Technalogix TAV25L VHF Television Broadcast Transmitter User Manual TXV 25
Technalogix, Ltd. VHF Television Broadcast Transmitter TXV 25
USERS MANUAL
TAV-25 POWER AMPLIFIER NEW ADVENTURES IN BROADCASTING 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 DIRECTIONAL COUPLER................................................................................................. IV-4 FILTER ............................................................................................................................ IV-4 SECTION V - POWER SUPPLY SECTION ......................................................................V-1 SECTION VI - MONITOR AND CONTROL SYSTEM ....................................................... VI-1 CONTROL BOARD OVERVIEW (INSIGHT)........................................................................ VI-1 USER INTERFACE MODULE ............................................................................................ VI-1 COUPLER CONDITIONING MODULE ................................................................................ VI-2 RF CONDITIONING MODULE .......................................................................................... VI-3 TEMPERATURE SENSOR MODULE ................................................................................. VI-4 TXNET MODULE .............................................................................................................. VI-5 REMOTE PORT ............................................................................................................... VI-6 FAULT SHUTDOWN......................................................................................................... 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 INSPECTION ......................................................................................VIII-6 LOCATION AND FUNCTION OF CONTROLS AND CONNECTORS (TXV-25 POWER AMPLIFIERS ).................................................................................................................VIII-7 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. If you require technical service on the site, the cost to you will be $800.00 per day plus air fare and meals. 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. Please look under our web site (www.technalogix.ca) for the RMA form (Service) and fill it out. Either fax it to us or email to us. • 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 • 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 • 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 TAV-25 power amplifier supplies a 25-watt peak video signal with an aural carrier level 10 to 13 dB below visual carrier (dBc) on any of the VHF television channels 2 through 13. 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 TAV-25 power amplifier is a modular solid-state 25-watt broadcast amplifier utilizing readily available RF components wherever possible, thus enhancing the serviceability of the equipment. The TAV-25 is comprised of a VHFTV-25-L pallet for low-band VHF frequencies or VHFTV-25-H pallet for high-band VHF frequencies. The TAV-25 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 VHFTV-25 driver before the signal passes through 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-25 DIRECTIONAL COUPLER CIRCULATOR ATTENUATOR RF INPUT RF OUT A=-0.5dB typ. A=+40dB typ. low band VHF A=+34dB typ. high band VHF A=-0.05dB typ. TO WATTMETER AND ANTENNA A=-0.6dB typ. 50-OHM TERMINATION TAV-25 Block Diagram Rev ID Date: May 23, 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 VHF Channel 2 to 13 ±0.5 dB ±250 Hz 60 dB (adjacent channel) 0 dBmV 25 Watts 10% of peak visual power +35 dBmV nominal 75 Ohms 50 Ohms > 60 dB below rated power dBc = decibels below visual carrier > -53 dBc > -53 dBc > -53 dBc > -53 dBc > -53 dBc > -53 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 TAV-25 Power Amplifier 115 VAC , 4 AAC or230 VAC , 2 AAC 0 - 50°C TAV-25 Power Amplifier W-19" flange (17” encl.) , D-21.25", H-5.25” (3U) Operating Temperature Dimensions III-6 Section IV – RF Components Amplifier Pallets The VHFTV-25 pallet is a two stage ultra linear class-A linear pallet. The VHFTV-25-L has a typical gain of 40dB and the VHF TV-25-H has a typical gain of 34dB. These pallets draw no more than 3.0Adc 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 VHFTV25 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. 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 TECHNALOGIX LTD. 25 W UHF HI BAND DRIVER P25-UHF R.S. MCDONALD 14 SEPTEMBER, 2000 23 TECHNALOGIX LTD. 25 W UHF LO BAND DRIVER P25-UHF-L R.S. MCDONALD 14 SEPTEMBER, 2000 Filter The passive bandpass filter rejects spurious and harmonic output products and passes the VHF channel RF output. The cavity resonator uses aperture coupling and is a linear resonator design. Typical insertion loss is 0.6 dB to 1.0 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 analog-to-digital converters and provide the control system with valuable data for monitoring purposes. The directional couplers installed in the power amplifier and filter enclosures have peak detection circuits on the forward RF power side of the coupler and average detection circuits on the reflected RF power side of the coupler. This is to allow the end user to set power in a manner that is more independent of modulation and closer to a true tip-of-sync meter. Hence the readings of the displays in the power amplifier system are peak for forward and average for reflected. Output power should be set following the operating procedure found elsewhere in this manual. The directional coupler has a typical insertion loss of 0.5dB and its Type N connectors can handle 1,500 watts peak. 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 31.0 Vdc nominally. The power supply is a Mean Well S-240-30. 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 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 S-240 240W Single Output Switching Power Supply series Features : Auto switched 88 ~ 264VAC input Built-in passive PFC choke Protections:Short circuit/Over load/Over voltage/Over temperature Forced air cooling by built-in DC fan Built-in cooling Fan ON-OFF control LED indicator for power on Fixed switching frequency at 75KHz 2 years warranty SPECIFICATION MODEL OUTPUT S-240-5 S-240-7.5 S-240-12 S-240-15 S-240-24 S-240-30 S-240-48 DC VOLTAGE 5V 7.5V 12V 15V 24V 30V 48V RATED CURRENT 40A 30A 18A 15A 10A 8A 5A CURRENT RANGE 0 ~ 40A 0 ~ 30A 0 ~ 18A 0 ~ 15A 0 ~ 10A 0 ~ 8A 0 ~ 5A RATED POWER 200W 225W 216W 225W 240W 240W 240W RIPPLE & NOISE (max.) Note.2 150mVp-p 200mVp-p 150mVp-p 150mVp-p 180mVp-p 180mVp-p 240mVp-p VOLTAGE ADJ. RANGE 6 ~ 9V 2.0% 10 ~ 14V 1.0% 12 ~ 18V 1.0% 20 ~ 28V 1.0% 27 ~ 33V 1.0% 41 ~ 56V 1.0% VOLTAGE TOLERANCE Note.3 INPUT LINE REGULATION 0.5% 0.5% 0.5% 0.5% 0.5% 0.5% 1.0% LOAD REGULATION 1.0% 1.0% 0.5% 0.5% 0.5% 0.5% 1.0% SETUP, RISE TIME 1000ms, 20ms at full load HOLD TIME (Typ.) 36ms at full load VOLTAGE RANGE 88 ~ 132VAC / 176 ~ 264VAC auto switch FREQUENCY RANGE 47 ~ 63Hz EFFICIENCY (Typ.) 78% AC CURRENT (Typ.) INRUSH CURRENT (Typ.) 5A/115VAC 15A/115VAC 80% 248~370VDC 82% 83% 84% <2mA / 240VAC OVER LOAD 105 ~ 135% rated output power Protection type : Hiccup mode, recovers automatically after fault condition is removed. OVER VOLTAGE 6 ~ 7V 9.4 ~ 10.9V 14.4 ~ 16.8V 18.5 ~ 21.5V 31.2 ~ 36V Protection type : Hiccup mode, recovers automatically after fault condition is removed. FAN CONTROL, O.T.P. WORKING TEMP. RT1 40 -10 ~ +60 85% 87% 34.5 ~ 40.5V 57.6 ~ 67.2V 2.5A/230VAC 30A/230VAC LEAKAGE CURRENT PROTECTION FUNCTION 4.5 ~ 5.8V 2.0% FAN ON, 35 FAN OFF, 70 output shutdown (Refer to output load derating curve) 20 ~ 90% RH non-condensing WORKING HUMIDITY ENVIRONMENT STORAGE TEMP., HUMIDITY -20 ~ +85 , 10 ~ 95% RH TEMP. COEFFICIENT 0.03%/ (0 ~ 50 ) 10 ~ 500Hz, 2G 10min./1cycle, 60min. each along X, Y, Z axes VIBRATION UL60950-1, TUV EN60950-1 Approved (7.5V Design refer to TUV EN60950-1) SAFETY STANDARDS WITHSTAND VOLTAGE I/P-O/P:3KVAC I/P-FG:1.5KVAC O/P-FG:0.5KVAC SAFETY & ISOLATION RESISTANCE I/P-O/P, I/P-FG, O/P-FG:100M Ohms/500VDC EMI CONDUCTION & RADIATION Compliance to EN55022 (CISPR22) Class B EMC (Note 4) HARMONIC CURRENT EMS IMMUNITY MTBF OTHERS DIMENSION PACKING NOTE Compliance to EN61000-3-2,-3 Compliance to EN61000-4-2,3,4,5,6,8,11; ENV50204, Light industry level, criteria A 179.3K hrs min. MIL-HDBK-217F (25 190*93*65mm (L*W*H) 1.2Kg; 12pcs/15.3Kg/0.78CUFT 1. All parameters NOT specially mentioned are measured at 230VAC input, rated load and 25 of ambient temperature. 2. Ripple & noise are measured at 20MHz of bandwidth by using a 12" twisted pair-wire terminated with a 0.1uf & 47uf parallel capacitor. 3. Tolerance : includes set up tolerance, line regulation and load regulation. 4. The power supply is considered a component which will be installed into a final equipment. The final equipment must be re-confirmed that it still meets EMC directives. File Name:S-240-SPEC 2005-09-13 S-240 240W Single Output Switching Power Supply Mechanical Specification Case No. 911 series Unit:mm 159.5 139.5 133 49.5 20 4-SO M3 L=6 44 43.5 41.5 62.5 93 84.5 9.5 Air flow direction 190 171.25 26 7.5 37.5 50 65 3-M4 L=6 Terminal Pin. No Assignment Pin No. Pin No. 4,5 6,7 Assignment AC/L AC/N FG Assignment DC OUTPUT -V DC OUTPUT +V Output Derating Static Characteristics (24V) OUTPUT VOLTAGE (V) 100 80 LOAD (%) 60 40 20 -10 10 20 30 40 50 AMBIENT TEMPERATURE ( ) 60 (HORIZONTAL) 300 28 250 24 200 20 150 16 100 12 50 25 80 160 85 170 90 180 95 190 100 200 105 210 110 220 115 230 120 240 125 250 OUTPUT RIPPLE (mVp-p) Ta=25 32 130 260 INPUT VOLTAGE (V) 60Hz File Name:S-240-SPEC 2005-09-13 Section VI – Monitor and Control System Control System Overview (Insight) The Insight control system is used for a variety of functions, the most important of which is ensuring that the transmitter continues to operate in a safe manner. The control system also allows the user to monitor and control the transmitter from both the front panel and the remote access port. Five modules comprise the Insight control system. These modules work together to provide all the functions of the control system. The modules are: the user interface module, the coupler condition module, the RF conditioning module, the temperature sensor module, and the TxNET module. The operation of each module is outlined in the following sections. User Interface Module The primary function of the user interface module is, as the name suggests, providing the user interface for the control system. This circuit board is mounted to the front panel of the transmitter, directly behind the LCD display. The membrane switch on the front panel is also connected to the user interface module. These components together provide the user with the ability to monitor the transmitter from the front panel. The following parameters can be monitored from the front panel: • Forward (incident) power at the transmitter output. • Reflected (reverse) power at the transmitter output. • DC voltage of the transmitter power supply. • DC current for each pallet in the transmitter. • Temperature of the heat sink of the transmitter. • The time since the transmitter was last shut down. The hardware of the user interface module is based around a microcontroller (U112). This microcontroller interfaces directly with the LCD and the membrane switch to provide output and receive input from the user. The microcontroller also communicates with the coupler conditioning board over a controller area network (CAN) bus. This communication is facilitated be two ICs, U113 and U114, and passes through a CAT5 cable attached to connector J105. The communication link with the coupler conditioning module allows the user interface module to receive information about the foreword power, reflected power, and temperature of the transmitter, as well as relay commands from the user to the rest of the system. If the transmitter includes more than on amplifier module, a second CAN connection will be present between the user interface module (J106) and the TxNET board to facilitate communication between enclosures. Other elements of the user interface module are also controlled by the microcontroller. A buzzer (BZ101), a status LED (D113), and a relay to control the backlight of the LCD (RL101), are all controlled through a buffer (U116). In order for the user interface module to monitor the current draw of each pallet in the system, the DC supply wires pass through the user interface module on their way from the power supply to the pallets. The DC enters through connector J101 from the power supply, and exits through J102 to go to the pallets. As the current passes through shunt resistors (R117, R118, R120, R121, R123, R124, R126, R127, R129, R130), the voltage drop is VI-1 monitored by U101 to U105, buffered by U106 to U108, and sent to the analog to digital converter integrated into the microcontroller. There are five circuits for which the current is monitored by this system. As the DC supply passes through the user interface module, it undergoes filtering to ensure that the supply to the pallets is as clean as possible. Each of the five circuits passes through a network of transient voltage suppressors, capacitors, and inductors. Each connection is also fused at the input to insure an over-current condition does not persist. The fuses are a replaceable mini blade type fuse with a 42V voltage rating, and a current rating depending on application. Coupler Conditioning Module The coupler conditioning module serves to monitor the output of the directional coupler which provides a voltage proportional to the foreword and reflected power at the output of the transmitter. The coupler conditioning module also interfaces with each of the other boards in the control system, acting as the hub of communications for the system. Lastly, the coupler conditioning board sends and receives signals through the remote access port, via the TxNET board. The analog signals produced by the coupler for forward and reflected power are passed onto the coupler conditioning module by connectors J206 and J207 respectively. Each signal is filtered by CLC networks, and buffered and amplified by the op-amp U214. The level of the forward signal can be adjusted by VR201, and the reflected signal by VR202. These two potentiometers can be used to fine tune the power readings of the transmitter if they go out of calibration. The analog signals are converted to digital by an analog-to-digital converter integrated into the microcontroller U202. Aside from taking readings from the coupler, the microcontroller on the coupler conditioning module also interfaces with the RF conditioning module (through J201A) and the temperature sensor (through J201B). The microcontroller interfaces with the CAN bus using U203 and U204. Through the CAN bus, the coupler conditioning board is able to communicate with the user interface module, and any other amplifiers that are in the system. The CAN bus is connected through J201C, and J201D if there are multiple amplifiers in the transmitter system. The last task of the coupler conditioning board is to send and receive remote access signals to and from the TxNET board. Two analog outputs, proportional to forward and reflected power and produced by the digital-to-analog converter U212 after it receives input from the microcontroller. The analog outputs are then buffered by U211 before being sent through J203 to the TxNET board. J203, along with J204, also bring the digital inputs and outputs from the TxNET board to the coupler conditioning module. The digital signals are then connected to the microcontroller through the opto-isolators U205, U206, U207, U208, and U209. VI-2 RF Conditioning Module The RF conditioning board is located at the RF input of the amplifier. Its main function is to act as a variable attenuator, so that the control system can add attenuation to the input of the amplifier in order to limit the output power of the transmitter. The RF signal comes in to the RF conditioning module through J302 before it passes through a manually variable attenuator made up of R305, VR303, and R307. The signal then passes through the digitally-controlled variable attenuator U302 before exiting through J303. The input for the digital attenuator comes from the coupler conditioning module through J304. The input signals are passed through the opto-isolators U303, U304, and U305 before being sent to the digital attenuator. In total, five control signals go to the digital attenuator, allowing for attenuations of up to 31dB in 1dB steps. Temperature Sensor Module The temperature sensor module is a small board mounted to the main heatsink of the amplifier. The main purpose of the temperature sensor module is to take temperature readings of the heatsink. The temperature sensor IC is U1 which, after it has taken a reading, relays the digital information to the coupler conditioning module through J1. Also passing through J1 is a driver disable signal coming from the coupler conditioning module. The temperature sensor module simply takes this signal and passes it through to J2, where it is connected to the driver pallet. TxNET module The TxNET module is simply a passive board that acts as an interface between the wiring on the inside of the amplifier enclosure and connections on the outside of the enclosure. The DB-25 connector for the remote port (J602) is attached to the TxNET module. The signals travelling through this port are connected to the coupler conditioning module through J601 and J603. The TxNET module also includes up to four straight through RJ45 connections: J604 to J605, J606 to J607, J608 to J609, and J610 to J611. These connections are only used on systems with multiple enclosures, to pass control signals between enclosures. VI-3 Remote Port The remote port allows external control of the transmission system via the DB25. The functions of each pin on the remote port are indicated in the following table: Pin Number Description Ground Forward power sample1 Reflected power sample1 Carrier off2 Carrier on2 Increase carrier level (level must have been decreased) 2 Decrease carrier level (1dB increments) 2 Soft reset2 Reset2 10 Power supply fault flag3 11 High temperature flag3 12 High VSWR flag3 13 Amplifier overdriven flag3 14 +5Vdc 15 +3.3Vdc 16 Ground 17 Ground 18 N/C 19 N/C 20 N/C 21 N/C 22 N/C 23 N/C 24 N/C 25 N/C Notes: 1. Analog output with voltage ranging from 0 to 5Vdc. 2. TTL level digital input, active on rising edge. 3. TTL level digital output, active high. VI-4 Fault Shutdowns On the LCD (Liquid Crystal Display) the following messages may appear: If you see this message, the system has been driven to a power level higher than it is rated for. This message will likely only appear momentarily, before the amplifier will add attenuation at its input to bring the output power to a safe level. This message indicates that excessive reflected power has been detected at the output of the transmitter. Periodically, the amplifier will cycle on, and re-check for reflected power. If high reflected power continues, the transmitter will eventually shut down completely. This message indicates that the transmitter is experiencing unsafe internal temperatures. Output power is reduced until a safe temperature is reached. VI-5 Monitor and Control System (Insight) Bills of Materials Circuit: Revision: User Interface Module 1.03 Designations Qty Description Package U112 IC MICROCONTROLLER 256 BYTE RAM 64QFP C106, C107, C117, C118, C128, C129, C141, C142, C148, C149, C163 11 CAPACITOR 0.01 uF 50V 10% C108-116, C119127, C130-140, C143-145, C161 33 Manufacturer Mfg. Part Number Texas Instruments MSP430F135IPM 0805 Yageo 08052R103K9B20D CAPACITOR 0.1uF 50V 10% 0805 Yageo 08052R104K8B20D C146, C147 CAPACITOR 33pF 50V 5% 0805 Panasonic ECJ-2VC1H330J R101, R104, R107 R110, R113 RESISTOR 2.7K? 0805 Yageo 9C08052A2701FKHFT C162 CAPACITOR 1uF, 50V 0805 TDK Corporation C2012Y5V1H105Z R132 RESISTOR 37.4K? 0805 Yageo 9C08052A3742FKHFT R133 RESISTOR 3.3K? 0805 Yageo 9C08052A3301FKHFT R134, R135, R136, R137, R138, R139 RESISTOR 249K? 0805 Yageo 9C08052A2493FKHFT R140, R141, R144 R145, R146, R147 R150, R151, R156 RESISTOR 10K? 0805 Yageo 9C08052A1002FKHFT R142, R143, R148 R149, R154, R155 RESISTOR 1K? 0805 Yageo 9C08052A1001FKHFT R152 RESISTOR 100? 0805 Yageo 9C08052A1000FKHFT R119, R122, R125, R128, R131, R153 RESISTOR 100K? 0805 Yageo 9C08052A1003FKHFT R158 RESISTOR 430? 0805 Yageo 9C08052A4300FKHFT R160 RESISTOR 1.4K? 0805 Yageo 9C08052A1401FKHFT R161 RESISTOR 27K? 0805 Yageo 9C08052A2702FKHFT R162 RESISTOR 6.2K? 0805 Yageo 9C08052A6201FKHFT R157 R117, R118, R120 R121, R123, R124 R126, R127, R129 R130 RESISTOR 4.7? 2010 Panasonic ERJ-12ZYJ4R7U 10 RESISTOR 0.006? 1% 1W 2512 Vishay WSL25126L000FEA 4mm SMD Bourns 3314G-1-103E R159 R102, R103, R105 R106, R108, R109 R111, R112, R114 R115 POTENTIOMETER 10K? 10 RESISTOR 20? 1 W 2512 Panasonic ERJ-1TYJ200U RN101 SMT Panasonic EXB-A10P103J F107 SMD Raychem MINISMDC200-2 F108 RESISTOR NETWORK 10K? RESETTABLE FUSE, POLYFUSE, 2A RESETTABLE FUSE, POLYFUSE, .5A SMD Raychem MINISMDC050-2 VI-6 L106, L107, L108, L109, L110 INDUCTOR 0.01uH 1210 TDK NLV32T-010J-PF Y101 6.00 MHz CRYSTAL SMT Citizen HCM49-6.00 U111 IC SUPERVISOR 2.70V LOW SOT23 Microchip Technology MCP130T-270I/TT U114 IC TXRX 3.3V CAN 8-SOIC Texas Instruments SN65HVD232D U113 IC CAN CONTROLLER W/SPI 18-SOIC Microchip Technology MCP2510-I/SO U115 IC REG SIMPLE SWITCHER T O-263-5 National Semiconductor LM2576HVS-5.0 U116 IC DARL TRANS ARRAY 16-SOIC Texas Instruments ULN2003ADR U117 IC REG LINEAR LDO SOT223 National Semiconductor LM1117MP-3.3 U118 IC VOLTAGE COMVERTER 8-SOIC National Semiconductor LM2660M 8-SOIC Fairchild Semiconductor MOCD211M SOT23-5 Texas Instruments INA168NA 8-SOIC Texas Instruments OPA2340UA D0214AA Crydom SMBJ30A U109, U110 OPTOCOUPLER DUAL CHANNEL U101, U102, U103 U104, U105 IC CURRENT MONITOR U106, U107, U108 IC OP AMP SINGLE SUPPLY D101, D103, D105 D107, D109, D111 DIODE TVS 30V D102, D104, D106 D108, D110 D113, D115, D117 DIODE LED GREEN 1206 Lumex SML-LX1206GC-TR D114 DIODE SCHOTTKY SMC International Rectifier 30BQ060 D116 DIODE RECTIFIER 1A 200V SMA Diodes Inc. S1D-13 D118 DIODE SCHOTTKY 5A 50V SMC Diodes Inc. B550C-13 or B550C-13F C152 CAPACITOR 10uF 16V TANTALUM 3528 Kemet T491B106K016AS C156-160 CAPACITOR 22uF 35V TANTALUM D (SMT) Kemet T495D226K035ASE300 S101 SWITCH DIP 7 POSITION SMT 0.1" CTS 219-7MST S102 HEADER 3POS 0.1" Through Hole AMP/Tyco 640452-3 RL101 RELAY SPST 5VDC SMT Omron G6L-1F-DC5 L101, L102, L103, L104, L105 INDUCTOR 1.3uH SMT Panasonic ETQ-P6F1R3LFA C153, C154, C155 CAPACITOR 100uF, 10V D (SMT) Panasonic ECE-V1AA101SP U119 IC REG SIMPLE SWITCHER T O-263-7 Texas Instruments LM2679S-ADJ C101, C102, C103, C104, C105, C150 CAPACITOR 100uF 63V G (SMT) Panasonic ECE-V1JA101P BZ101 BUZZER CUI Inc. CT-1205C J107 CONNECTOR 14POS HEADER Through Hole AMP/Tyco 103308-2 J108 Through Hole Keystone 7701 J105,J106 SMT CONNECTOR SCREW TERMINAL CONNECTOR MODULAR JACK 8 VERTICAL Through Hole AMP/Tyco 5556416-1 F101, F102, F103, F104, F105, F106 FUSE AND FUSE HOLDER 42V MINI Through Hole Littelfuse 02970xx.WXNV and 01530008Z J103 CONNECTOR 5POS HEADER Through Hole AMP/Tyco 3-644695-5 J102 CONNECTOR, 2 PART 0.3" 10POS Through Hole Weiland 25.390.4053.0 J101 CONNECTOR 2 PART 0.3" 6POS Through Hole Weiland 25.390.3653.0 L111 INDUCTOR 150uH S6 Talema SWS-2.0-150 L112 INDUCTOR 33uH 5A 260kHz Through Hole Pulse P0849NL J104 16 POST HEADER Through Hole Samtec TSW-116-18-T-S C151 CAPACITOR 1000uF, 10V Panasonic ECE-V1AA102P G (SMT) VI-7 Circuit: Revision: Coupler Conditioning 1.04 Designations Qty C201, C203, C204, C205, C208, C209, C212, C213, C214, C215, C216, C217, C218, C219, C220, C221, C222, C223, C224, C225, C226, C227, C228, C229 24 C202 C206, C207 C210, C211 D201, D202 Capacitor, ceramic, 0.01uF, 50Vdc, +/-20% Capacitor, ceramic, 0.1uF, 50Vdc, +/-20% Capacitor, ceramic, 33pF, 50Vdc, 5% Capacitor, electrolytic, 100uF, 10V, +/-20% Diode, TVS, 5.0Vdc, 600W, unidirectional D203, D204 Diode, LED, red, 2.0V D205 Diode, rectifier, 200V, 1A D206 J201 J202 J203, J204 J205 J206, J207 Diode, zener, dual, 10V Connector, modular, female, 4-port, 8-position, rt. angle Connector, header, IDC, 0.1" spacing, 14-pos Connector, modular, female, 8position, vertical Connector, header, 3-position, 0.1", square post Connector, header, vertical, 3-pos, 0.1" spacing K201 L201, L202, L203, L204, L205, L206, L207, L208, L209, L210, L211, L212 Relay, SPST, 5Vdc coil, SMT R203, R208, R213, R218, R221, R201 R204, R211, R214, R219, R222, R224 Description Package 16 Resistor, thick film, 5%, 1kohm, 1/8W Mfg. Part Number SMD 0805 Kemet C0805C103K5RACTU SMD 0805 Yageo America C0805C104M5UACTU SMD 0805 Panasonic ECJ-2VC1H330J SMD 'D' Panasonic ECE-V1AA101SP General Semiconductor SMBJ5.0A-13 SMB SMD 1206 Inductor, 0.01uH, Imax=0.45A, DCR=0.13 omhs Resistor, thick film, 5%, 100ohm, 1/8W 12 Manufacturer Lumex SML-LX1206IW-TR SMA Diodes Inc. S1D-13 SOT -23 Diodes Inc. AZ23C10-7-F Through Hole AMP/Tyco 557562-1 Through Hole AMP/Tyco 103308-2 Through Hole AMP/Tyco 5556416-1 Through Hole AMP/Tyco 644695-3 Through Hole Molex 22-02-2035 SMT Omron G6L-1F-DC5 SMD 1210 KOA KL32TE010K SMD 0805 Panasonic ERJ-6GEYJ101V SMD 0805 Panasonic ERJ-6GEYJ102V SMD 0805 Panasonic ERJ-6GEYJ103V SMD 2512 Panasonic EXB-A10P103J SMD 2512 Panasonic EXB-A10P102J SMD 0.1" CTS 219-7MST Micro chip Technology MCP130T-270I/TT R207, R212, R217, R220, R223, R205, R206, R209, R210, R215, R216 RN201, RN202, RN204 RN203 S201 U201 Resistor, thick film, 5%, 10kohm, 1/8W Resistor network, 10kohm, 8-resistors, 10-terminations, bussed, 5% Resistor network, 1kohm, 8-resistors, 10-terminations, bussed, 5% Switch, DIP, 7-position, SPST IC, supervisor, 2.7V, internal pull-up resistor, open drain, active low VI-8 SOT -23 U202 IC, microcontroller, 16-bit, 16k X 8 program, 48 I/O, flash 64-QFP Texas Instruments MSP430F135IPM U203 IC, CAN transceiver, 3.3V SOIC-8 Texas Instruments SN65HVD232D U204 IC, CAN controller, industrial temp, 3 transmit buffers, 2 receive buffers 18-SOIC Microchip Technology MCP2510-I/S0 U205, U206, U207, U208, U209 IC, optoisolator, dual, transistor o/p, Vceo=30V SOIC-8 Fairchild MOCD211M U210 IC, buffer, Darlington, array SOIC-16 Texas Instruments ULN2003ADR U211, U214 IC, op-amp, dual, single supply SOIC-8 Texas Instruments OPA2340UA U212 SOIC-8 Texas Instruments TLV5625CD U213 SOT -23 National Semiconductor LM4040BIM3-2.5 VR201, VR202 IC, DAC, dual, 8-bit, serial IC, voltage reference, 2.50V, +/0.2% Potentiometer, 2kohm, 11-turn, 5mm, top SMT Murata PVG5A202C01R00 Y201 Crystal, 6.000MHz SMT Citizen HCM49-6.00 Circuit: Revision: RF Conditioning 1.05 Designations Qty C301, C306, C311 C302, C303, C305, C312, C320 Description Package Capacitor, ceramic, 0.1uF, 50Vdc, +/-20% Manufacturer Mfg. Part Number SMD 0805 Yageo America C0805C104M5UACTU SMD 0805 Kemet C0805C103M5RACTU SMD 0805 Panasonic ECJ-2VB1H223K SMD 0805 Kemet C0805C102K5RACTU SMD 0805 Panasonic ECJ-2VC1H331J C309 Capacitor, +/-20% Capacitor, +/-10% Capacitor, +/-10% Capacitor, +/-10% C313, C314, C315, C316, C317, C318, C319 DNS D301 Diode, TVS, 30V, 600W Diodes Inc. SMBJ30A-13 D302 Diode, LED, green, Vf=2.2V SMD 1206 Lumex SML-LX1206GW-TR D303, D304, D305, D306, D307 Diode, LED, red, Vf=2.0V SMD 1206 Lumex SML-LX1206IW-TR Fairchild Semiconductor MMBD914 Fuse-miniSMD PCB THT (0.2") Littelfuse MINISMDC014-2 Wieland 25.350.3253.0 PCB End Launch Wieland 25.340.3253.0 Johnson Components 142-0701-801 PCB THT Amp (Tyco) 5556416-1 TDK NLV32T-010J-PF Alberta Printed Circuits PCB301 C304 C307, C308, C310 ceramic, 0.01uF, 50Vdc, ceramic, 0.022uF, 50Vdc, ceramic, 1000pF, 50Vdc, ceramic, 330pF, 50Vdc, SMD 0805 SMB D308 Diode, ultrafast SOT -23 D309, D310 T O-92 F301 J301 J301 J302, J303 J304 DNS Fuse, resettable, miniSMD, Ihold = 0.14A, Itrip = 0.34A Connector, terminal block, header, 2-position, straight Connector, terminal block, plug, 2position, straight Connector, SMA, PCB End Launch, 50-ohms Connector, modular, female, 8position, vert ical L301 PCB301 Inductor, 0.01uH Printed circuit board, FR4, proto 2 or equivalent VI-9 1210 R301 Resistor, thick film, 5%, 620ohm, 1W DNS SMD 2512 Panasonic ERJ-1TYJ621U SMD 0805 Yageo America 9C08052A1001JLHFT SMD 0805 Yageo America 9C08052A1300FKHFT R302, R303 R304, R312, R313, R318, R319, R322 R305, R307 Resistor, thick film, 5%, 1.0kohm, 1/8W Resistor, thick film, 1%, 130ohm, 1/8W R308, R309, R314, R315, R320 Resistor, thick film, 5%, 1.2kohm, 1/8W SMD 0805 Yageo America 9C08052A1201JLHFT R310, R311, R316, R317, R321 Resistor, thick film, 5%, 10kohm, 1/8W SMD 0805 Panasonic 9C08052A1002JLHFT R323 Resistor, 100ohm, 1/8W SMD 0805 Yageo America 9C08052A1000FKHFT Yageo America 9C08052A3R32FGHFT Murata PVG5A502C01R00 Murata PVG5A201C01R00 CTS Corporation 219-5MST National Semiconductor LM78M05CDT Skyworks (Alpha) AA110-85 Fairchild MOCD211M Mini-Circuits DBTC-20-4 Analog Devices AD8362ARU R324 Resistor, 3.3ohm, 1/8W SMD 0805 R325, R326, R327, R328, R329 DNS SMD 0805 VR301 Potentiometer, 5kohm SMD 5MM VR302 DNS SMD 5MM VR303 S301 SMT 5MM CTS 219-5 SMD U301 Potentiometer, 200ohm Switch, DIP, 5-position, SPST, gold finish, sealed IC, voltage regulator, 5V output, 500mA U302 SSOP-20 U303, U304, U305 IC, digital attenuator, 5-bit, 1dB LSB IC, optoisolator, dual, transistor o/p, Vceo=30V U306 Directional coupler U307 U308 IC, power detector DNS (replace with two 0805 0ohm resistors) U309 DNS Circuit: Revision: T O-252 SOIC-8 TSSOP-16 T O-243 Temperature Sensor 1.02 Designations Qty C701 J701 Description Package Manufacturer Mfg. Part Number 0805 Yageo 08052R104K8B20D CAPACITOR 0.1uF 50V 10% CONN MOD JACK 8-8 R/A PCB 50AU SMT Molex 44144-0003 J702 TERMINAL SCREW VERTICAL PC MNT Keystone 8191 U701 IC DIG TEMPERATURE SENSOR 8-MSOP National Semiconductor LM70CIMM-3 Package Manufacturer Circuit: Revision: TxNet 1.02 Designations Qty F601, F602, F603, F604 Description Fuse, resettable, Ihold=0.14A, Itrip=0.34A, Vmax=60V SMD VI-10 Tyco Mfg. Part Number MINISMDC014-2 J601, J603, J604, J605, J606, J607, J608, J609, J610, J611 10 Connector, modular, jack, 8position, vertical, PCB mount Tyco 5556416-1 J602 Connector, D-sub, 25 position, female, vertical, PCB mount Kycon K85-BD-25S-R VI-11 Insight System Schematics The following pages contain the schematics for the Insight system. VI-12 User Interface Module DC Supply Conditioning Vin J101A L101 ETQ-P6F1R3LFA F101 V1 Input V1 Cond TAC 58V see table SMBJ30A TV SMBJ48A FM J101B D101 C101 100uF 63V R102 20 R101 2.7k TV 4.87k FM R103 20 D102 Green SML-LX1206GW L102 ETQ-P6F1R3LFA F102 V2 Input V2 Cond TAC 58V see table SMBJ30A TV SMBJ48A FM J101C D103 C102 100uF 63V R105 20 R104 2.7k TV 4.87k FM R106 20 D104 Green SML-LX1206GW L103 ETQ-P6F1R3LFA F103 V3 Input V3 Cond TAC 58V see table SMBJ30A TV SMBJ48A FM J101D D105 C103 100uF 63V R108 20 R107 2.7k TV 4.87k FM R109 20 D106 Green SML-LX1206GW L104 ETQ-P6F1R3LFA F104 V4 Input V4 Cond TAC 58V see table SMBJ30A TV SMBJ48A FM J101E D107 C104 100uF 63V R111 20 R110 2.7k TV 4.87k FM R112 20 D108 Green SML-LX1206GW L105 ETQ-P6F1R3LFA F105 V5 Input V5 Cond TAC 58V see table SMBJ30A TV SMBJ48A FM D109 C105 100uF 63V R114 20 R113 2.7k TV 4.87k FM R115 20 D110 Green SML-LX1206GW F106 VgenCond TAC 58V tbd SMBJ30A TV SMBJ48A FM D111 J101F GND IN Fuse Table PA5-UHF PA10-UHF P50-UHF P150-UHF U60LD UHF U200LD UHF P350-FM P750-FM 2A 3A 10 A 10 A/side 3A 7.5 A/side 15 A 15 A/side PA25-VHF-L PA25-VHF-H P200-VHF-L P200-VHF-H P400-VHF-L P400-VHF-H 4A 5A 15 A 15 A 15 A/side 10 A/side A. Sivacoe, N. Hendrickson User Interface Module Rev ID Insight Control System Date: April 30, 2005 Page: 1 of 9 User Interface Module Current Monitoring L106 0.01uH +3.3 Vdc C107 0.01uF C106 0.01uF R117 0.012 V1 Cond J102A V1 Out R118 0.012 U101 INA168 I1 Buff R119 100k U106A OPA2340UA C109 0.1uF C108 0.1uF C110 0.1uF C111 0.1uF C112 0.1uF R120 0.012 V2 Cond J102B V2 Out R121 0.012 U102 INA168 I2 Buff R122 100k U106B OPA2340UA C114 0.1uF C113 0.1uF C115 0.1uF C116 0.1uF L107 0.01uH +3.3 Vdc C118 0.01uF C117 0.01uF R123 0.012 J102C V3 Cond V3 Out R124 0.012 U103 INA168 I3 Buff R125 100k U107A OPA2340UA C120 0.1uF C119 0.1uF C121 0.1uF C122 0.1uF C123 0.1uF R126 0.012 J102D V4 Cond V4 Out U104 INA168 R127 0.012 I4 Buff R128 100k U107B OPA2340UA C125 0.1uF C124 0.1uF C126 0.1uF C127 0.1uF A. Sivacoe, N. Hendrickson User Interface Module Rev ID Insight Control System Date: April 30, 2005 Page: 2 of 9 User Interface Module Voltage/Current Monitoring L108 0.01uH +3.3 Vdc R129 0.012 R130 0.012 V5 Out U105 INA168 I5 Buff R131 100k U108A OPA2340UA C131 0.1uF C130 0.1uF C132 0.1uF C133 0.1uF C134 0.1uF R134 R132 V1 ADC Vin 37.4k - TV 68.1k - FM J102E V5 Cond C128 0.01uF C129 0.01uF 249k R133 3.3k U108B OPA2340UA C135 0.1uF R135 249k I1 Buff I1 ADC C136 0.1uF R136 249k I2 Buff I2 ADC C137 0.1uF R137 249k I3 Buff I3 ADC C138 0.1uF R138 249k I4 Buff I4 ADC C139 0.1uF R139 249k I5 Buff I5 ADC C140 0.1uF Membrane Switch Inputs +3 Vdc R140 R141 10k 10k U109 R142 R143 1k 1k MOCD211M R144 R145 10k 10k J103D Pow-IN J103A Nav-IN P1 P2 P3 P4 Pow-uPC P8 P7 P6 P5 Nav-uPC +3 Vdc U110 R146 R147 R148 R149 10k 10k 1k 1k MOCD211M R150 R151 10k 10k J103B Sel-IN J103E Res-IN Sel-uPC P1 P2 P3 P4 P8 P7 P6 P5 RESET A. Sivacoe, N. Hendrickson J103C GND User Interface Module Rev ID Insight Control System Date: April 30, 2005 Page: 3 of 9 User Interface Module Microcontroller U111 MCP130 L109 0.01uH +3.3 Vdc C141 0.01uF RESET Reset GND Vcc C142 0.01uF TCK TMS TDI TDO C143 0.1uF CAN CLK I1 ADC LED1 I2 ADC Buzzer I3 ADC BkLtCtrl I4 ADC I5 ADC Pin15LCD J104 V1 ADC P64 AVcc P63 DVss P62 AVss P61 A2 P60 A1 P59 A0 P58 RST P57 TCK P56 TMS P55 TDI P54 TDO P53 P52 P51 P50 P49 LED A C144 0.1uF LED K LCD D7 LCD D6 LCD D5 DVcc P1 A3 P2 A4 P3 A5 P4 A6 P5 A7 P6 P7 Xin P8 Xout P9 P10 P11 P1 0 P12 P1 1 P13 P14 P15 P16 C146 30pF C147 30pF Y101 6.00MHZ C145 tbd P48 MCLK P47 P46 P45 P44 P43 P42 P41 P40 P39 P38 P37 P36 P35 P34 P33 U112 MSP430F133 LCD D4 LCD D3 LCD D2 LCD D1 LCD D0 LCD E LCD R/*W LCD RS LCD Vo P17 P18 P19 P20 P21 P2 2 P22 P23 P24 P25 P26 P27 P28 SIMO0 P29 SOMI0 P30 UCLK0 P31 P32 LCD Vdd Pow-uPC LCD Vss +5 Vdc Pin3LCD Nav-uPC Sel-uPC SCK - DIP SWITCH 7,6,5 SET ID - DIP SWITCH 2 SETS CALIBRATION MODE - DIP SWITCH 1 ENABLES CAN BUS TERMINATION SOMI SIMO CAN CS S101 +3.3 Vdc A. Sivacoe, N. Hendrickson CANterm1 User Interface Module CANterm2 RN101 10k Rev ID Insight Control System Date: April 30, 2005 Page: 4 of 9 User Interface Module J105D +5Vdc +5V-1 J106D CAN and Programmer Interface +5V-2 J105F +3.3Vdc +3.3V-1 J106F +3.3V-2 J105E GND-1 J106E GND-2 L110 0.01uH J106A RESET RESET-2 +3.3Vdc C148 0.01uF J105H C149 0.01uF CANH-1 J106H CANH-2 U114 SN65HV232 D P1 GND P2 Vcc P3 R P4 J105G CANL-1 J106G P8 P7 CANH P6 CANL P5 U113 CAN CLK TXCAN P1 RXCAN P2 P3 P4 P5 P6 P7 P8 OSC1 P9 Vss P10 CANL-2 CANterm1 P20 Vdd P19 RESET P18 CS P17 SO P16 SI P15 P14 SCK P13 P12 P11 R152 100 CANterm2 RESET MCP2510 SCK SIMO SOMI CAN CS R153 100k J107 JTAG header TDO TDI +3.3Vdc TMS TCK A. Sivacoe, N. Hendrickson User Interface Module Rev ID Insight Control System Date: April 30, 2005 Page: 5 of 9 User Interface Module Power Supplies U115 LM2576S-5.0 F107 +5 Vdc Gnd Vin C150 100uF L111 100uH Littlefuse 1812L R154 tbd Vout VgenCond On/Off Feedbk D114 30BQ060 U116 ULN2003 P1 P2 P3 P4 P5 P6 P7 P8 LED1 Buzzer BkLtCtrl R156 10k C151 1000uF D113 Green SML-LX1206GW P16 P15 P14 P13 P12 P11 P10 P9 D116 S1D-13 D115 +5V LED R155 1k RL101 G6L-1F 5Vdc BZ101 R157 4.7 Pin15LCD +5 Vdc U117 LM1117MP-3.3 IN C152 10uF 10V tantalum F108 +3.3 Vdc OUT Littlefuse 1812L C153 100uF COM R158 430 D117 +3.3V LED U118 LM2660M P1 P2 P3 P4 P8 P7 P6 P5 C154 100uF Pin3LCD S102 R159 10k 40% C155 100uF R160 1.4k R161 27k VgenCond C157 22uF C158 22uF C161 0.1uF Rads C156 22uF Gnd Vin SoftStart LM2679 U119 Feedbk Cboost R162 6.2k C163 0.01uF L112 33uH J108 FanOut Vout C162 1uF C159 22uF D118 DIODE C160 22uF A. Sivacoe, N. Hendrickson User Interface Module Rev ID Insight Control System Date: April 30, 2005 Page: 6 of 9 Coupler Conditioning Module Microcontroller U201 MCP130 +3.3 Vdc RESET Reset GND Vcc TCK TMS TDI TDO C201 0.01uF C202 0.1uF L201 0.01uH C203 0.01uF L202 0.01uH FWD-POW C204 0.01uF C205 0.01uF P64 AVcc P63 DVss P62 AVss P61 A2 P60 A1 P59 A0 P58 RST P57 TCK P56 TMS P55 TDI P54 TDO P53 P52 P51 P50 P49 RFL-POW DVcc P1 A3 P2 A4 P3 A5 P4 A6 P5 A7 P6 P7 Xin P8 Xout P9 P10 P11 P1 0 P12 P1 1 P13 P14 P15 P16 DRVR DIS LED1 LED2 C206 33pF C207 33pF Y201 6.00MHZ CAN CLK P48 MCLK P47 P46 P45 P44 P43 P42 P41 P40 P39 P38 P37 P36 P35 P34 P33 U202 MSP430F133 - DIP SWITCH 3,2,1 SET ID - DIP SWITCH 7 ENABLES CAN TERMINATION S201 CANterm1 CANterm2 C208 0.01uF L203 0.01uH C209 0.01uF 10k +3.3 Vdc P17 P18 P19 P20 P21 P2 2 P22 P23 P24 P25 P26 P27 P28 SIMO0 P29 SOMI0 P30 UCLK0 P31 P32 RN201 DAC CS SCK +5 Vdc SOMI SIMO ATEN-Vcc CAN CS J201a4 ATEN1 J201a2 PSU J201a1 TEMP ATEN2 J201a3 VSWR ATEN3 J201a5 OVERDRV ATEN4 ATEN5 J201a7 J201b2 SOFT RES J201b4 J201b3 CAR ON J201b8 CAR OFF J201b1 CAR UP TMP VCC TMP SCK TMP SO TMP CS TMP GND CAR DOWN N. Hendrickson, A. Sivacoe Coupler Conditioning Rev ID 1.04 Insight Control System Date: June 17, 2005 Page: 1 of 4 Coupler Conditioning Module CAN and Programmer Interface +5Vdc C210 100uF J201c4 D201 +5V-1 J201d4 +5V-2 J201c6 +3.3Vdc +3.3V-1 C211 100uF J201d6 D202 +3.3V-2 J201c2 GND-1 J201d2 GND-2 L204 0.01uH J201c1 +3.3Vdc RESET C212 0.01uF RESET-1 C213 0.01uF J201c8 CANH-1 J201d8 CANH-2 U203 SN65HV232 D P1 GND P2 Vcc P3 R P4 J201c7 CANL-1 J201d7 P8 P7 CANH P6 CANL P5 U204 CANL-2 CANterm1 R201 100 CANterm2 CAN CLK MCP2510 RESET SCK SIMO SOMI CAN CS TDO J202 JTAG header TDI +3.3Vdc TMS TCK N. Hendrickson, A. Sivacoe Coupler Conditioning Rev ID 1.04 Insight Control System Date: June 17, 2005 Page: 2 of 4 Coupler Conditioning Module +3.3 Vdc Remote Access Port U205 MOCD211M +5 Vdc P1 P2 P3 P4 R207 1k R208 1k J204 U207 MOCD211M P1 P2 P3 P4 P8 P7 P6 P5 R209 10k P8 P7 P6 P5 CAR DOWN RN RN RN RN 202 202 203 203 10k 10k 1k 1k CAR UP U208 MOCD211M PSU CAR ON RN RN 202 202 10k 10k R206 10k J203 TEMP CAR OFF R205 10k R204 1k RN RN RN RN 202 202 203 203 10k 10k 1k 1k R203 1k P8 P7 P6 P5 VSWR P1 P2 P3 P4 OVERDRV P8 P7 P6 P5 P1 P2 P3 P4 U206 MOCD211M RN RN 202 202 10k 10k R210 10k U209 MOCD211M RFL-OUT SOFT RES RESET P8 P7 P6 P5 P1 P2 P3 P4 FWD-OUT RN RN RN RN 204 204 203 203 10k 10k 1k 1k RN 204 10k R211 1k DRVR DIS LED1 LED2 P1 P2 P3 P4 P5 P6 P7 P8 R212 1k D203 U210 ULN2003 +5 Vdc +3.3 Vdc D204 L205 0.01uH P16 P15 P14 P13 P12 P11 P10 P9 R213 1k J201 DISABLE b7 C214 0.01uF C215 0.01uF D205 K201 J205 N. Hendrickson, A. Sivacoe Coupler Conditioning Rev ID 1.04 Insight Control System Date: June 17, 2005 Page: 3 of 4 Coupler Conditioning Module RF Power Output C216 0.01uF L206 0.01uH C217 0.01uF +5 Vdc U211A OPA2340UA R214 1k SIMO FWD-OUT DAC CS P1 P2 P3 P4 1 3 U212 TLV5625 P8 P7 P6 P5 D206A RFL-OUT U211B OPA2340UA U213 LM4040-2.5 R215 10k 1 2 SCK D206B R216 10k Coupler Input L207 L208 0.01uH 0.01uH +5Vdc +3.3 Vdc C218 0.01uF C219 0.01uF C220 0.01uF C221 0.01uF R217 1k J206A FWD-GND J206B FWD-5V J206C FWD-IN L209 U214A OPA2340UA 0.01uH C222 0.01uF C223 0.01uF L210 0.01uH R218 FWD-POW 1k R219 1k C224 0.01uF VR201 R220 1k R221 1k J207A RFL-GND C225 0.01uF J207B RFL-5V J207C RFL-IN L211 RFL-POW 0.01uH C226 0.01uF L212 0.01uH R222 C227 0.01uF R223 1k U214B OPA2340UA 1k C228 0.01uF VR202 C229 0.01uF R224 1k N. Hendrickson, A. Sivacoe Coupler Conditioning Rev ID 1.04 Insight Control System Date: June 17, 2005 Page: 4 of 4 J301 F301 U301 R301 PSU In IN L301 +5 Vdc OUT COM R302 R304 D301 Ground C301 R303 J301 C302 C303 D302 CTL 1dB U302 Alpha 110-85 RF 2 P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 CTL 2dB P20 P19 P18 P17 P16 P15 P14 P13 P12 P11 CTL 4dB CTL 8dB CTL 16dB C304 C305 J303 +5 Vdc RF OUT C306 Ext 5Vdc J304 4 +5 Vdc S301 2dB in 1dB in S301 J304 2 U303 P1 P2 P3 P4 J304 1 P8 P7 P6 P5 R308 R309 S301 8dB in 4dB in S301 CTL 2dB CTL 1dB R310 R311 R312 R313 D303 D304 U304 J304 5 P1 P2 P3 P4 J304 3 P8 P7 P6 P5 R314 R315 S301 CTL 8dB CTL 4dB R316 R317 R318 R319 D305 D306 Shutdown U305 D308 J304 7 16dB in P1 P2 P3 P4 R320 P8 P7 P6 P5 CTL 16dB R321 R322 D307 A. Sivacoe, N. Hendrickson RF Conditioning Module Rev ID 1.04 Insight Control System Date: Sept. 19, 2005 Page: 1 of 2 U306 DBTC-20-4 RF 1 RF 2 DIR. COUPLER R324 U307 AD8362 P1 P2 P3 P4 P5 P6 P7 P8 C307 R323 C310 P16 P15 P14 P13 P12 P11 P10 P9 C308 DIP16 Shutdown C320 RF IN R305 VR303 VR301 C309 U308 SAGE WIRE -HCT2 J302 +5 Vdc C311 C312 RF 1 R307 HYBRID COUPLE C314 C313 R325 R326 D309 D310 R327 U309 78L20 PSU In IN C316 C315 R329 R328 OUT VR302 COM C317 C318 C319 A. Sivacoe, N. Hendrickson RF Conditioning Module Rev ID 1.04 Insight Control System Date: Sept. 19, 2005 Page: 2 of 2 Temperature Sensor DRV DIS TMP SO TMP SCK TMP GND TMP VCC TMP CS J1G U1 LM70 J1C P1 P2 P3 P4 J1D J1A J1B J1H P8 P7 P6 P5 C1 1uF J2 TMP VCC N. Hendrickson, A. Sivacoe Temperature Sensor Board Rev ID 1.02 Insight Control System Date: May 8, 2005 Page: 1 of 1 PSUflag J601 RFL samp TEMPflag FWD samp VSWRflag ODRVflag ground CAR on J603 F602 J602 13 12 11 10 CAR off CAR up +5 Vdc CAR down +3.3 Vdc Soft RES RESET F604 OUT 1 IN 2 OUT 2 IN 3 OUT 3 IN 4 OUT 4 IN 5 OUT 5 IN 6 OUT 6 IN 7 OUT 7 IN 8 OUT 8 OUT 1 IN 2 OUT 2 IN 3 OUT 3 IN 4 OUT 4 IN 5 OUT 5 IN 6 OUT 6 IN 7 OUT 7 IN 8 OUT 8 OUT 1 IN 2 OUT 2 IN 3 OUT 3 IN 4 OUT 4 IN 5 OUT 5 IN 6 OUT 6 IN 7 OUT 7 IN 8 OUT 8 J609 OUT 1 IN 2 OUT 2 IN 3 OUT 3 IN 4 OUT 4 IN 5 OUT 5 IN 6 OUT 6 IN 7 OUT 7 IN 8 OUT 8 IN 1 J610 J607 IN 1 J608 J605 IN 1 J606 25 24 23 22 21 20 19 18 17 16 15 14 F603 IN 1 J604 F601 J611 TxNET Rev ID 1.02 Date: Dec. 5, 2005 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 12.5 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 (TAV-25 Power Amplifier) The following illustration depicts the location of the connectors when installing the 25-watt power amplifier (TAV-25). Technalogix Ltd. VIII-7 POWER - Tactile button to turn carriers on and off. NAVIGATE - Tactile button to move between menu items, or to refresh the screen after it has timed out. SELECT- Tactile button to select menu item, or to refresh the screen after it has timed out. RESET - Tactile button to reset microcontroller in control board. Also clears existing faults. The amplifier will come back on with the 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 - Port to monitor and control the amplifier externally. See “ Monitor and Control” section for pin-out. AC IN – AC input to switching power supply. AC BREAKER – 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. Ensure that the antenna has been swept and has a return loss of greater than 20dB (VSWR = 1.2:1). This should be done before connecting the antenna cable to the transmitter output. 2. Check that your video source is present. 3. 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. 4. Place an appropriate AC power line protector, conditioner, and/or surge suppressor across the AC supply line. 5. 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. 6. Plug power amplifier into AC mains. 7. Switch AC rocker switch to “on” position. 8. 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). 9. 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). 10. 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 TAV25 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 TAV-25 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. 4. Plug the 3U power amplifier enclosure into AC mains. 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. 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 TAV-25 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% on the filter enclosure - depending on signal content. The system is set up for 25 watts peak visual power using the sync and blanking signal and should read 100 % 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 attenuateshould 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 reading is also displayed as a percentage of rated forward power. 12. Verify that the power supply reads approximately 28 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 there DC power to the site and the equipment? • 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 Weak output or picture Possible Fault Low level input signal Low output power High reflected power Incorrect modulation depth Incorrect load X-2 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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