Axell Wireless 50 1892SERIES User Manual

5 Ch. VHF Radio Repeater Equipment

(Bi-directional Amplifier)

For

Day Wireless Systems

AFL Works Order Q116073
AFL Product Part No. 50-189201 (5 Ch. VHF System 80dB)

5 Ch. VHF Radio Repeater Equipment

Document Number 50-189201HBK – Issue 1 Page 1 of 48

Table of Contents

1. INTRODUCTION.......................................................................................................................... 4

1.1. Scope and Purpose of Document .............................................................................................4

1.2. Limitation of Liability Notice ...................................................................................................... 4

2. SAFETY CONSIDERATIONS ...................................................................................................... 5

2.1. Earthing of Equipment .............................................................................................................. 5

2.2. Electric Shock Hazard............................................................................................................... 5

2.3. RF Radiation Hazard ................................................................................................................ 5

2.4. Lifting and other Health and Safety Recommendations............................................................ 5

2.5. Chemical Hazard ...................................................................................................................... 6

2.6. Laser Safety.............................................................................................................................. 6

2.7. Emergency Contact Numbers...................................................................................................6

3. EQUIPMENT OVERVIEW............................................................................................................ 7

3.1. Overall System Diagram ........................................................................................................... 8

4. BDA VHF SYSTEM RACK 1 (50-189212) ...................................................................................9

4.1. BDA VHF System Rack 1 (50-189212) System diagram........................................................ 10

4.2. BDA VHF System Rack 1 (50-189212) Photographs ............................................................. 11

4.3. BDA VHF Downlink Output Combiner (50-189208)................................................................ 13

4.3.1. BDA VHF Downlink Output Combiner (50-189208) Major Components .......................... 13

4.3.2. BDA VHF Downlink Output Combiner (50-189208) System diagram ..............................14

4.4. BDA VHF Uplink Input Splitter (50-189210)............................................................................ 15

4.4.1. BDA VHF Uplink Input Splitter (50-189210) Major Components...................................... 15

4.4.2. BDA VHF Uplink Input Splitter (50-189210) System diagram .......................................... 16

4.5. BDA VHF Channel Shelves (50-189202 to 50-189206) .........................................................17

4.5.1. BDA VHF Channel Shelves Major Components ..............................................................17

4.5.2. BDA VHF Channel 1 Shelf (50-189202) System diagram................................................ 20

4.5.3. BDA VHF Channel 2 Shelf (50-189203) System diagram................................................ 21

4.5.4. BDA VHF Channel 3 Shelf (50-189204) System diagram................................................ 22

4.5.5. BDA VHF Channel 4 Shelf (50-189205) System diagram................................................ 23

4.5.6. BDA VHF Channel 5 Shelf (50-189206) System diagram................................................ 24

4.6. BDA VHF UPLINK OUTPUT COMBINER (50-189209)......................................................... 25

4.6.1. BDA VHF Uplink Output Combiner (50-189209) Major Components............................... 25

4.6.2. BDA VHF Uplink Output Combiner (50-189209) System Diagram ..................................26

4.7. BDA VHF DOWNLINK INPUT SPLITTER (50-189207).......................................................... 27

4.7.1. BDA VHF Downlink Input Splitter (50-189207) Major Components ................................. 27

4.7.2. BDA VHF Downlink Input Splitter (50-189207) System Diagram..................................... 28

4.8. 24V PSU Shelf (50-146512) ...................................................................................................29

4.8.1. 24V PSU Shelf (50-146512) Specification .......................................................................29

4.8.2. 24V PSU Shelf (50-146512) Major Components ............................................................. 29

4.8.2. 24V PSU Shelf (50-146512) System Diagram ................................................................. 31

5. BDA VHF SYSTEM RACK 2 (50-189213) .................................................................................32

5.1. BDA VHF System Rack 2 (50-189213) System Diagram ....................................................... 34

5.2. Hybrid Splitter/Combiner Tray (50-189211) ............................................................................ 35

5.2.1. Hybrid Splitter/Combiner Tray (50-189211) Major Components ...................................... 35

5.2.2. Hybrid Splitter/Combiner Tray (50-189211) System Diagram.......................................... 36

6. BDA VHF SYSTEM RACK 3 (50-189214) .................................................................................37

6.1. BDA VHF System Rack 3 (50-189214) System Diagram ....................................................... 39

7. INSTALLATION.......................................................................................................................... 40

7.1 Initial Installation Record......................................................................................................... 40

8. FAULT FINDING & MAINTENANCE.......................................................................................... 40

8.1 General Fault Finding Procedures.......................................................................................... 40

8.2 Downlink ................................................................................................................................. 40

8.3 Uplink...................................................................................................................................... 41

8.4 Fault repair.............................................................................................................................. 41

8.5 Checking service..................................................................................................................... 41

8.6 Service Support ...................................................................................................................... 41

8.7 Tools & Test Equipment.......................................................................................................... 41

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8.8 General Maintenance Procedures .......................................................................................... 42

8.9 Module Removal (LNAs, general procedure).......................................................................... 42

8.10 Module Replacement (general) ........................................................................................... 42

8.11 Power Amplifiers.................................................................................................................. 42

8.12 Low Power Amplifier Replacement...................................................................................... 43

8.13 Module Transportation......................................................................................................... 43

APPENDIX A .......................................................................................................................................44

A.1. Glossary of Terms used in this document ...........................................................................44

A.2. Key to Drawing Symbols used in this document.................................................................. 45

A.3. EC Declaration of Conformity .............................................................................................. 46

A.4. Amendment List Record Sheet............................................................................................ 47

5 Ch. VHF Radio Repeater Equipment

Document Number 50-189201HBK – Issue 1 Page 3 of 48

1. INTRODUCTION

1.1. Scope and Purpose of Document

This handbook is for use solely with the equipment identified by the Aerial Facilities Limited (AFL) Part
Number shown on the front cover. It is not to be used with any other equipment unless specifically
authorised by AFL. This is a controlled release document and, as such, becomes a part of Aerial
Facilities’ Total Quality Management System. Alterations and modification may therefore only be
performed by AFL.

AFL recommends that the installer of this equipment familiarise themselves with the safety and
installation procedures contained within this document before installation commences.

The purpose of this handbook is to provide the user/maintainer with sufficient information to service
and repair the equipment to the level agreed. Maintenance and adjustments to any deeper level must
be performed by AFL, normally at the company’s repair facility in Chesham, England.

This handbook has been prepared in accordance with BS 4884, and AFL’s Quality procedures, which
maintain the company’s registration to BS EN ISO 9001:2000 and to the R&TTE Directive of the
European Parliament. Copies of the relevant certificates and the company Quality Manual can be
supplied on application to the Quality Manager.
This document fulfils the relevant requirements of Article 6 of the R&TTE Directive.

1.2. Limitation of Liability Notice

This manual is written for the use of technically competent operators/service persons. No liability is
accepted by AFL for use or misuse of this manual, the information contained therein, or the
consequences of any actions resulting from the use of the said information, including, but not limited
to, descriptive, procedural, typographical, arithmetical, or listing errors.

Furthermore, AFL does not warrant the absolute accuracy of the information contained within this
manual, or its completeness, fitness for purpose, or scope.

AFL has a policy of continuous product development and enhancement, and as such, reserves the
right to amend, alter, update and generally change the contents, appearance and pertinence of this
document without notice.

All AFL products carry a twelve month warranty from date of shipment. The warranty is expressly on a
return to base repair or exchange basis and the warranty cover does not extend to on-site repair or
complete unit exchange.

5 Ch. VHF Radio Repeater Equipment

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2. SAFETY CONSIDERATIONS

2.1. Earthing of Equipment

Equipment supplied from the mains must be connected to grounded outlets and earthed
in conformity with appropriate local, national and international electricity supply and
safety regulations.

2.2. Electric Shock Hazard

The risk of electrical shocks due to faulty mains driven power supplies whilst
potentially ever present in any electrical equipment, would be minimised by adherence
to good installation practice and thorough testing at the following stages:

a) Original assembly.
b) Commissioning.
c) Regular intervals, thereafter.

All test equipment must be in good working order prior to its use. High current power supplies can be
dangerous because of the possibility of substantial arcing. Always switch off during disconnection and
reconnection.

2.3. RF Radiation Hazard

RF radiation, (especially at UHF frequencies) arising from transmitter outputs
connected to AFL’s equipment, must be considered a safety hazard.

This condition might only occur in the event of cable disconnection, or because a

‘spare’ output has been left un-terminated. Either of these conditions would impair the
system’s efficiency. No investigation should be carried out until all
removed. This would always be a wise precaution, despite the severe mismatch between the
impedance of an N type connector at 50, and that of free space at 377, which would severely
mitigate against the efficient radiation of RF power. Radio frequency burns could also be a hazard, if
any RF power carrying components were to be carelessly touched!

Antenna positions should be chosen to comply with requirements (both local & statutory) regarding
exposure of personnel to RF radiation. When connected to an antenna, the unit is capable of
producing RF field strengths, which may exceed guideline safe values especially if used with
antennas having appreciable gain. In this regard the use of directional antennas with backscreens
and a strict site rule that personnel must remain behind the screen while the RF power is on, is
strongly recommended.

Where the equipment is used near power lines or in association with temporary masts not having
lightning protection, the use of a safety earth connected to the case-earthing bolt is strongly advised.

RF power sources have been

2.4. Lifting and other Health and Safety Recommendations

Certain items of AFL equipment are heavy and care should be taken when lifting them
by hand. Ensure that a suitable number of personnel, appropriate lifting apparatus
and appropriate personal protective equipment is used especially when installing Cell
Enhancers above ground e.g. on a mast or pole.

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2.5. Chemical Hazard

Beryllium Oxide, also known as Beryllium Monoxide, or Thermalox™, is sometimes

used in devices within equipment produced by Aerial Facilities Ltd. Beryllium oxide
dust can be toxic if inhaled, leading to chronic respiratory problems. It is harmless if
ingested or by contact.

Products that contain beryllium are load terminations (dummy loads) and some power amplifiers.
These products can be identified by a yellow and black “skull and crossbones” danger symbol (shown
above). They are marked as hazardous in line with international regulations, but pose no threat under
normal circumstances. Only if a component containing beryllium oxide has suffered catastrophic
failure, or exploded, will there be any danger of the formation of dust. Any dust that has been created
will be contained within the equipment module as long as the module remains sealed. For this reason,
any module carrying the yellow and black danger sign should not be opened. If the equipment is
suspected of failure, or is at the end of its life-cycle, it must be returned to Aerial Facilities Ltd for
disposal.

To return such equipment, please contact the Quality Department, who will give you a Returned
Materials Authorisation (RMA) number. Please quote this number on the packing documents, and on
all correspondence relating to the shipment.

PolyTetraFluoroEthylene, (P.T.F.E.) and P.T.F.E. Composite Materials
Many modules/components in AFL equipment contain P.T.F.E. as part of the RF insulation barrier.
This material should never be heated to the point where smoke or fumes are evolved. Any person
feeling drowsy after coming into contact with P.T.F.E. especially dust or fumes should seek medical
attention.

2.6. Laser Safety

General good working practices adapted from
EN60825-2: 2004/ EC 60825-2:2004

Do not stare with unprotected eyes or with any unapproved optical device at the fibre
ends or connector faces or point them at other people, Use only approved filtered or attenuating
viewing aids.
Any single or multiple fibre end or ends found not to be terminated (for example, matched, spliced)
shall be individually or collectively covered when not being worked on. They shall not be readily
visible and sharp ends shall not be exposed.
When using test cords, the optical power source shall be the last connected and the first
disconnected; use only approved methods for cleaning and preparing optical fibres and optical
connectors.
Always keep optical connectors covered to avoid physical damage and do not allow any dirt/foreign
material ingress on the optical connector bulkheads.
The optical fibre jumper cable maximum bend radius is 3cm; any smaller radii may result in optical
cable breakage or excessive transmission losses.
Caution: The FO units are NOT

weather proof.

2.7. Emergency Contact Numbers

The AFL Quality Department can be contacted on:
Telephone [phone]
Fax. [phone]
e-mail

[e-mail]

5 Ch. VHF Radio Repeater Equipment

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3. EQUIPMENT OVERVIEW

5 channel radio repeater 50-189201 is supplied in three 43U equipment mounting racks.

Rack 1 (50-189212) houses the main amplification modules along with the various splitters and
combiners.

Rack 2 (50-189213) houses the Cavity FIlters for the TX (Downlink) path

Rack 3 (50-189214) houses the Cavity FIlters for the RX (Uplink) path

Downlink.
Channel 1 – 154.190MHz
Channel 2 – 154.070MHz
Channel 3 – 158.910MHz
Channel 4 – 155.700MHz
Channel 5 – 158.850 MHz

The input splitter shelf (50-189207) receives Downlink VHF signals from the off-air RX antenna and
the signal is split and passed through a series of bandpass and crystal filters. The resultant five signal
paths then leave the shelf, each path going to the downlink section of a dedicated amplifier shelf
(BDA VHF Channel Shelves 1 to 5, 50-189202/06); these amplifier shelves also contain channel
selective modules to achieve the narrow bandwidth required.
Upon leaving the Amplifier shelves the five signal paths enter BDA VHF Downlink Output Combiner
(50-189208) where the five separate signal paths are combined into three. The three signal paths are
then fed into the cavity combiner in Rack 2 where they are combined into a single signal path before
being fed into BDA VHF DAS Hybrid Splitter/Combiner (50-189211) where the signal path is split into
two feeds, one for each LCX feed

Uplink
Channel 1 – 156.195MHz
Channel 2 – 155.325MHz
Channel 3 – 154.785MHz
Channel 4 – 154.830MHz
Channel 5 – 156.150 MHz

Uplink signals from the LCX are fed into BDA VHF DAS Hybrid Splitter/Combiner (50-189211) where
they are combined into a single signal path and passed into the first stage of the cavity filter in Rack

3. In the first stage cavity filter the signal path is split into three and each path passes through a cavity
filtering section and the three signal paths then are fed into the BDA VHF Uplink Input Splitter (50-

189210) in Rack 1, here the three paths are split into five and each path pases through a crystal filter
which passes the channel required.
Upon leaving the BDA VHF Uplink Input Splitter, each of the five signal paths is fed into the uplink
section of a dedicated amplifier shelf (BDA VHF Channel Shelves 1 to 5, 50-189202/06); these
amplifier shelves also contain channel selective modules to achieve the narrow bandwidth required.
From the amplifier shelves the five signal paths are fed into the Uplink Output Combiner (50-189209)
where the five signal paths are combined into three path before being fed into the second stage of the
cavity filter in Rack 3. After passing through the cavity filters the separate signal paths are combined
into a single path whis passes through a bandpass filter before being fed to the TX antenna

5 Ch. VHF Radio Repeater Equipment

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3.1. Overall System Diagram

Drawing number 50-189281

5 Ch. VHF Radio Repeater Equipment

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4. BDA VHF SYSTEM RACK 1 (50-189212)

Rack 1 (50-189212) houses the main amplification modules for uplink and downlink along with the
various splitters, combiners and the inputs from the RX antenna and the outputs to the TX antenna

Rack 1 is a 43U equipment mounting rack (600mm x 600mm) and comprised of the following
modules, listed from the top of the rack

Component

Part
50-189208 BDA VHF Downlink Output Combiner 1
50-189210 BDA VHF Uplink Input Splitter 1
50-189202 BDA VHF Channel 1 Shelf 1
50-189203 BDA VHF Channel 2 Shelf 1
50-189204 BDA VHF Channel 3 Shelf 1
50-189205 BDA VHF Channel 4 Shelf 1
50-189206 BDA VHF Channel 5 Shelf 1
50-189209 BDA VHF Uplink Output Combiner 1
50-189207 BDA VHF Downlink Input Splitter 1
50-146512 24V PSU Shelf 1

Component Part Description Qty Per

Assembly

5 Ch. VHF Radio Repeater Equipment

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4.1. BDA VHF System Rack 1 (50-189212) System diagram

Drawing number 50-189292

5 Ch. VHF Radio Repeater Equipment

Document Number 50-189201HBK – Issue 1 Page 10 of 48

4.2. BDA VHF System Rack 1 (50-189212) Photographs

Top of rack

Rack Interconnections
(see below)

A BDA VHF Downlink Output Combiner 50-189208
B BDA VHF Uplink Input Splitter 50-189210
C BDA VHF Channelised Amplifier Channel 1 Shelf 50-189202
D BDA VHF Channelised Amplifier Channel 2 Shelf 50-189203
E BDA VHF Channelised Amplifier Channel 3 Shelf 50-189204
F BDA VHF Channelised Amplifier Channel 4 Shelf 50-189205
G BDA VHF Channelised Amplifier Channel 5 Shelf 50-189206
H 2U Blanking Panel
I 1U Blanking Panel

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Bottom of rack

I 1U Blanking Panel
J BDA VHF Uplink Output Combiner 50-189209
K BDA VHF Downlink Input Splitter 50-189207
L VHF/UHF System PSU 24v 50-146512
M 2U Blanking Panel
N 3U Blanking Panel

Rack interconnections are on the top of the rack rack

Ant Connection to RX Antenna
E1 D/L Channel 4 to Cavity Combiner Rack 2
E2 Combined D/L Channel 1 & 2 to Cavity Combiner Rack 2
E3 Combined D/L Channel 3 & 5 to Cavity Combiner Rack 2
G1 Combined U/L Channel 3 & 4 from first stage Cavity Combiner Rack 3
G2 U/L Channel 2 from first stage Cavity Combiner Rack 3
G3 Combined U/L Channel 1 & 5 from first stage Cavity Combiner Rack 3
H1 Combined U/L Channel 3 & 4 to second stage Cavity Combiner Rack 3
H2 U/L Channel 2 to second stage Cavity Combiner Rack 3
H3 Combined U/L Channel 1 & 5 to second stage Cavity Combiner Rack 3

5 Ch. VHF Radio Repeater Equipment

Document Number 50-189201HBK – Issue 1 Page 12 of 48

4.3. BDA VHF Downlink Output Combiner (50-189208)

The BDA VHF Downlink Output Combiner takes amplified signals from the Channelised Amplifier
shelves in Rack 1 and combines them before passing the signals to the Cavity Combiner in rack 2

Channels 1 and 2 are combined by hybrid combiner (01-004201) and the resultant signal is passed
through two notch filters (01-004201) before leaving the shelf to go to the cavity combiner in rack 2

Channels 3 and 5 are combined by hybrid combiner (01-004201) and the resultant signal is passed to
the cavity combiner in rack 2

Channel 4 is passed through two notch filters (01-004201) before leaving the shelf to go to the cavity
combiner in rack 2
This is a passive shelf and has no connection to the PSU and no alarms.

4.3.1. BDA VHF Downlink Output Combiner (50-189208) Major
Components

Component
Part
01-004201 Notch Filter 4
05-000103 Hybrid combiner 2
97-100010K 5U Rack Mount Chassis

Component Part Description Qty Per

Assembly

A Port E2 Combined D/L Channel 1 & 2 output
B Port B5 D/L Channel 5 input
C Port B3 D/L Channel 3 input
D Port B1 D/L Channel 1 input
E Port E3 Combined D/L Channel 3 & 5 output
F Port E1 D/L Channel 4 output
G Port B4 D/L Channel 4 input
H Port B2 D/L Channel 2 input

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4.3.2. BDA VHF Downlink Output Combiner (50-189208) System diagram

Drawing number 50-189288

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4.4. BDA VHF Uplink Input Splitter (50-189210)

BDA VHF Uplink Input Splitter (50-189210) takes the three signal path inputs from the first stage
uplink cavity filter in rack 2 and splits two of the signals to produce five signal paths which are then
fed to the crystal filters.
The outputs from the five crystal filters then leave the Uplink Input Splitter shelf to go to the uplink
sections of the Channelised Amplifier shelves.
This is a passive shelf and has no connection to the PSU and no alarms,

4.4.1. BDA VHF Uplink Input Splitter (50-189210) Major Components

Component
Part
19-000822K 2U Rack Mount Chassis 1
93-980196 Crystal Filter 154.785MHz 1
93-980225 Crystal Filter 154.830MHz 1
93-980227 Crystal Filter 155.325MHz 1
93-980228 Crystal Filter 156.150MHz 1
93-980229 Crystal Filter 156.195MHz 1

Top View – lid removed

Component Part Description Qty Per

Assembly

Close-up
of connectors

A Port G3 Input from cavity combiner
B Port G1 Input from cavity combiner
C Port C4 U/L Channel 4 output
D Port C2 U/L Channel 2 output
E Port G1 Input from cavity combiner
F Port C5 U/L Channel 5 output
G Port C3 U/L Channel 3 output
H Port C1 U/L Channel 1 output

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