote port are simply hard-wired or paralleled to existing wiring to
provide a secondary method of control to the user, and are activated as follows:
pin 1: ground to reset microcontroller, float otherwise
pin 2: ground for 2 seconds to toggle carrier on/off, float otherwise
pin 3: common ground
pin 4: DC power supply sample
VI-8
Series II - Bill of Materials
revision: H
date: 2-Dec-04
Item Qty
Components
BZ1
C1 (solder side), C5
(solder side)
C2 (electrolytic), C6
(solder side)
Description
Tolerance
BUZZER, magnetic, 5V, single tone
Package
Through hole
Equivalency
Challenge Electronics TDB05; Global Components
TDB05, Tranducers USA TRIE-1205P
Panasonic ECE-V1JA101P, NIC
NACEW101M63V10x10.5
Panasonic ECE-V1VA331P, NIC
NACEW331M35V10x10.5
CAPACITOR, electrolytic, 100uF, 63V
<=20%
SMT (Panasonic VS "G" size)
CAPACITOR, electrolytic, 330uF, 35V
<=20%
SMT (Panasonic VS "G" size)
<=20%
SMT 0805
<=20%
SMT 1206
Utech GMC31X7R104K50NT
<=20%
SMT (Panasonic VS "E" size)
Panasonic ECE-V1EA101UP
<=20%
SMT 3216
<=20%
f <= 0.5%
C <= 20%
Through hole, radial, 5mm diameter
KOA TMC1CA105KLRH
Nichicon LB/VX/USA/SA; Panasonic KA/KS/SU;
Sprague 501D/513D
C1 (0805 comp. side),
C2 (0805 near U8), C3
(0805 PSU filter), C4
(0805 near buzzer), C4
(0805 RFL I/P), C5
(0805 comp. side), C6
(comp. side), C7 (0805
near FWD I/P), C8
(0805 near U8), C9
(solder side), C10
(solder side), C11, C12,
C13, C14, C15, C16,
C17, C18 (0805 beside
uPC), C19, C20, C21 CAPACITOR, ceramic, 0.01uF, 63V
22
C7 (1206 near pow.
conn.), C10 (1206
solder side), C45, C46,
C47, C48, C49
CAPACITOR, ceramic, 0.1uF, 25V
10
Optional part depending on power level of TV or FM
C8 (electrolytic), C9
(electrolytic comp. side) CAPACITOR, electrolytic, 100uF, 25V
C15, C18 (1210
tantalum)
CAPACITOR, tantalum, 1uF, 16V
C25, C28, C31, C34, C3
(electrolytic)
CAPACITOR, electrolytic, 1uF, 16V
CLOCK, ceramic resonator, 4.000 MHz,
CR1
w/caps
Through hole, 3-position, 0.1" spacing
ECS Inc. ZTT-4.00MG
D1
DIODE, TVS, 600 watts, Vwm=30V, Vbr
min=33.3 (for TV power amplifier)
SMB
Crydom SMBJ30A; GI SMBJ30A
DIODE, TVS, 600 watts, Vwm=48V, Vbr
min=53.3 (for FM power amplifier)
DIODE, schottky, If=3A, Vr=60V
SMB
SMC
DO-41
Crydom SMBJ48A; GI SMBJ48A
International Rectifier 30BQ060
Micro Commercial 1N4004, ON Semiconductor
1N4004RL, General Semiconductor 1N4004
SMB
SMT 1206
Crydom SMBJ5.0A; GI SMBJ5.0A
Lumex SML-LX1206IW
0.23" lead spacing, 20AWG leads
Raychem RXE075; Bourns MF-R075
miniSMD
Raychem miniSMDC014-2
11
12
D1
D2,D3
13
D4
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
11
30
31
32
33
Q1, Q2
34
R1
35
R2
36
DIODE, rectifier, If=1A, Vr=400V
DIODE, TVS, 600 watts, Vwm=5.0V, Vbr
D9, D10
min=6.4
D12
DIODE, LED, RED, clear or diffused
FUSE, resettable, Ihold=0.75A, Itrip=1.5A,
F1
Vmax=72V
FUSE, resettable, Ihold=0.14A,
F6, F7, F8
Itrip=0.34A, Vmax=60V
CONNECTOR, 4-position plug, 180
degree wire entry, 90 degree screw
J1, J8
access, 5.08mm
CONNECTOR, 4-position header,
J1, J8
pluggable, vertical, closed, 5.08mm
CONNECTOR, breakaway header strip, 3J2, J5, J6
and 2-position required
J2, J5, J6
CONNECTOR, 2-position post shunts
CONNECTOR, 5-position plug, 90 degree
wire entry, 180 degree screw access,
J3
5.08mm
CONNECTOR, 5-position header,
J3
pluggable, vertical, closed, 5.08mm
CONNECTOR, 3-position plug, 180
degree wire entry, 90 degree screw
J7
access, 5.08mm
CONNECTOR, 3-position header,
J7
pluggable, vertical, closed, 5.08mm
J9
CONNECTOR, terminal strip, 16-position
J9
CONNECTOR, socket strip, 16-position
INDUCTOR, 680uH, Irms=0.4A,
L1
DCR=2.02 ohms
L2, L4, L5, L6, L7, L8, INDUCTOR, 0.01uH, Imax=0.45A,
L9, L10, L11, L12, L13 DCR=0.13 omhs
INDUCTOR, 680uH, Irms=1.3A, DCR=0.2
L3
ohms
20 X 4 character liquid crystal display,
LCD1
LED backlit
Series II, revision H printed circuit board,
PCB1
soldermask, silkscreen, FR4
37
12
R3
R4, R5, R6, R7, R10,
R11, R12, R13, R16,
R32, R34, R36
38
R8, R9, R14, R15
RESISTOR, 1.00 kohm, 1/10 watt, thick
film
RESISTOR, 10.0 kohm, 1/10 watt, thick
film
Molex 22-28-4300; Samtec TSW-130-05-T-S
AMP 382811-6; Samtec SNT-100-BK-T
Through hole, 0.2" spacing
Wieland 25.340.3553
Wieland 25.350.3553
Wieland 25.340.3353, Weco 10.808.103
Through hole, 0.2" spacing
Through hole, 0.1" spacing
Through hole, 0.1" spacing
Wieland 25.350.3353, Weco 20.806.127
Samtec TSW-116-18-T-S
Samtec SSW-116-03-T-S
SMT
JW Miller 3316-681M
SMT 1210
KOA KL32TE010K
SMT (Talema S5)
Talema SWS-0.85-680
4-40 pem mount (4)
Varitronix 20464K
SMT SOT-23
Alberta Printed Circuits, MPC, GRM, Enigma, …
Fairchild MMBT2222A; Zetex FMMT2222A; Diodes
Inc MMBT2222A-7
5%
Through hole, axial 0.4
Yageo CFR-25JB-4R7 (4.7QBK-ND)
1%
SMD 0805
Panasonic ERJ-6ENF15R0V
1%
SMD 0805
Panasonic ERJ-6ENF75R0V
1%
SMD 0805
Panasonic ERJ-6ENF1001V
1%
SMD 0805
Panasonic ERJ-6ENF1002V
TRANSISTOR, NPN, Ic=1A, Vce=40V
RESISTOR, 4.7 ohm, 1/4 watt, carbon film
RESISTOR, 15.0 ohm, 1/10 watt, thick
film
RESISTOR, 75.0 ohm, 1/10 watt, thick
film
Wieland 25.350.3453, Weco 20.806.128
Through hole, 0.1" spacing
0.1" spacing
+/- 10%
Wieland 25.340.3453, Weco 10.808.104
Through hole, 0.2" spacing
Series II - Bill of Materials
revision: H
date: 2-Dec-04
Optional part depending on power level of TV or FM
39
R17
40
R26 (next to VR2)
41
R26 (next to VR2)
42
R31
43
R31
44
45
R28, R30
R33
46
RLY1
47
U1
48
49
U2
U3
50
U4
51
52
U5, U6
U8
53
54
U9
U10
55
U11, U12
56
U13
57
U14
58
59
60
J10
U15
VR2, VR3, VR4
RESISTOR, 4.99 kohm, 1/10 watt, thick
film
RESISTOR, 2.7 KOHM, 1/10 watt, thick
film
RESISTOR, 680 OHM, 1/10 watt, thick
film
RESISTOR, 37.4 kohm, 1/10 watt, thick
film (for TV amplifier)
RESISTOR, 15 kohm, 1/10 watt, thick
film (for FM amplifier)
RESISTOR, 121 kohm, 1/10 watt, thick
film
RES, 120 ohm, 1/10 watt, thick film
RELAY, SPDT, 5Vdc coil,
5A@30Vdc/10A@125Vac contact
REGULATOR, switching, 5Vdc, 3A,
fosc=52kHz
REGULATOR, switching, 5Vdc, 1A,
fosc=150kHz
REGULATOR, linear, 5V, 1A
REGULATOR, inverter, 100mA
OPTOISOLATOR, dual, Viso=2500V,
Vce=30V
OP AMP, quad, low voltage
REFERENCE, 2.50V (for TV PA >=
250Wpk)
ADC, 10-bit, 10-channel
LOGIC, 8-bit shift register with latches
SUPERVISOR, n-channel, open drain,
internal pullup resistor
MICROCONTROLLER, OTP, 4k, 22 I/O
lines
Connector, socket, 28-position, DIP, 0.3"
spacing
MEMORY, 8k X 8, EEPROM, SPI
RES, variable, 2 kohm, 11 turn
1%
SMD 0805
1%
SMD 0805
Panasonic ERJ-6ENF4991V
1%
SMD 0805
1%
SMD 0805
Panasonic ERJ-6ENF3742V
1%
SMD 0805
Panasonic ERJ-6ENF4991V
1%
1%
SMD 0805
SMD 0805
Panasonic ERJ-6ENF1213V
Panasonic ERJ-6ENF1200V
Aromat JS1-5V; P&B T7CS5D-05
+/-0.2%
SMD TO-263-5
National LM2576HVS-5.0
Through hole TO-220-5
Through hole TO-220
SMD SOIC-8
National LM2595T-5.0
7805CT
National LM2660M; Analog Devices ADM8660,
Maxxim MAX660
Through hole, DIP-8
SMD SOIC-14
Fairchild MCT6
National LMV324M
SMD SOT-23
SMD SOIC-20
National LM4040BIM3-2.5
Analog Devices AD7812YR
Fairchild MM74HC595M; On Semi MC74HC595AD;
Phillips 74HC595D
SMD SOIC-16
SMD SOT-23
MCP130T-450I
Through hole DIP-28
Microchip PIC16C63A-04/SP
Through hole DIP-28
SMD SOIC-8
SMD
Jameco 112299CL or equivalent
Microchip 25LC640I/SN
Murata PVG5A202A01R00
SERIES II, REV. H - Control System
Vin Cond
U1
C1
ELECTROLYTIC
SOLDER SIDE
D1
L1
L5
Vout 2
+5Vdc
C4
0805 CHIP
NEAR BUZZER
5 On/Off
1 Vin
Vin
3 Gnd
J1
Feedbk 4
F1
C2
ELECTROLYTIC
D2
C14
J1
GND
U2
Feedbk 4
L3
R1
Vout 1
D3
BK LT
CTRL
SELECT
C6
ELECTROLYTIC
SOLDER SIDE
J2
BkLtCtrl
U3
IN
Pin15LCD
COMPONENT SIDE
5 On/Off
3 Gnd
C5
ELECTROLYTIC
SOLDER SIDE
2 Vin
J1
+8V OUT
OUT
C7
1206 CHIP
NEAR POW. CONN.
COM
J1
GND
VR1
U4
P8
P7
P6
P5
P1
P2
P3
P4
+5Vdc
C8
ELECTROLYTIC
R2
Pin3LCD
C9
ELECTROLYTIC
COMPONENT SIDE
R3
A. Sivacoe
SERIES II: Control System
Rev
ID
Power Supply Section
Date: May 14, 2004
Page: 1 of 1
SERIES II, REV. H - Control System
+5Vdc
R4
PWR In
J3
R5
R6
R8
J4
+5Vdc
P1
P2
P3
P4
R7
VW In
NAV In
R9
U5
J3
J4
P8
P7
P6
P5
VW uPC
PWR uPC
+5Vdc
R10
R11
R12
R14
NC(RC6)
SEL In
J3
J4
R15
U6
P1
P2
P3
P4
+5Vdc
P8
P7
P6
P5
PIN17uPC
RES uPC
R13
RES In
Ground
J3
J4
J3 5
J4 3
+5Vdc
BZ1
J5
R16
Buzzer
Q1
Buzzer
delete
+5Vdc
J6
+5Vdc
J7
Rly. COM
J7
Rly. N/O
RLY1
D4
J7
Rly. N/C
R17
Rly.Ctrl
Q2
A. Sivacoe
SERIES II: Control System
Rev
ID
Interface Section
Date: March 5, 2004 Page: 1 of 1
SERIES II, REV. H - Control System
U7
4/4
13 +
12
F2
J8
R18
R19
U7
3/4
F3
J8
R20
D6
Isoltd 7
Isoltd 6
R21
2+
U7
1/4
F4
J8
10 +
11
Analog 7
Isoltd 8
C10
SOLDER SIDE
1206 CHIP
For U7
D5
14
11
Analog 8
11
Analog 6
R22
D7
R23
C9
SOLDER SIDE
0805 CHIP
U7
2/4
6+
F5
J8
R24
D8
Isoltd 5
11
Analog 5
L1
R25
C10
SOLDER SIDE
0805 CHIP
L11
C18
0805
BESIDE
uPC
U8
4/4
R26
14
C13
Isoltd 4
11
13 +
12
+5V
VR2
Low Threshold Adjust
U8
3/4
L6
C18
1210
TANTALUM
C5
0805
COMP.
SIDE
VR3
2+
R29
D10
VR4
6+
C19
C3
R31
D11
Isoltd 1
11
J8
U8
2/4
Vin Cond
PSU
Isoltd 2
R30
L2
F8
U8
1/4
F7
C7
0805
NEARI/P
FWD
Isoltd 3
R28
FWD
J8
Analog 2
D9
11
RFL
C6
0805
COMP.
SIDE
R27
11
C15
C4
0805
RFL I/P
9+
10
F6
L4
Analog 3
J8
R32
Analog 1
A. Sivacoe
Series II: Control System
Rev
ID
Analog Input Section
Date: May 14, 2004
Page: 1 of 2
SERIES II, REV. H - Control System
+5Vdc
PSU
L7
C11
C12
Isoltd 1
C25
R33
FWD
L3
Isoltd 2
C1
0805 CHIP
COMP. SIDE
L9
Low Thresh
C16
Isoltd 3
C15
L10
C28
C2
0805
NEAR U8
C17
C31
L8
Isoltd 4
U9
C20
C21
U10
C34
C35
C36
C37
C38
C39
Isoltd 5
C40
Vref
Cref
Vin1
AGND
Vin2
Vin3
Vin4
Vin5
Vin6
Vin7
2 1
RFL
1210 CHIP
SOLDER SIDE
C8
0805
NEAR U8
Pin 3 on U9 is left
unconnected on PCB
Vdd
ConvStart
Dclk
Din
Dout
RFS
TFS
DGND
A0
Vin8
ConvStrt
Dclk
DfromUPC
DtoUPC
Isoltd 6
Isoltd 7
C45
For U10
C41
Isoltd 8
C42
A. Sivacoe
Series II: Control System
Rev
ID
Analog Conversion Section
Date: May 14, 2004
Page: 1 of 1
1
J9
J9
J9
J9
J9
J9
14
J9
13
J9
12
J9
11
J9
10
J9
J9
J9
J9
15
J9
LED K
LED A
LCD D0
LCD D1
LCD D2
LCD D3
LCD D4
LCD D5
LCD D6
LCD D7
LCD E
LCD R/*W
LCD RS
LCD Vo
LCD Vdd
LCD Vss
SERIES II, REV. H - Control System
16
J9
U12
serial_out
GND
reset
Qh(out_7)
shift_clk Qg(out_7)
latch_clk Qf(out_6)
output_en Qe(out_5)
serial_in Qd(out_4)
Qa(out_1) Qc(out_3)
Vcc
Qb(out_2)
U11
serial_out
GND
reset
Qh(out_7)
shift_clk Qg(out_7)
latch_clk Qf(out_6)
output_en Qe(out_5)
serial_in Qd(out_4)
Qa(out_1) Qc(out_3)
Vcc
Qb(out_2)
Pin3LCD
Pin15LCD
BkLtCtrl
+5Vdc
C46
DfromUPC
Dclk
R34
Latch1CS
Latch2CS
J10
R35
Q3
uPCPIN14
Ext. PSU
LCD data bus (D0...D7)
D0...D7 is text or instruction
Unbuf A
U12:
Unbuf B
LCD control signals,
LCD backlight control, and
External interface outputs
Unbuf C
U11:
Unbuf D
J10 J10 J10 J10
A. Sivacoe
Series II: Control System
Rev
ID
LCD Section
Date: March 8, 2004 Page: 1 of 1
SERIES II, REV. H - Control System
Vcc
U13
Reset
Reset
GND
Vcc
+5Vdc
C47
C48
U14
Dclk
DfromUPC
DtoUPC
Latch1CS
Latch2CS
Buzzer
CR1
GND OSC1
OSC2
CONVST
MCLR/Vpp
RB7
RA0
RB6
RA1
RB5
RA2
RB4
RA3
RB3
RA4
RB2
RA5
RB1
Vss
RB0/INT
OSC1/CLKin
Vdd
OSC2/CLKout
Vss
RC0/T1CKI
RC7/RX/CK
RC1/CCP2
RC6/TX/CK
RC2/CCP1
RC5/SD0
RC3/SCK/CLRC4/SDI/SDA
Dig.Out1
Dig.Out2
Rly.Ctrl
Dig.In 3
Dig.In 2
Dig.In 1
D12
R36
U15
Vcc
*HOLD
SCK
SI
*CS
SO
*WP
Vss
C49
C50
A. Sivacoe
Series II: Control System
Rev
ID
Microcontroller Section
Date: March 8, 2004 Page: 1 of 1
Section VII – Mechanical Section
The heat sink allows the amplifiers to operate at a cooler temperature and prevents overheating,
which helps the longevity of the entire system. The heat sink has hollow fins, which help dissipate
the heat from the amplifiers faster than a conventional serrated or corrugated fin.
In addition to the cooling effects of the heat sink, there is a fan that provides 110 cubic feet per
minute (CFM) of air flow (into zero static pressure).
VII-1
Section VIII - Installation
This section contains installation recommendations, unpacking, inspection, and installation instructions
for the power amplifier. We are sure that you are chomping at the bit to install your new system, so we
recommend that you read the following sections very carefully.
Building Recommendations
The quality of the building is of great importance if you are to expect long life and continued
performance from the power amplifier. The building must be clean, dry, temperature controlled and
secure. Don’t forget to allow space in the building for any additional racks to house test equipment, a
workbench area, line regulating transformers, ladders, equipment and parts storage, first aid kit,
emergency generator if used, as well as heating and cooling devices that may be unique to your
installation. A sloping roof will tend to develop leaks less rapidly. The building should be well roofed
with good material. The cooling load will be lowered with reflective or light colored roofing material.
Technalogix Ltd.
VIII-1
Heating and Cooling Requirements
The environment’s temperature will contribute greatly to the length of the power amplifier’s life.
Technalogix recommends that the building’s filtered air intake must have capacity for all air-flow in the
building plus an additional 20%. Keep the intake below the roofline to avoid intake of solar heated air.
Please ensure that the intake and exhaust areas are on the same side of the building to avoid
pressure differentials during windy conditions. Also, do not position intake near exhaust’s preheated
air. If air conditioning is required to cool the shelter, discuss the situation with a qualified HVAC
technician. Under average conditions, 12,000 BTUs will cool approximately 500 square feet to a
comfortable level.
Technalogix Ltd.
VIII-2
Electrical Service Recommendations
Technalogix recommends that a qualified, licensed local electrician be consulted for the required
electrical service. We suggest local electricians because:
• The personnel knows the local codes
• The personnel can be on site readily
• You are apt to get better overall support if you give what business you can to local suppliers
Technalogix recommends that proper AC line conditioning and surge suppression be provided on the
primary AC input to the power amplifier. All electrical service should be installed with your national
electrical code in your area, any applicable provincial or state codes, and good engineering practice.
Special consideration should be given to lightning protection of all systems in view of the vulnerability
of most transmitter or translator sites to lightning. Lightning arrestors are recommended in the service
entrance. Straight and short grounds are recommended. The electrical serviced must be well
grounded. Do not connect the unit to an open delta primary power supply, as voltage fluctuations could
harm the unit. Branch your circuits. Do not allow your lights, your workbench plugs, and your
transmitting or translating equipment to operate on one circuit breaker. Each transmitter or translator
should have its own circuit breaker, so a failure in one does not shut off the whole installation.
Technalogix Ltd.
VIII-3
Antenna and Tower Recommendations
Your preliminary engineering workgroup should establish your antenna and tower requirements, both
for receiving and transmitting antennas. Construction of sturdy, high quality antenna/tower systems will
pay off in terms of coverage of your service area, the overall quality and saleability of your radiated
signal, and reduced maintenance expenses. Technalogix provides complete turnkey antenna systems
if needed. If your site is serving as a translator, your receiving antenna should be in line of sight to the
originating station all year round. The foliage will change with season. Transmitting antennas can
enhance or seriously impair the transmitter/translator output.
The selection, routing, and length of coaxial cable are extremely important in the installation. If there is
a 3 dB line loss in the cable between your unit’s output and the transmitting antenna, a 100-watt unit
will only deliver 50 watts to the antenna. Buy the best cable you can obtain, route it via the shortest
way to the antenna, and keep it straight. Do not form it into sharp bends on its way. Do not use any
more cable fittings for the installation than absolutely necessary. All cautions here apply equally to all
coaxial cables in the system - input and output.
Pay attention to radial ice accumulation when designing the transmission system. It is not uncommon
for at least an inch of ice to build up on the tower and antenna. This in turn significantly increases the
weight, cross section, and wind loading of the system.
Attaching the transmission line to the tower is crucial to maintain a safe and reliable operation. Nylon
wire ties and electrical tape will breakdown in the sunlight and ultimately fail, creating a potentially
dangerous situation. It is important to use proper clamps and hoisting grips and also ensure that the
transmission line is grounded to the tower in several locations. When high currents flow through the
tower in the event of lightening strikes, some of that current will through the outer conductors of the
transmission lines. Due to the resistance difference between the steel tower and copper transmission
line, a significant voltage can be developed, often resulting in arcing between the outer jacket and
outer conductor, thus pitting the conductor.
Preventative maintenance is crucial in ensuring that safety is maintained. Specifically, check that
transmission line grounds are tight and are not missing any hardware. Frequently inspect support
clamps or spring hangers. Consider investing in an ice break, if you haven’t already done so, as
shards of falling ice can damage the transmission line – and if it is going to happen, it will happen at an
important time. Check the tower light photocells and conduit.
The better-known tower manufacturers offer complete technical and safety documentation with their
towers. Be sure that you have this information as it regards wind loading, guying, etc. The bestdesigned antenna system will function poorly if shortcuts and compromises are used during installation.
Follow the manufacturer’s instructions exactly, along with any engineering data prepared for the site.
Be absolutely safe and certain about this aspect as human lives may be at stake.
Technalogix Ltd.
VIII-4
Shelter Security
The FCC requires that the transmitter or translator be secure from entry or control by unauthorized
persons, and that any hazardous voltages or other dangers (including most tower bases) be protected
by locks or fences as necessary to protect personnel and prevent unauthorized tampering or
operation. Security of the building further implies that it be secure from wildlife. Use sturdy construction
materials, including sheet metal if necessary. Holes around conduit, cable, and other similar entry
points should be stuffed with steel wool and caulked to prevent entry of wildlife. Other features of
security for your shelter may include its location with respect to the prevailing wind conditions. A
location leeward of some natural topographical feature will prevent wind damage and snowdrifts. Check
the soil runoff conditions that may slow or hasten wind or water erosion and other concerns that may
be unique to your location.
Technalogix Ltd.
VIII-5
Unpacking and Inspection
Check the outside of the container. Carefully open the container and remove the power amplifier.
Retain all packing material that can be reassembled in the event that the equipment must be returned
to the factory.
Exercise care in handling equipment during inspection to prevent damage due
to rough or careless handling.
Visually inspect the enclosure of the power amplifier for damage that may have occurred during
shipment. Check for evidence of water damage, bent or warped chassis, loose screws or nuts, or
extraneous packing material in connectors or fan failures. Inspect all connectors for bent connector
pins. If the equipment is damaged, a claim should be filed with the carrier once the extent of the
damage is assessed. Technalogix cannot stress too strongly the importance of immediate careful
inspection of the equipment and subsequent immediate filing of the necessary claims against the
carrier if necessary. If possible, inspect the equipment in the presence of the delivery person. If the
equipment is damaged, the carrier is your first area of recourse. If the equipment is damaged and must
be returned to the factory, phone for a return authorization. Claims for loss or damage may not be
withheld from any payment to Technalogix, nor may any payment due be withheld pending the outcome
thereof. Technalogix cannot guarantee the carrier’s performance.
Technalogix Ltd.
VIII-6
Location and Function of Controls and Connectors (TAU-100 Power Amplifier)
The following illustration depicts the location of the connectors when installing the 100-watt power
amplifier (TAU-100).
Technalogix Ltd.
VIII-7
POWER -
Tactile button to turn carriers on and off. To turn off, must be depressed for
at least 2 seconds. Tied internally through DB9 connectors to all other
POWER buttons.
NAVIGATE -
Tactile button to refresh screen after two minute screen saver times out. All
monitoring and protection continues during screen saver.
SELECT-
Tactile button to refresh screen after two minute screen saver times out. All
monitoring and protection continues during screen saver.
RESET -
Tactile button to reset microcontroller in control board. Also clears existing
faults. Individual control board with reset comes back on with soft start feature.
RF IN –
RF input from modulator or processor. BNC connector, 50 ohm.
RF OUT –
100-watt RF output. Connects to inline wattmeter (not supplied) and antenna. N
connector, 50 ohm.
REMOTE PORT -
pin 1: ground to reset microcontroller, float otherwise
pin 2: ground for 2 seconds to toggle carrier on/off, float otherwise
pin 3: common ground
pin 4: DC power supply sample (28Vdc nominal)
AC IN –
AC input to switching power supply. Switching power supply draws a maximum
of 1 AAC at 115 VAC .
AC BREAKER –
10-ampere resettable circuit breaker is used to protect against inrush
currents and high current draw from switching power supply. The thermal
circuit breaker is a single pole configuration.
AC ON/OFF -
AC rocker switch (SPST) to supply AC to the AC-DC switching power supply
Technalogix Ltd.
VIII-8
Initial Hook Up
1. Place the transmitter/translator in its permanent location near a receptacle supplying required
AC voltage.
DO NOT APPLY AC POWER AND TURN ON POWER TO THE TRANSMITTER /
TRANSLATOR AT THIS TIME SINCE THE RF OUTPUT MUST BE PROPERLY
LOADED BEFORE OPERATION.
2. Place an appropriate AC power line protector, conditioner, and/or surge suppressor across the
AC supply line.
3. Hook up the modulator or processor as shown in their respective manuals for a transmitter or
translator. Do not connect the modulated signal from the RF OUT on the modulator or
processor to RF IN on the power amplifier at this time. Because of the characteristics of
LDMOS devices, the RF drive should not be connected to the power amplifier until after the
power supply and bias voltages are present and stable.
4. Ensure that modulator or processor RF output level is turned down as far as possible.
5. Ensure that the audio modulation is set to 100% with the audio signal supplied, as described in
the appropriate modulator/processor manual (will be factory set).
6. Ensure that the video modulation level is set to 87.5% with the video signal supplied, as
described in the appropriate modulator/processor manual (will be factory set).
7. Connect the transmitting antenna cable to the RF OUT N-type connector on the power
amplifier enclosure RF output.
Technalogix Ltd.
VIII-9
Section IX - Operating Procedure
Assuming the previous installation instructions have been completed and cautions noted, and the TAU100 power amplifier is ready to receive a properly modulated video and audio signal, proceed with the
following steps to place the system in operation. The TAU-100 power amplifier has been factory
aligned for channel frequency (per system specification), signal levels and optimum performance.
IT IS HIGHLY RECOMMENDED THAT YOU RUN YOUR SYSTEM INTO A DUMMY LOAD BEFORE
INSTALLING TO MAKE SURE THERE ARE NO DAMAGES CAUSED IN SHIPPING AND THE UNIT IS
RUNNING PROPERLY
1. Do not apply RF drive signal to the power amplifier at this time.
2. Verify that all control and RF cables are tight and properly seated in or on the mating connector.
3. Plug the modulator or processor into AC mains (110Vac).
4. Plug the 3U power amplifier enclosure into AC mains (110Vac).
5. Switch AC rocker switch to “ON” position
6. Verify that the power amplifier enclosure’s fan is on.
7. Ensure that the modulator/processor is turned on and set up according to its instructions. Depress
the POWER tactile button to turn the unit on.
8. The internal soft start circuitry will turn the bias voltages off until the power supply to the amplifier
pallets is fully stable. The message on the LCD indicates when the soft start is running. Once
complete, the Forward and Reflected Power and Power Supply readings will appear on the LCD in
the filter and power amplifier enclosures.
9. After the soft start is complete, apply the RF drive signal (which still should be turned down)
between the modulator or processor and the power amplifier RF In. This ensures that the RF drive
signal is applied only after the power supply is stable and the bias voltages are applied to the
amplifier.
IX-1
10. The TAU-100 LCD shows the user the present status of the amplifiers. Adjust RF output power to
desired level (see Important RF Power Notice in previous section). Verify that the FWD Power
reads 80 to 100 Watts on the filter enclosure - depending on signal content. The system is set up
for 100 watts peak visual power using the sync and blanking signal and should read 100 watts
FWD Power on the LCD under this condition only. The output power level can be adjusted
using the modulator or processor’s RF output level adjust. Keep in mind that the system will shut
down should the forward RF output power level be exceeded.
11. Ideally, the RFL Power should read zero. However, should a high VSWR be detected, the system
will automatically shut down and cycle as previously described. This is also a peak wattage
reading.
12. Verify that the power supply reads approximately 30 Volts DC (see supplied final inspection sheet
for factory settings of power supply levels) on the LCD of the power amplifier.
13. Look at the transmitted output using a suitable monitor. The picture and sound quality should be
clean and sharp. If the output picture and sound quality is unsatisfactory, check the input signals,
connections to the antenna system, antenna and transmission line VSWR, and the physical
condition of the antenna.
If reception problems are encountered, and the quality of transmission is satisfactory, the difficulty is
often with the receiving antenna or with obstructions in the path between the transmitter/translator and
receiver.
IX-2
Section X – Maintenance and Troubleshooting
Periodic Maintenance
If your unit employs a filter on the air inlet for the fans, the filter should be cleaned every 30 days. If the
equipment is operated in a severe dust environment, the filters on the inlet fan may need to be cleaned
more regularly. Turn the system off and unplug all of the AC inlet cords. The filter can be lifted off the
fan and cleaned using an air compressor at low pressure. While the filter is out, clean the fan blades
themselves with a small brush. The fans themselves do not need lubrication.
The interior of the cabinets should be cleaned and inspected annually. Turn the system off and unplug
all of the AC inlet cords. Remove the top lid by unscrewing the 6-32 machine screws.
Use extreme caution when working near the AC input terminal. The power
amplifier and power supply store hazardous capacitances and voltages.
Using either compressed air or a brush with soft bristles, loosen accumulated dust and dirt and then
vacuum the interior of the cabinet. Complete a visual inspection of the interior, making sure there are
no loose connections or discolorations on any components from heat. Nothing inside the power
amplifier enclosure exceeds a temperature that is not comfortable to the touch under normal operating
conditions, so any signs of discoloration indicate potential damage.
All modular components inside the enclosure are attached to aluminium mounting plates for easy
removal and replacement. Ensure that plates are secured and the mounting hardware is tight.
X-1
Troubleshooting
The first and most important aspect of troubleshooting anything is to be systematic. Note where you
have looked and what you found.
Look first for the obvious.
•
Make a physical inspection of the entire facility. Are all necessary connections properly made? Do
you see any signs of obvious damage within the equipment?
•
Is the AC power ‘ON’ to the site and the equipment? (Check fuses and circuit breakers if
necessary.)
•
Are all the switches in the correct operating position?
•
Is the input signal present?
•
Check LCD readings for presence of forward and reflected power and 30 V DC supply levels.
The above is an aid in determining the fault if some aspect of the system is not operating. The
following table deals with quality of operation:
Symptom
Possible Fault
Horizontal bars in picture (may
roll either way depending on
phase)
AC grounding / AC interference
Diagonal lines in picture
Correction
Install EMI/RFI filter in AC line
Ensure modulator/processor
and power amplifier share a
common ground
Install EMI/RFI filter in AC line
Determine source and
frequency of interfering signal
(spectrum analyzer may be
required)
Interference
X-2
Symptom
Weak output or picture
Possible Fault
Low level input signal
Low output power
High reflected power
Incorrect modulation depth
Incorrect load
X-3
Correction
Verify presence and level of
input signal
Verify power amplifier output
with wattmeter and dummy load
Adjust to meet specification
Ensure amplifier connected to
transmission line
Ensure
correct
antenna
impedance (50 ohms)
Check antenna tuning and
VSWR. Verify correct cable for
transmission line length
Check all cables for visible
damage (kinks, nicks or cuts)
Check all connectors for poor
connections, water or corrosion
Check alignment of antenna
Check for physical damage of
antenna, including ice build-up
Thank you
for choosing
Technalogix Ltd.

---

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