Thomson Broadcast and Multimedia 8BUHPB250-A User Manual 8

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Document ID	847
Application ID	xqKPpCNGl8+FKzR4r35pYQ==
Document Description	8
Short Term Confidential	No
Permanent Confidential	No
Supercede	No
Document Type	User Manual
Display Format	Adobe Acrobat PDF - pdf
Filesize	181.21kB (2265179 bits)
Date Submitted	1998-05-05 00:00:00
Date Available	1998-07-06 00:00:00
Creation Date	2001-07-17 09:42:17
Producing Software	Acrobat Distiller 4.0 for Windows
Document Lastmod	2001-07-17 09:42:19
Document Title	8

__—________—————
Communication Microwave Corp
395 Oakhill Road
Mountaintop, PA 18707
_____—_—___————————
Technical Manual
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Created by: Kimberly Simeon:
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HPBZSO-A Top Level Description
HPB250—A RACK ASSEMBLY
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The HPBZSO-A is a high power and high gain, on—channel signal booster. 11 receives and
retransmits multiple television signals to fill in shadowed service areas where line-of-site access
to the headend is obscured. The HP3250»A consists of two or three power supplies, eight Power
Amplifier Segments, two Backup System Controllers, and four Drivers which are contained
within a Rack and Sub-rack. The HPB250-A is fully redundant. The Power Supplies and Power
Amplifier Segments allow hot replacement. Identical drivers are provided for both MDS and
ITFS frequencies. A Backup System Controller indicates output power and enables the
secondary driver should a failure occur in the primary driver.
The HPB Series of Boosters is available in both Upgradeable and NorrUpgradeable models. A
Non-Upgradeable model provides maximum space efficiency; where, the modular system
architecture of an Upgradeable model allows it to be easily upgraded from l Watt per channel to
4 Watts per channel. Similarly, it may also be downgraded; and the Power Amplifier Segments
may be used elsewhere or kept as spares for hot replacement. As the output power is modified,
the model name will change respectively (refer to the following table). The Federal
—_—————-———-———'—_—_
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(cm wove HPBZSfl-A Top Level Descriptian
(refer to the following table). The Federal Communications Commission Identifier
(FCC ID) will also be altered corresponding to the new model and power level.
Model Name Output Power
per channel
HPBZSO-A 1 Watt CHPSBUHPBZSO-A
HPBSOO-A 2 Watts CHPSBUHPBSOO—A
HPBIOOO-A 4 Watts l CHPSBUI—IPBIOOO-A
A new front panel label is needed to accommodate each FCC ID. The label is located on
the Backup System Controller as shown in the diagram below and will be replaced with
each upgrade as needed.
In order to maximize power density, both the Rack and Sub—rack are integral subsystems
of the booster design. The Rack provides phase to phase AC power to the Drivers, DC
power to the Sub-rack, and the cooling for the Power Amplifier Segments. Similarly,
the Sub—rack provides an interface between the Power Amplifier Segments and the entire
system.
___—________————————
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Rack Theory of Operation
The Rack is an integral part of the transmitter assembly, It supplies three phase AC power to the
transmitters, DC power to the Sub-Rack, and the cooling for the Power Amplifier Segments.
The rack is available in different sizes to accommodate the various physical configurations of the
HP Series of transmitters/boosters and to allow for future upgrades to higher output power levels.
The table below describes the types of HPSC Transmitters and the Rack configurations required
by each type.
Highm Power Denstty
Power 10 40/70" w Upgradeable
(150 W Analog) 34
100 W Average Highest Power Density
Power 40/70’ 21 3 w Nol Upgradeuule
(300 W Analog) 34.500"D
100 w-zoo W 85 875"H High Power Density
Average Power 21.063"W Possible to Increment
(300 W - 600W 34.500‘D Output Power in 12 SW
Steps
(37 5 Analog)
77.125’1-1 Upgrade Path to A11 Power
21 .063"W Levels Due to Lower Power
34 500"D Density.
Three Phase AC Power enters the AC Power Distribution Box, which is located on the top of the
rack. It is connected to the AC Power Harness which distributes both three phase and phase to
phase power to the entire rack.
100 w Average
Power Upgradeahle
(300 W Analog)
Each transmitter requires an AC to DC Front End Converter which is mounted behind the
blanking panel, to supply the DC Power to the Sub- Rack This power supply 15 connected to the
Power Amplifier Segments via the DC Power Harness. The DC Power Harness connects the AC
to DC Front End Converter and the Sub -Ra.ck
Fans attached to the rear door of the Rack supply cooling for the
Power Amplifier Segments Each fan pulls cool air from the
front of the rack to the rear The transmitters will be
automatically placed into standby when the rear door of the rack
is opened. This will prevent thermal shutdown of the Power
Amplifier Segments. Note: The number offans is dependent upon
transmitter configuration.
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Rack Power Supply for High Power Booster Series
The Power Supply for the rack consists of three 48-Volt modules in a rectifier shelf designed to
minimize installation and maintenance time. Hotswap insertion technology (hot replacement)
allows easy system power upgrades. The Power Supply is equipped with logic and visual status
indications, automatic load sharing and complete from access.
Front panel features include PWR IN and DC OK LED indicators, output voltage and current
limit adjustments, voltage and current monitor test points, and digital display indication current
or voltage output of the Power Supply.
The modules are housed in a three bay rectifier shelf to provide easy—guide module insertion and
extraction. Forced air cools the Power Supply by drawing ambient air through the intake on the
front of the Power Supply and exhausting out the rear of the shelf.
Protection is provided against overvoltage, overcurrent, and overtemperature. The Power Supply
will shut off if the voltage exceeds the nominal voltage by 20%, The AC input or the remote
on/off must be recycled to restart the rectifier. The Power Supply will also shut down if the
internal temperature reaches an unsafe level. Restart is automatic when the Power Supply returns
to normal operating range,
________———————
Datum ii.“ 10-1200]
RE V: P!
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AC Power Interconnections
The AC Power Interconnections include an AC Power Distribution Box, 15 Ampere circuit
breaker, terminal strip, AC to DC Front End Converter, Driver Chassis, Ultra Low Phase Noise
Drawer (Agile applications only) and fans. The AC Power Interconnections provide phase-to-
phase 208 VAC and three phase-208 VAC* to each transmitter in the Rack.
The three-phase power is connected to the Rack through the AC Power Distribution Box, which
is located on the top of the Rack. The AC Power Distribution Box distributes the three phase
power via two or three 350 Ampere, 600 VAC, three pole terminal blocks. The number of
terminal blocks depends upon the number of transmitters in each Rack. Each transmitter has its
own lS-Ampere circuit breaker, which trips at 20 Amperes. The lS-Ampere circuit breaker is
connected to the AC Power Distribution Box via 6 AWG, 3000 Volt, and stranded-tinned-copper
wire with Polyvinylchloride insulation. The circuit breaker is located on the rear of the Rack. A
plastic cover to prevent accidental shut down of the transmitter protects it.
The terminal strip is connected to the circuit breaker via 12 AWG Polyolefm-insulated wire,
rated at 600 Volts with a breakdown voltage of 6000 Volts. The terminal strip is constructed of
Phenolic-insulated material with a breakdown voltage of 9000 Volts. The Zinc-plated Steel
terminals are rated at 30 Arnperes of current. The terminal strip distributes the three phase power
to the AC to DC Front End Convener and phase-to- phase 208 VAC to the Driver, Ultra Low
Phase Noise Drawer (Agile applications only) and the fans. The Driver and Ultra Low Phase
Noise Drawer require phase to phase 208 VAC, which is delivered by a 14 AWG-three
conductor line cord. The terminal strip also supplies phase-to-phase power to the 208 VAC, 80—
Watt, 600—CFM fans, which are mounted on the rear door of the Rack. The number of fans per
transmitter is dependent upon the transmitter model. The fan power harness is constructed of
eight 14 AWG wires. Two wires are required for each fan; the unused wires are fastened in place
and terminated to allow for future upgrades
The table below illustrates the configuration of a Rack for different models and the possible
output power levels of each transmitter.
Output Power '
Digital (Fixed) 100 W 150 W
Analog (Fixed) 300 W 375 W 450 W
Digital (Agile) 80 W 100 W 120 W
Analog (Agile) 240 W 300 W 360 W
Power Supplies 4@K3’243 3 egg“ 3 EVZASG 3 (133.072 KVA 3 gig“ lgéifiw
Fans 4@KUVA | 8@BOVA 6@80VA s@xUVA l12@KOVA |2@sovA
Drivers 4@IO0VA 4@100VA J®lOfl VA
VA TOTALS 9232 VA 6924 P7460 12012 VA 13551VA
VA VA
"Other power options available upm- requesL
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AC POWER
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Transmitter Transmitter
POWER
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15 A Circuit
Breaker
TERMINAL
STRIP
Agile ayplicatinn: only
_______—_____—————————
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DC Power Interconnections
The DC Power Interconnection for each transmitter includes an AC to DC Front End Convener.
a DC Power Harness, a DC to DC Convener, and a Mother Board
The AC to DC Front End Converter accepts a 208 V AC 3-phase input and converts it to 48 VDC.
The Front End Converter is a 4000-Watt MOSFET switching power supply with .985%
minimum Power Factor. The 48 VDc output is connected to the Mother Board and the DC to DC
Convener via the DC Power Harness.
The DC Power Harness provides a path for 48 VDC to the Mother Board and the DC to DC
Convener. The DC Power Harness consists of standard tinned 14 gauge copper conductors with
.032 thick Polyolefin insulation, rated at 600 volts,
The DC to DC Converter is a 75—Watt, 15 Amp, 48 VDC to 10 VDC, single output converter. It
supplies 10 VDC to the Power Amplifier Segments through the Mother Board on the Sub-Rack.
The Mother Board supplies 10 VDC and 48 VDC to the Power Amplifier Segments through
connections located on eight 14-pin connectors. Control and Diagnostic signals are also routed
through the Mother Board to the Microcontroller board within each segment.
The total DC power for each transmitter configuration is specified below in table A-l:
00
HPB250-
HPBSOO- HPBSOO-A
HPB 1 OOO—A HPB l 000—
Note:
1. Each amplifier module receives 48 VDC at 5 Amps.
2. Each amplifier module receives 10 VDC at .35 Amps.
The AC to DC Front End Converter provides an input to the DC to DC Converter of 48 VDC, as
specified below in table A-2:
______________—————
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Table A-2
Immagffomw PoweflWfit’Ls}
Fixed Fixed Agile Agile
Digital Analog Digital Analog
50 200 40 120
1 00 3 00 80 240
125 375 100 300
150 450 120 360
1 75 525 140 420
200 600 160
HPB250-A HPBZSO-A
HPB500-A HPBSOO-A
HPBl 000-A HPB 1 000-A
DC Power
Harness
AC to DC
U" Front End ”'
Convener
203 VAC
3—l’hase
Convener
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Mother Board
Sub-Rack
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Sub-Rack Theory of Operation
The Sub—Rack is the unit which houses the Power Amplifier Segments and provides an interface
between the Segments and the entire System. It is capable of housing up to 16 individual
Segments. The Sub-Rack consists of a Mother Board (see Document #: HG3—01B02 for details,
one Mother Board is needed for eight Segments and two Mother Boards are needed when more
than eight Segments are used), guide rails, protective Lexan overlay, and miscellaneous sheet
metal parts. Each Segment slides into the Sub-Rack on nylon slides and connects to the Mother
Board(s) via floating connectors. The key-lock switch, located on the Segment’s front panel,
must be in the OFF position in order to plug the Segment into the subrack. This is to ensure that
there is no arcing between connections before the Segment is fully engaged, Once the Segment
is slid into place, thumb screws on the Segment’s front panel are fastened to the Sub-Rack to
secure it and provide a reliable ground connection. The key»lock switch may now he turned to
the ON position to apply power to the Segment,
The interface for RF Input and Output is provided by floating OSP connectors which are
mounted on the back panel of the Sub-Rack and the back side of the Power Amplifier Segment
Interim .
Power, ground, and data interface between the Mother Board(s) and the system are as follows. A
DC to DC converter supplies the mother board(s) with one 10 VDc connection (6). A separate 48
VDC and ground connection (4) for each Power Amplifier Segment is supplied to the mother
board(s) from the main system power supply. A ten position single-row header (3) affords data
input from the driver and a six position RJ-ll connector (2) provides communication of control
and diagnostics data to the Mother Board(s). A two position DIP switch (1) located on the
Mother Board(s) can be set to OPEN for communication, or CLOSED for termination.
Power, ground, and data interface between the Segment and the Mother Board(s) is provided
through a float—mounted, blind—mating, receptacle on the Segment and a blind— mating header (5)
on the Mother Board(s).
_____—_——_—————
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Driver Theory of Operation
The driver receives a microwave multi—carrler signal typically from —55 dBm to —25
dBm/can-ier. A stagger AGC keeps the total level of the output signal at 0 dBm ildB,
as well as improving the C/N for a high level input signall
The AGC chain provides the filtering necessary to reduce the noise out of the band. The
constant output signal is now pre—distorted and amplified by two amplifiers. The
microwave pre-corrector also performs the ALC to keep the output power of the booster
constant.
___—_____——-————-
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Power Amplifier Board
The Power Amplifier Board has a high gain architecture with 47 dBm output power at 1 dB
compression point and 29.5 dB gains The input signal passes through a microwave switch for
hot stand-by operation. This feature allows the control board to set up all DC parameters and
check for proper amplifier operation without the influence of an RF signal. The signal then
passes through a pin diode attenuator which sets the overal gain of the amplifier.
In the first stage, a 3 dB hybrid provides a reliable load to the driver and a flat broadband
frequency reSponse to the amplifier. The second and third stages of amplification five the proper
output power with minimum distortion and high efficiency. A low output VSWR (Voltage
Standing Wave Ratio) is provided by the 3 dB combining system. The directional coupler
provides a sample signal proportional to the forward and reflected power. This measurement
ensures that the amplifier delivers the correct power. An IC measures the operating temperature
of the amplifier which is monitored by the MCU The Amplifier is placed in a faulted state if the
temperature exceeds a limit set by the MCU.
The Control Board acknowledges the input signal presence from the Driver. It places the
microwave switch in the hot stand-by mode and adjusts the current of each FET. The current
sensor , located on the power supply, provides the current samples to the Control Board to check
for proper operation of the transistors. The Control Board sets the variable Attenuator to the
correct amplifier gain, and removes the microwave switch out of “STANDBY” and into the
through path.
The microwave circuit amplifies the input signal with high linearity performance and broadband
frequency response This feature allows the amplifier to be used for any channel without
retuning. The FET’s are protected from catastrophic failure by an [C on the Amplifier Board.
The temperature sensor supplies the control board with a voltage proportional to the heatsink
temperature. The Microcontroller will sense this voltage and protect the amplifier against high
temperature or from failure of the cooling system. The output directional coupler measures the
forward and reflected power. These measurements provide the Microcontroller with the
information needed to verify the status of the amplifier.
___—_____—__—————
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Control Board
Monitoring and control of the Power Amplifier Segment is accomplished through a Control
Board located within a section of the Segment housing. The Control Board utilizes an 8-bit
microcontroller (MCU) with on-board memory to perform the monitoring and control functions.
The Control Board circuitry includes analog signal conditioning, A/D and D/A converters,
supply voltage regulation, arid two serial data interfaces.
Monitoring operations involve collecting analog signals and logic data from the Power Amplifier
Segment Analog inputs Forward Power, Reflected Power, and Temperature are received from
the RF Power Amp connector Jl. Analog inputs Drain Supply Voltage (V DD) and High Voltage
DC are received from the Power Supply connector J2. Forward Power and Reflected Power
inputs are amplified by op-amps with a gain of approximately 3; while, Temperature, Drain
Supply Voltage (VDD) and High Voltage DC are buffered by unity gain stages. Following the
Van buffer stage, a resistor divider network scales VDD to 1/4 its input voltage, followed by a
second unity gain buffering stage. Each of these inputs are voltage-limited to 5.1 VDC by means
of Zener diodes at the input to the Control Board. They are protected from voltages more
negative than -O.4 VDc by Schottky diodes at the output of the Op-Amp gain stages to protect the
MCU AID converter inputs.
Drain currents drawn by FETs in the RF Power Amplifier section of the Power Amplifier
Segment are monitored by the Control Board, which is performed by monitoring the voltages
dropped across series resistors in the drain supply circuits on the Power Supply Board. These
eight voltages are received by the Control Board from the Power Supply connector J2. Each
signal is selected by the MCU and related CPLD logic through an 8-channel analog multiplexer
(MUX) IC, and in turn compared to VDD by a differential amp/gain op-amp stage. The resulting
outputs are 10 times greater than the voltages dropped across the series monitoring resistors.
These outputs are protected from voltage excursion greater than 5.1 VDC by Zener diodes, and
from excursion more negative than -0.4 VDC by Schottky diodes. The resulting signal is
connected to input ANO/IDSMON on the MCU A/D converter. This signal varies through time
with each of the eight monitored signals as selected by the MCU.
The Control Board generates negative FET gate supply voltages with a Digital to Analog (D/A)
converter and analog voltage inverter circuits. The 8-bit D/A IC is provided with a 2.5 VDC
reference and with data from the MCU to set the output voltage on each of 8 channels to a
positive voltage of the same value as the absolute value of the desired gate voltage. These
positive voltages (e.g. +Vgs) are then inverted by unity gain inverter op»amp circuits to negative
voltages (eg. -Vgs). The negative gate voltages are output to the RF Amplifier section on RF
Power Amplifier connector J 1.
The negative FET gate supply voltages supplied to the RF Power Amplifier section are retumed
to the Control Board through internal segment harnessing. These returned gate voltages provide
the Control Board with monitoring of the gate voltages arriving at the RF Amplifier section,
allowing incorrect gate voltage or gate interlock break to be detected. The monitored gate
___—__—__—————
Document it: 10-1060]
REV: B
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signals, input on RF Power Amplifier connector 11, are multiplexed by a MUX IC in a manner
similar to that for the drain MUX described above. The time-varying MUX output, which
generally carries negative Voltages, is inverted by a unity gain invener op-amp circuit to provide
a positive voltage to the ANINGSMON input on the MCU A/D converter.
Various logic inputs and outputs are provided by the Control Board. A drain supply enable logic
signal, PS_ENABLE, is output from the Control Board on H. The state of PS_ENABLE is
controlled by the MCU, which tests other signals such as Standby and Gate Voltage Interlocks,
to determine if it is safe to enable the power supply. The MCU outputs the Enable Signal to the
CPLD, which in turn outputs the PSiENABLE on 12. If the MCU detects a condition in which
it would be improper or unsafe to allow the drain supply to operate, the CPLD will be made to
output a logic-LOW on the PS_ENABLE control output.
Output signals which control the RF Power Amplifier section RF switch and attenuator are
generated on me Control Board. Signal RFfiSWT, output on connector Jl, controls the
terminated or unterminated state of the RF Power Amplifier section RI" switch. RF_SWT is
driven to a logic-HIGH when the Power Amplifier Segment is set to the TRANSMIT state. This
logic-HIGH will cause the RF switch to route the RF Amp microwave input signal into the
Amplifier circuitry. Signals RF_ATTEN_CTRL1 and -2 are analog outputs which reciprocate to
control the branches of the RF attenuator network located in the RF Amplifier section. These
analog voltages are developed in a D/A converter IC and NPN and PNP transistors.
The Serial Input/Output (I/O) capabilities of the Power Amplifier Segment originate on the
Control Board and the MCU‘s SCI port. In general, the Power Amplifier Segment may be
connected on an RS-485 multidrop network as an individually addressed node with other Power
Amplifier Segment nodes. Node address switch1 SW], is a DIP multi-pole switch which is
programmed with a Power Amplifier Segments unique node address in binary form. While
present on the network, a Power Amplifier Segment may be issued specific commands from and
return formatted responses to a master communications device. By default, the RS-485 driver IC
is enabled and RS-485 serial 1/0 is available at the Board's J3 backplane connector. An RS-232
serial I/O port is also available but the RS-232 driver IC is disabled by default. This port is
interfaced through an RJ—ll connector on the Power Amplifier Segment front panel. When the
ENA7R5232 control input line is given a logic-LOW (as when the proper interface cable is
plugged into the Power Amplifier Segment RJ-ll connector), the RS—232 port is enabled. At this
time, the RS—485 port is disabled, causing a loss of communications with the RS-485 network.
The same Power Amplifier Segment command and response capabilities available on the RS-485
port are provided on the RS-232 port.
A computer operating properly ‘watchdog‘ function is provided on the Control Board to
safeguard against loss of MCU program control. Under normal circumstances, MCU IC input
lines RESET and XIRQ will be provided with a logic-HIGH by an on—board watchdog IC. If
Jumper JK3 is in place, the CPLD device must provide a toggle in the CPLD WDI Output line
every 1.6 seconds to indicate to the watchdog IC that the MCU is operating properly. The CPLD
will interpret a PGB/WDI input from the MCU, or activity on the UC_RS485_ENA control line,
or activity on the RS-485 communications lines, as indications that the MCU is operating
____________————
Document It: 10—10G01
REV. B
zomiwove Cor/Ira! Board
properly, and will toggle the CPLD WDI output line, If a toggle in the WDl line does not occur
within 1.6 seconds, it is assumed the MCU is no longer executing the desired program properly.
The watchdog [C will drive low the XIRQ signal, which will ultimately result in a reset of the
MCU and restart of the MCU program.
Two power supply voltage inputs of approximately +10 VDc are provided to the Control Board to
supply the digital regulator and analog regulator circuits. The digital regulator circuits are fused
by Fl at their +10 VDC inputi +5 VDC for the digital circuitry is developed with a linear voltage
regulator. The +5 VDC digital circuit has a separate ground plane for the digital devices. A
switching regulator IC and associated components develop DC output voltages of approximately
$14.5 VDC which are then regulated by linear regulators to +12 Vnc and -12 VDC for various
digital and analog circuitryi The +5 VDC analog regulator is supplied from at +10 VDC input
separate from the digital +10 VDc input, and is fused by F2. +5 Vac for the analog circuitry is
developed with a linear voltage regulator. The +5VDC analog circuit has a separate ground plane
for the analog devices.
_________—__———————
Document #: 10-1000]
REV: B
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300 Watt Power Supply Board
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The Power Supply Board consists of two DC/DC converters, input and output voltage
monitoring, standby switching, over voltage protection, and current sensing. All functions of the
Power Supply Board are interfaced with the Control Board.
The Power Supply reduces the high voltage, low current from end power supply input to the
nominal output voltage of 10.5 volts. The DC/DC converters are high power density, high
efficiency, switching power supplies. The over voltage protection consists of a voltage detector,
a crowbar, and the fusing. The standby switching uses a high efficiency FET.
new Summersm:
After engaging the Power Amplifier Segment, the Control Board checks the input voltage and
turns the PET switch on. The DC/DC converter has a master/slave configuration, which provides
the total current for the RF Amplifier. This configuration allows for accurate current sharing
between the master and the slave.
The Control Board will then detect the output voltage. If the output voltage rises above the
nominal value to a preset value, the crowbar will be activated and cause the fuse to open. When
this occurs the Control Board will disable the standby switch and the DC/DC converters. The
Power Supply distributes eight lines of power with current sensing. These lines are monitored by
the Control Board and used for the current control loop.
_________—__————
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com wave Installation
Installation
The Racks should remain in their original packing containers until they are placed in the
equipment shelter. Place all Racks outside of the shelter sequentially so they can be installed in
their proper position. Packing materials should be removed from the Racks inside the equipment
shelter as they are being installed.
The Drivers and Power Amplifier Segments should be removed from their boxes as they are
ready to be installed. Any unused equipment should remain in the original packing box until
needed. As each piece of equipment is being unpacked, compare the packing list with the
contents of the box and check for in-transit damage. Should any damage be noted, notify the
freight carrier immediately to file a freight claim. Also, notify Comwave of any damages or of
materials missing from the shipment. Refer to the Customer Service Document # 18-0100] for
information about contacting Comwave,
” Please do not discard original packaging materiaL It should be
' returned to Comwave to be recycled. Be sure to retain several boxes for
each type of equipment at the transmitting site. This is to be used in the
-’ event the equipment is shipped back to the factory for repairs, upgrades,
or modifications to ensure adequate protection.
Installation of the Rear Door
Install the rear door of each transmitter as it is unpacked. Place the hinged portion of the door
over the corresponding holes in the fan shroud assembly. Insert the screws provided into the
existing rack clips, Afler adjusting the door position, close and lock the door to ensure proper
mechanical operation.
AC Power Connections to the Exhaust Fans
The exhaust fans located on the rear door of the Rack have attached wiring harnesses. The
harnesses must be routed into the transmitter chassis through a hole in the fan shroud and
connected to the AC terminal strip. The terminal strip must be accessed before the Racks are
bolted together. Verify that the circuit breaker is in the OFF position. Connect the fan harness to
the terminal strip following the AC Interconnect Diagram located in the schematic section of this
manual.
—_____.——————————
Documenl #l4-OIOOI
REV: A
tomiwnve lnstaIIation
Bolling the Racks Together
A minimum of six bolts should be used to bolt each Rack to the adjacent (three in the front and
three in the rear). After all of the Racks have been placed in their final destination, insert the
provided hardware in the accessible~side-panel holes of the Racks. The hardware can be located
on the bottom side of the Racks Refer to the following diagram for hole locations.
NOTE: Be sure that all three aposedphmes of the Racks are straight and/lush before the halts are tightened.
Afler the Racks are bolted together, Bolt the side-panels to the ends of the outer Racks.
Side-Panel
Holes
____——-————-———-—
Dacumem #: l4—0l001
REV: A
Installation
Com wove
Installation of the Driver Chassis
The Rack is equipped with slide rails for convenient installation of the Driver Chassis. Slide
rails also enable easy access to internal adjustable controls and other maintenance/adjustments.
To install the Driver Chassis in the Rack, pull the slide mils outward until they lock into place.
Carefully align drawer with the slide rails and mate. Unlock the slide rails by depressing the lock
button on each rail while pushing the chassis inward. The chassis should slide easily into rack.
If binding occurs, rail mounting brackets are in need of adjustment. Loosen brackets and
manipulate drawer to seat rails to match transmitter drawer. Tighten brackets once free sliding
motion has been achieved.
Once the Driver Chassis has been installed in the Rack and the Rack slides are adjusted, cabling
can begin. Pull the Driver out of the Rack until the Rack slides lock, to provide access to the rear
panel of the Driver Chassis. Wrap-around labels are located on each cable to denote proper
destination. Refer to the following diagram to assist in cabling of the Driver Chassis.
__—__—______-——————
Document it. 14-0100]
RE V: A
com EVIOVE Installation
Installation of the Power Amplifier Segmenm
The Power Amplifier Segments slide into the Sub-Rack on Nylon slides and connects to the
Mother Board via a floating connector. The key-lock switch, located on the Segment’s Front
Panel, must be in the OFF position in order to plug the Segment into the Sub-rack. This is to
ensure that there is no arcing between connections before the Segment is frilly engaged Once
the Segment is slid into place, thumb screws on the Segments Front Panel are provided to fasten
the Segment to the Sub-rack and to provide additional ground connection. The key-lock switch
may now be turned to the ON position to apply power to the Segment. Once the key-lock switch
is turned on, the Segment will automatically set the gain and currents of the amplifier.
Hot Replacement of the Power Amplifier Segment may be required if a failure occurs. To
remove a Segment mm the key—lock switch to the OFF position, loosen the thumb screws on the
Segment’s Front Panel and slide the failed Segment out of the Sub—rack Before the replacement
Segment can be installed, the Node Address must be set. A set of DIP switches is accessible
through the cover of each Segment directly behind the key-lock switch. Set the DIP switches of
the replacement Segment to the same positions as the failed Segment’s DIP switches. Insmll the
replacement Segment as described above.
Module Position Node Address Mode Switch Setting
ON - X
1 2 OFF 1 53 4 5 6 7 s
2 3 02: 1.2:4gbé 7 B
3 4 o‘ii Tie???”
4 5 02:1 1-:3 4 5 X 7 3
ON _
5 6 OFF1.2345X;>7(8
ON
6 7 °FF 1 2 3 4 5 250783
ON
7 8 w@
8 9 02? 1 2 :=:)6(>7(8
NOTE: Do not change Node Swiu'h Settings 6, 7, and 8. They should remain as set by
thzfizclory.
Document it: 14-0100]
RE V: A
comfwove Installation
Envfioniientflim Means.
Environmental Considerations
The equipment can be safely operated in ambient temperatures of -30 to +50 degrees Celsius (-22
to +122 degrees Fahrenheit). However, moderate temperatures generally extend equipment life.
Although the equipment my be operated with relative humidity of up to 95%, the equipment
must be protected from conditions which cause condensation within the equipment.
A rear door is used to force proper ventilation through the cabinet (600 cfm fans per transmitter
are used). If failure of a fan occurs, replacement should be made as soon as possible. An air or
temperature interlock should be incorporated for protection against interruption of ventilation.
The area should be kept dry and clean.
There should be sufficient space in front of the transmitter cabinet for the serviceman and test
equipment plus the full extension of the racked 27” deep chassis. A minimum of 36” behind the
cabinet should be free for rear cabinet access and air movement. Also,
ample room must be available at the cabinet rear for cable placement.
Safety Considerations
This equipment utilizes a grounding plug on all power
cords, For personal safety, do not defeat this safety
feature. As with all similar types of equipment, high
voltage can be accessed when the Driver Chassis cover is
removed. Special care should be given in areas of fuses,
line switches, and power supplies.
Modern high power solid state equipment contain low output voltage power supplies with very
high current Capability. To prevent severe burns, avoid contact of rings, watch bands, etc, with
these circuits. When servicing the transmission line and antenna, care must be taken to avoid
exposure to high energy microwave.
—_—_—_—-—_——
Document #.' 14-0100]
RE V.“ A
COMEWQVQ Metering Calibrations
Metering Calibration
Calibration of the system is completed by COMWAVE Service Technicians prior to shipping;
however, recalibration of the Driver may become necessary when the input or output power
levels are changed. Due to the equal gain of the Power Amplifiers, recalibration of the Segments
is not necessary.
For proper calibration, adjustments are performed in a specific sequence. Before beginning, place
the Driver into “STANDBY” and attach a -30 dB directional coupler and a termination to the
internal combiner as shown in the diagram below.
Power Calibration
Test Setup
One 10 I6 Power Anplrfizr
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COMBINER 1
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or Power Meter \Ngl Milne
MINER m
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Cable
Xi termination which is
equal (a or greater (Iran in:
map"! pnwer of m
Imnmll'n‘er should be used.
Document #: 14-0400]
REV: A
comlwuve MzteringMbingfihfibmtions
NOTE: Tltis procedure is applicable for making MINOR adjustments to output power and
analog metering only. Do NOTadjust power more than 1:5 113. Adjustments more than $5
dB may result in increased intermodulatian distortion proclaim. For larger adjustments to
outpatpower rat-calibration of the IF Precorrectar is necessary. Contact Comwave Customer
Service for further assistance.
1. Apply a Digital Microwave Input Signal.
2. Turn the Microwave Processor ALC switch, 32, to “MANUAL.”
3. Connect an HP435B power meter or equivalent to the -30 dB coupler forward port.
4. Calculate the power meter reading necessary for 100% output power.
Example:
Transmitter Output @ 7.5 Watts = +3900 dBm (31 carriers)‘
—30 dB Coupler = -30.00 dB
Expected Power Meter Reading : +9.00 dBm
5. Rotate the function switch from “STANDBY" to “FWD PWR” to enable transmit.
6. Adjust the Microwave Attenuator located on the Microwave Precorrectnr so that the
power meter reads the desired output power.
7. Adjust the Mother Board forward metering potentiometer, VR4, so that the Driver front
panel meter indicates 100% forward power output. Refer to the Driver Top View
Diagram for potentiometer locations.
84 Turn the ALC switch, 82, to “AUTO.”
NOTE: Analog Power output is dependent upon Modulation Depth. 0mm proper Modulation Depth prior or setting
Output Power leveLs. Use a video generator capable of Black No Burst (0 m5 = u an eorreaian factor) or Black Burst
with setup {2.6 dB correction foam) for pmper power level adjustments.
1. Apply an Analog Microwave Input Signal.
2. Turn the Microwave Preoorrector ALC switch, 52, to “MANUAL.”
3. Connect an HP435B power meter or equivalent to the -30 dB coupler forward port
4. Calculate the power meter reading necessary for 100% output, accounting for the coupler loss
and correction factor
Example:
Transmitter Output @ 100 Watts = +5000 dBmW
-30 dB Coupler = -30.00 dB
Correction Factor = - 2.60 dB
Expected Power Meter Reading = +1740 dBmW
_—_—_—_——_—_
Document it: Int-Jamar
REV‘ P1
comlque Metering Calibrations
5. Rotate the function switch from “STANDBY” to “FWD PWR” to enable transmit.
6 Adjust the Microwave Attenuator located on the Microwave Precorrector so that the power
meter reads the desired output power.
7. Adjust the Mother Board forward metering potentiometer, VR4, so that the Driver front panel
meter indicates 100% forward power output. Refer to the Driver Top View Diagram for
potentiometer locations.
8. Turn the ALC switch, 82, the “AUTO."
Driver Top View
ll Rotate the function switch to “STANDBY” and tum the ALC switch, S2, to “MANUAL.”
2. Momentarily interchange the coax cables at the Peak Detector Sample Ports.
3. Rotate the function knob from “STANDBY” to “REF” to enable transmitting,
4. Adjust the Mother Board reflected metering potentiometer, VRl, so that the Driver front
panel meter indicates 100% reflected poweri Refer to the diagram of the Driver Top View
for potentiometer locations.
—____—_——_———
Document #.‘ 111-me
REV: Pl
COMEWQVQ
Rotate the function knob to “STANDBY?
Return the Peak Detector coax cables to the original configuration.
Turn the ALC switch, 82, “AUTO.”
Rotate the function knob to “REF.” The meter should indicate less than 7% residual reflected
power reading into a resistive termination
wsam
. Usmg a digital voltmeter, measure the switching power supply output.
. Confirm that the switching power supply voltage output is +1030 VDC.
3. Rotate the function switch to +11 VPSr
4. Adjust the Mother Board +11 VPS potentiometer, VR3, so that the Driver front panel meter
indicates 100% +11 VPS metering. Refer to the diagram of the Driver Top View for
potentiometer locations.
____._—.__—-—-_—
Dotflmbllflhflm
RE REV: Pl
com wove System Operation
System Operation
Prior to any initial equipment turn-on, verify that all appropriate wiring interconnections have
been accomplished and the installation procedures have been followed precisely. Ensure
properAC Power Distribution to the exhaust fans and cabling of the Driver Chassis and the
Ultra Low Phase Noise Drawer (Agile applications only).
1. Position the front panel rotary function switch to “STANDBY?
2. Place the circuit breaker on the rear of the Rack in the “ON” position.
3. The following GREEN LEDs continuously illuminate verifying successful Initial Operation:
c [N SIGNAL (Modulator operation is required If an input signal is applied)
0 l'NTERLOCK (Mother Board Video Presence switch, SW1, in by-pass)
Power Amplifier Segment Initial Operation
No initial operation procedure is needed for the Power Amplifier Segments. Proceed to the
Normal Operation Procedures.
Driver Normal Operation
Driver operation is enabled by rotating the function switch from “STANDBY" to any other
position Once the function switch is rotated, the following GREEN LEDs continuously
illuminate confirming normal operation:
- INSIGNAL
- INTERLOCK
Absence of a green LED indicates a missing signal or parameter. Continuous illumination of
any red status LED indicates a failure has been detected by the diagnostic circuitry. Refer the
Document it 16-01001 for troubleshooting of failures.
To verify other transmitter parameters using the front panel meter, rotate the function svw'tch.
+11 VDC PS and FWD PWR should have meter readings of 100%. REFL PWR is a function of
combiners, the transmission line and antenna Reflected power readings less than 10% are
typical.
—__——-_—-_—
Document #' 15-0100]
REV: A
com wove system Operation
Power Amplifier Segment Normal Operation
Power Amplifier Segment operation is accomplished by turning the key-lock switch to the
“ON/LOCKED” position. Note: The lack: are an added safety feature; however, the keys are
interchangeable.
The POWER/FAULT LED should continuously illuminate GREEN. If the LED flashes RED,
the Power Amplifier Segment has faulted. Afier three faults, a failure will occur and the
Segment will shut down. It may be Reset by turning the key-lock switch to the
“OFF/UNLOCKED” position and then back to the “ON/LOCKED” position. Should failure
occur again, hot replacement is necessary. Turn the key-lock switch to the “OFF/UNLOCKED”
position and pull the failed Segment out of the Rack by the handle. Slide 5 new Power Amplifier
Segment into the vacant space, set the correct Node Address, and turn the key-lock switch to the
“ON/LOCKED” position. Refer to Document # 14—01001 for Power Amplifier Segment
Installation if needed.
_____—————_——
Document #.‘ 15-0100]
REV: A
coril\yave Troubleshooting aftluDrivzr
Troubleshooting of the Driver
The Driver is equipped with comprehensive diagnostic circuitry that monitors the status
of Power Amplifier Modules and critical circuits sn failures can be readily detected
Complete operational status is known by observing the fi'ont panel LED Diagnostic
Display, Analog Panel Meter and Diagnostic Interface. The following tables explain
various failure mode displays and possible solutions
NOTE: Due to internal transmitter design, there are no user serviceablz man/es, pom, or
componmls. Repair oflllese modules is not recammemlzd or advised. Contact COMWA VE customer
support should a failure occur.
GREEN LEDs
The LED’s fisted below continuously operate GREEN during normal operation» Absence of a
green LED indicates a missing signal or parameter which results in a oontrolled automatic
shutdown.
IN SIGNAL ~ Defective cabling to [F . Check Cabling
(Missing Microwave signal). INPUT . Verify input signal
a No Input signal - Replace LNA
- LNA failure 0 Measure voltages at 25 pin
Diagnostic Interface, J2
INTERLOCK - RF module unplugged or 0 Check Driver for
(Missing System 1mm" 538ml)- shorted disconnected module(s)
- Measure voltages at 25 pin
Diagnostic Interface, J2
—__.——._————
Docunwm #: Ill-01001 P-ge l of 4
REV: A
con/Wave Tmubleshaan‘ng o/rhe Driver
RED LEDS
The following LEDs continuously illuminate RED when a failure is detected. Controlled
automatic transmitter shut down is a function of the failure and severity. Presence of a RED
status LED with normal meter readings and/or normal transmitter operation indicates an out of
tolerance condition with that circuit
Measure voltages at 25 pm
DRIVER - Driver Module Current -
(DERClive Driver Module-l - Power Supply Failure Diagnostic Interface, J2
FINAL (Pammnpmrea - Final Module Current 0 Measure voltages at 25 pin
(Defective Fin“ Meade) - Power Supply Failure Diagnostic Interface, 12
—12 VDC Defective —12 VDc source Check —12 VDC source
(Low or rmssiflz -12 VDC)- . Disconnected module - Check module connectors
Shorted module - Measure voltages at 25 pin
Diagnostic Interface, J2
Check fan operation
0 Check site air conditioning
. Allow transmitter to cool:
Reset latched failure logic
by rotating function switch
momentarily to “STANDBY”
. Measure voltages at 25 pin
Diagnostic Interface, J 2
Check switching power
supply output voltage
Check for defective fuses(s)
Measure voltages at 25 pin
Diagnostic Interface, J2
TEMPERATURE
lntemal chassis temperature
exceeded +140 degrees Fahrenheit
(+60 degrees Celsius).
Fans inoperative
0 Heavy accumulation of
debris on fans or heatsinks
Module(s) overheating
Site air conditioning
Defective main input line
fuse
0 Switching power supply
module
- Open switching power
supply fuse, F1
Shorted amplifier module
Open Mother Board fuse, Fl
+1 1 Van
(Switching power supply voltage
has deviated beyond a set operating
window {high or low».
__—_—____—_—
Docrlmen! #: 16-0100] Page 2 of 4
REV: A
cov§|\vlvnve Tmublzshauting afflu Driver
A 25 pin computer type Diagnostic Interface Connector, labeled as J2, is located on the
rear of the chassis to assist in troubleshooting. Critical Power Supply, module and
Mother Board voltage test points can be accessed/monitored at this location. Should a
failure occur, the combination of meter readings, Diagnostic LED status lights, and the
Diagnostic Interface voltage test points help identify the failure.
TROUBLESHOOTING WORKSHEE T
leshooting worksheet identifies each interface pin, the associated internal test point,
nominal value, and the expected voltage range. Please fill in all blank spaces completely.
Ground
+12Vm1>s +11. 88 +12.12
42 -n 38
mm
+5 vncs +550
MI 378
AMPZ 1.46
Final Q2 2.98
NM —
WA —
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...
17
18
PA Fault 5 50
Driver Standby 5. 00 5 50
55°
—— 550
——
m— '- 02
m— 2- 50
w ——
REFL Power
Customer’s Name:
202.
3’s
avg :
50>
"E
11,35
0.32
Company Name:
Phone #: Fax #.
Model: Channeh—— Serial it (Rear Panel):
Send Results to: CDMWA VE-Anmian Technical Sappan Toll Free 11 (USA only): 1-800-266-9283
PO Box 69, 395 Oakhil] Road 1-717474-6751
Mountaintop, PA 18707 USA Fax 95: 1-717-474—5469
Document IO: [$0100] Page 3 nr 4
REV: A
cor/Wave
Traubltshparlng afllre Driver
ANALOG METERING
The Analog Meter provides a visual indication of the +11 VDc Switching Power Supply, Peak
Relative Forward or Reflected Power. The +11 VDC Switching Power Supply and Forward
Power should indicate 100%. Reflected power meter readings less than 10% are typical.
+1 1 VPS
(Meter does not indicate 100m
REFL PWR
(Reflected power is greater than
low")
FWD PWR
(Meter does nol indicale l00%
forward power),
Defective Switching Power
Supply
Shorted Module
Open Switching Power
Supply Fuse, F1
Switching Power Supply
out of adjustment
Metering out of adjustment
Loose RF cable
connection(s)
RF cable kinked
Wave guide
leak/depressurized
Reflected metering out of
adjustment
Driver Module
Final Modu1e(s)
Switching Power Supply
Forward metering out of
adjustment
Check for defective fuse(s)
Check Switching Power
Supply output voltage
Troubleshoot per front panel
LED Diagnostic Display
Adjust Switching Power
Supply output voltage per
Document # 14-0400]
Calibrate meter per
Document # 14-0400]
Measure voltages at 25 pin
Diagnostic Interface, J2
Check integrity of all RF
cable connections
Check cabling for kinks or
severe bends
Check wave guide pressure
Calibrate reflected metering
per Document # 14-04001
Measure voltages at 25 pin
Diagnostic Interface
Confirm output power
Troubleshoot per front panel
LED Diagnostic Display
Check for defective module
Calibrate forward power
metering per Document it
14-0400]
Measure voltages at 25 pin
Diagnostic Interface, 12
Dncumenl ll.- 16-01001 Plge A til 4
REV:A
com EWOVE Equipment Fusing and Pratectian
Equipment Fusing and Protection
The Driver Chassis is equipped with three replaceable fuses. The locations and values of
each fuse are as follows:
Mother Board 10.0 Amperes
_m 15 AmPefes (510W blow)
5.0 Amperes
The AC line input is supplied with voltage suppressers to protect the equipment from
moderate power surges. Thermal protection is accomplished using a thermostat that
closes when internal temperature exceeds +l40 degrees Fahrenheit (+60 degrees
Celsius). When thermal shut down occurs, logic control removes power from the finals
until the unit is sufficiently cooled.
Interlocks are designed for transistor bias protection for both the FET gate and drain
power supply voltages
A three phase—15 Ampere circuit breaker is provided with each
transmitter for system protection. It is located on the rear of the
Rack above the fans. When the current exceeds 20 Amperes
the circuit breaker trips and the transmitter, including AC to DC
Front End Convener, Driver Drawer, Ultra Low Phase Noise
Drawer (Agile applications only), Power Amplifier Segments
and fans are shut down. A plastic cover is provided to protect
the circuit breaker from accidental shut down.
____——-———-——
Documan fit: Iii-02001
REV:A
com wave Mainmumcz 11mm!
MONTHLY MAINTENANCE RECORD
Document #. 1 7-01 001A
REV: Pl
cum wave C uslomer Service
Customer Service
Comwave’s customer service personnel are available 24 hours a day to assist with any
questions or complications that may arise.
Communication Microwave Corp
Crestwood Industrial Park
395 Oakhill Road
Mountaintop, PA 18707
' i'-8 ;266=—9283 ‘ ‘ USA only
1-7] 474-675]
14174746469 FAX
mfim '
In the event the equipment requires return for factory service, please follow the guidelines listed.
Comwave cannot be held responsible for damaged equipment received due to improper packing.
Contact Comwave with any questions or concerns regarding returning or packaging of
equipment.
1.
Contact Comwave: Call Comwave to report the problem and to obtain a “Return
Authorization” number (RA). This enables Comwave to accurately track and identify
returned equipment for prompt and efficient service.
2. Obtain packaging materiaLr: Use original boxes and packing materials when returning any
equipment. This will safe guard against most in-transit damages. If original boxes and
packing materials are not available, contact Comwave to obtain replacement materials.
Replacement materials are provided at a nominal cost.
Pack eguipment: Using original packing materials, equipment is packed in a box within
another box. Double boxing provides maximum protection.
Caution: Do not pack equipment using “PEAN U TS. ” Equipment packed using
“PEANUTS” as filler does NOT provide sufficient protection during shipping. Rough
handling by the carrier may cause permanent damage to the equipment being return.
—__.__-—_—
Document fl: 18-0100]
REV‘ A
(omfiwave Customer Service
,mfir8étunr ‘
Refer to the diagram below which corresponds to each step.
1. Place the cardboard inserts above and below the equipment.
2. Insert foam against the front panel, between the handle and the comer of the inner box.
3. Insert the foam block securely behind the fans to prevent equipment from shifting upon
transit.
4. Place the protective foam pieces on each corner of the inner box.
5. Place the inner box into the outer box.
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Document it: 18—01001A fiwmerlylnplujlfi-alflfll
RE V.‘ A
com VIQVE Customer Service
1. Align the Power Amplifier Segment as shown and place into the original inner packing box.
2. Place the piece of loose foam between the handle of the Power Amplifier Segment and the
side of the inner box.
3A Fold the edges of the inner box inward and close.
4. Place the inner box into the outer box, being sure to include three empty boxes for a secure fit.
Inner Box
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Document #~ 18-0100”! fimnym a mutant
RE V: A

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