M/A-Com 19D902797G3, 19D902797G6, 19D902797G7, 19D902797G8, 19D902797G9 Maintenance Manual

Maintenance Manual

450-470 MHz, 110 WATT POWER AMPLIFIER 19D902797G3
403-425 MHz, 90 WATT POWER AMPLIFIER 19D902797G6
425-450 MHz, 90 WATT POWER AMPLIFIER 19D902797G7
380-400 MHz, 75 WATT POWER AMPLIFIER 19D902797G8
470-494 MHz, 90 WATT POWER AMPLIFIER 19D902797G9
492-512 MHz, 90 WATT POWER AMPLIFIER 19D902797G10
410-430 MHz, 90 WATT POWER AMPLIFIER 19D902797G11

TABLE OF CONTENTS

Section Page

1.0 SPECIFICATIONS...................................................................................................................................................3

2.0 DESCRIPTION ........................................................................................................................................................4

3.0 CIRCUIT ANALYSIS..............................................................................................................................................5

3.1 POWER AMPLIFIER ..........................................................................................................................................5

3.1.1 Exciter (U7) ..................................................................................................................................................5

3.1.2 Small Signal Gain Stage ............................................................................................................................... 5

3.1.3 Low Level Amplifier (U1)............................................................................................................................ 5

3.1.4 Driver (Q1) ................................................................................................................................................... 5

3.1.5 Power Amplifier Finals (Q2 & Q3) .............................................................................................................. 6

3.1.6 Low Pass Filter ............................................................................................................................................. 6

3.2 POWER CONTROL ............................................................................................................................................7

3.2.1 Keying and Unkeying the PA .......................................................................................................................7

3.2.2 PA Output Power Set.................................................................................................................................... 7

3.2.3 PA Protection................................................................................................................................................ 7

3.2.4 Theory of Operation......................................................................................................................................7

3.2.5 Signal Interface.............................................................................................................................................8

4.0 TROUBLESHOOTING ......................................................................................................................................... 10

4.1 TROUBLESHOOTING GUIDE ........................................................................................................................ 10

4.2 LOW PASS FILTER TEST PROCEDURE.......................................................................................................13

4.2.1 Recommemded Test Equipment................................................................................................................. 13

4.2.2 Test Set-Up and Procedure .........................................................................................................................13

5.0 PARTS LIST .......................................................................................................................................................... 14

6.0 PRODUCTION CHANGES................................................................................................................................... 23

7.0 IC DATA ................................................................................................................................................................ 26

8.0 ASSEMBLY DIAGRAMS..................................................................................................................................... 29

8.1 POWER AMPLIFIER 19D902797G3 & G6 THROUGH G11..........................................................................29

8.2 COVER ASSEMBLY 19B801659G3 ................................................................................................................ 30

9.0 ASSEMBLY, OUTLINE & SCHEMATIC DIAGRAMS FOR LOW PASS FILTER MODULE 19D902856G331

10.0 OUTLINE DIAGRAM...........................................................................................................................................32

10.1 POWER AMPLIFIER BOARD A1 19D902856G3, G6, G7, G8, G9, G10 & G11........................................... 32

11.0 SCHEMATIC DIAGRAM ..................................................................................................................................... 33

11.1 POWER AMPLIFIER ASSEMBLY 19D902 797G3 & G6 THROUGH G11 ..................................................33

12.0 OUTLINE & SCHEMATIC DIAGRAM FOR 470-512 MHz LOW PASS FILTER MODULE 19D902856G9 . 34

LBI-38674L

NOTE

Repairs to this equipment should be made only by an authorized service technician or facility designated by the
supplier. Any repairs, alterations or substitution of recommended parts made by the user to this equipment not
approved by the manufacture could void the user’s authority to operate the equipment in addition to the
manufacture’s warranty.

This manual is published by M/A-COM, Inc., without any warranty. Improvements and changes to this manual necessitated by typographical
errors, inaccuracies of current information, or improvements to programs and/or equipment, may be made by M/A-COM, Inc., at any time
and without notice. Such changes will be incorportated into new editions of this manual. No part of this manual may be reproduced or
transmitted in any form or by any means, electronic or mechanical, including photocopying and recording, for any purpose, without the
express written permission of M/A-COM, Inc.

Copyright© 1992 - 2003 M/A-COM, Inc. All rights reserved.

2 LBI-38674L

1.0 SPECIFICATIONS1

ITEM SPECIFICATION

FREQUENCY

OUTPUT POWER (RF)

INPUT POWER (RF)

TEMPERATURE RANGE

SUPPLY VOLTAGE 13.4 Vdc

CURRENT

DUTY CYCLE Continuous

STABILITY

RUGGEDNESS AT HIGH
VSWR

450 MHz - 470 MHz (G3)
403 MHz - 425 MHz (G6)
425 MHz - 450 MHz (G7)
380 MHz - 400 MHz (G8)
470 MHz - 494 MHz (G9)
492 MHz - 512 MHz (G10)
410 MHz - 430 MHz (G11)

65 watts - 130 watts (G3)
55 watts - 110 watts (G6, G7, G9, G10 & G11)
45 watts - 90 watts (G8)

10 mW min. into

-30°C TO +60°C (Ambient air)

29 Amps max. (26 A typical @ rated power, 13.4V) (G3)
29 Amps max. (21 A typical @rated power , 13.4V)(G6, G7, G9, G10 &
G11)
29 Amps max. (20 A typical @ rated power, 13.4V) (G8)

Stable into 3:1 VSWR; all temp.,voltage,freq. 55 watts - 110 watts (G3)
or 45 watts - 90 watts (G6, G7, G9, G10 & G11) or 45 watts - 90 watts
(G8)

No damage into open or shorted load.

≤2:1 VSWR

SPECIFICATIONS

1

These specifications are intended to be used by service personnel during servicing. Refer to the appropriate Specification

Sheet for complete specifications.

LBI-38674L 3

DESCRIPTION

2.0 DESCRIPTION

The UHF Power Amplifier Assembly is a wide band RF power amplifier operating over
the 380-400, 410-430, 403-425, 425-450, 450-470, 470-494, and 492-512 MHz range
without tuning. Its main function is to amplify the 10 mW FM signal from the
Transmitter Synthesizer to the rated RF output at the antenna port. The output of the
Power Amplifier Assembly is adjustable from rated power to 3dB lower at the PA output
J104.

The assembly consists of a printed wiring board (A1) and associated components,
including a power module and three RF power transistors, mounted to the heat sink
assembly. The printed wiring board (A1) contains both the power amplifier circuitry and
the power control circuitry.

Unfiltered supply voltage, A+, for the power amplifier circuits enters the assembly via
feedthrough capacitor, C1. Power cable W4 routes the A+ from C1 to J103 on the PWB.
Filtered A+ voltage for the power control circuit enters the assembly via control cable
W13, which connects to the PWB at J201.

The Power Control circuitry sets the output power level by adjusting the PA Power Set
level. It keeps the output power constant despite variations in input power, power
amplifier gain, or temperature through the use of a feedback control loop in the PA
assembly.

4 LBI-38674L

CIRCUIT ANALYSIS

3.0 CIRCUIT ANALYSIS

3.1 POWER AMPLIFIER

The power amplifier section of the PA Board consists of an Exciter, a Small Signal Gain
Stage, a Low Level Amplifier, a Driver, and the Power Amplifier Finals. All these gain
stages have an input and output impedance of 50 ohms. Figure 1 is a block diagram
showing the signal flow within the Power Amplifier Assembly.

3.1.1 Exciter (U7)

The Exciter stage uses a broadband silicon monolithic microwave integrated circuit
(MMIC) amplifier. The signal from transmitter synthesizer, typically 10 dBm (10 mW),
is input to the Exciter through a 10 dB resistive pad (R1, R2, and R31). The Exciter
amplifies the resulting 0 dBm (1 mW) signal to 12 dBm (16 mW).

The MMIC requires a 5 volt supply source. The 8 volt regulator (U100) provides the 5
volts to the MMIC via a dropping resistor R30.

3.1.2 Small Signal Gain Stage

The Small Signal Gain Stage consists of Q7 and its associated bias and matching
circuitry. Collector voltage is fed through R39, R40, and L23. Resistor R33 sets the
quiescent bias of the part. The transistor input impedance is matched to the 50-ohm
output of the Exciter by C59, C61, C62, and L7. L23 and C49 provide the necessary
output matching. The stage provides 14 dB of gain to amplify the signal from the Exciter
to 26 dBm (400 mW).

3.1.3 Low Level Amplifier (U1)

The Low Level Amplifier (LLA) stage uses a 50 ohm thick film RF Power Module to
amplify and control the output power. Internally, the module is a three stage amplifier.
The power control circuitry controls the gain of the first and second stages by varying the
collector voltage level of Q203. The third stage gain remains constant with A+ providing
the DC supply voltage.

The signal from the Small Signal Gain stage, typically 26 dBm (400 mW), is input into
the LLA. Under typical Power Set conditions, the LLA amplifies the signal to a typical
output level of 40.5 dBm (11.2 W).

3.1.4 Driver (Q1)

The driver is a 6 dB RF amplifier consisting of transistor Q1 and its associated circuitry.
The signal from the LLA, typically 40.5 dBm (11.2 W), is amplified to 46.5 dBm (45.0
W). The transistor input is matched to 50 ohms by C65, C66, C27, C67, and a piece of
printed transmission line. The drive signal is then split with a printed in-phase Wilkenson
splitter, providing equal power to each of the final devices.

LBI-38674L 5

CIRCUIT ANALYSIS

1

3.1.5 Power Amplifier Finals (Q2 & Q3)

Each of the Power Amplifier final devices is capable of producing 5 to 6 dB of gain. The
output signal from the Splitter is impedance-matched to each of the finals. Under
optimum conditions each final amplifies the input signal to between 50 and 70 watts
output power (depending on band split). The outputs are then impedance-matched to the
input of the Combiner. The Combiner is a printed in-phase Wilkinson type, which
combines (sums) the output power of the finals. This produces an output power of
approximately 100W (depending on band split), which is coupled to the directional
coupler (part of A1 PWB) and on to the antenna circuits. In addition, the directional
coupler samples both forward and reverse power and sends this sample to the Power
Control circuitry

.

PAD

J101

RF IN

10mW

-10 dB

* All power data is per miminum spec. Nominal V oltage (13.4V), 50 Ohm Load,
Room Temperature.

12 dB

GAIN STAGE

16 dB

Q7

SMALL SIGNAL

EXCITER

U1

LOW LEVEL AMPL

3.1.6 Low Pass Filter

Following the Directional Coupler, the RF signal passes through a CHEBYSHEV LC
Low Pass filter (19D902856G3&G9). This passive circuit attenuates any residual
harmonics from the transmit carrier frequency and routes the signal through the RF
output to the antenna. Specifications for this filter are as follows:

Q1

DRIVER

=40W

6 dB

10W

CONTROL VOLTAGE

(4-8V) POWER SET

(2.5-4V) POWER SENSOR

SPLITTER

FILTER A+

PA KEY

=20W

=20W

FINALS

Q2 & Q3

5.0 dB

5.0 dB

Figure 1 - Block Diagram

=60W

=60W

POWER

CONTROL

COMBIMER

DIRECTIONAL

COUPLER

REV FWD

THERMAL

SENSE

J104
RF OUT
130W (G3)
110W (G6, G7, G9, G10 & G1
90W )(G8)

J1

L
P
F

J2

ANTENNA

Parameter

Specifications for Group 3 Specifications for Group 9

Frequency (MHz) 376-470 MHz 470-512 MHz

RF Power Handling (W) 150 Watts 150 Watts

Insertion Loss (dB) 0.4 dB 0.5 dB

Input (VSWR) 1.5:1 Maximum 1.5:1 Maximum

Output (VSWR) 1.5:1 Maximum 1.5:1 Maximum

Harmonic Attenuation (dB) 50 Minimum 760-1500 40 Minimum 940-1024

30 Minimum >1500 MHz 30 Minimum > 1500 MHz

6 LBI-38674L

CIRCUIT ANALYSIS

3.2 POWER CONTROL

The Power Control circuitry performs three basic functions. It keys and unkeys the PA,
sets the PA output power, and protects the PA against adverse conditions.

CAUTION

3.2.1 Keying and Unkeying the PA

To key the PA, the digital controller places 5 volts on the PA key line, J201-2. Zero volts
on the PA key line causes the PA to unkey. If the control cable (W13) is disconnected,
with nothing actively driving the PA key line, the PA will remain unkeyed.

3.2.2 PA Output Power Set

PA output power is set according to the level of the Power Set line. Four (4) volts on this
line will produce minimum power. As the voltage increases toward eight (8) volts, the
power will increase to its maximum rated output. The PA output power is initially set at
the factory. This is done by adjusting R43* while injecting a 10 mW signal at J1 and
applying 8 volts to J201-3. After setting the maximum power level, changing the output
power is done by varying the voltage applied on the Power Set line.

*Misadjustment of R43 may result in PA failure.

3.2.3 PA Protection

The Power Control also protects the PA against over temperature and high VSWR
conditions.

An over temperature condition exists when the flange temperature of the final output
transistor reaches 80°C. At this point the output power will drop below its set level. The
output power will continue to drop such that when the flange temperature reaches 125°C
the PA output drops at least 10 dB below its set level.

Reflected power is limited to 25% of the set power. If the output VSWR degrades to
worse than 3:1, the forward power will be reduced to limit the reflected power to 25% of
the set power. The Power Sensor line indicates when the PA is operating in a cutback
condition. If the PA is keyed and the power control is cutting back, the Power Sensor line
will drop to zero (0) volts and the PA alarm light on the station will turn on.

3.2.4 Theory of Operation

Power control of the MASTR® III Power Amplifier is accomplished with a feedback
control loop. The three possible feedback signals are: representation of forward power,
temperature sensitive scaled representation of forward power, or representation of
reflected power. These three signals are input to a diode summing junction which selects
the largest of the three for use as the feedback.

LBI-38674L 7

CIRCUIT ANALYSIS

The microstrip directional coupler samples the output power and produces a voltage, Vf,
proportional to the forward output power. The power control compares the forward
voltage, Vf, to a reference voltage at U3. The output of U3 controls the current flow thru
Q5 and the output of Q203. The collector output of Q203 adjusts the control voltage,
Vct1 and Vct2. This control voltage is capable of adjusting the total PA output power
since it provides the first two stages DC supply to the Low Level Amplifier, U1.

During over-temperature operation, a scaled representation of the forward power is
maintained constant by varying the control voltage line. Thermal resistor RT1, sensing an
increase in temperature, causes the output of U3.1 to increase. If the output of U3.1
becomes larger than the other feedback lines, the output of U3.4 will begin to decrease.
This in turn will cause the output of Q203 to decrease reducing the supply voltage to U1.
Since the scaling is a function of temperature, the power is reduced as the temperature
increases.

Under VSWR cutback operation the reverse voltage, Vr, representative of the reflected
output power, is held below a threshold by reducing the control voltage as necessary. If
Vr increases at U3.2 beyond the preset threshold, an increase at U3.4 will result. This
causes a subsequent reduction in the control voltage to U1. Thus the power control circuit
reduces the output power in order to limit the reflected power to 25% of the set power.

3.2.5 Signal Interface

The signal interface to the MASTR III Power Amplifier is supported by a six position
feedthrough connector, J201, with the following pinout:

1. PWR Sensor

2. PA Key

3. PA PWR Set

4. NC

5. Ground

6. Fil A+

3.2.5.1 Pwr Sensor

This line indicates when the PA is experiencing adverse conditions. Under normal
operation, while the PA is keyed, this line will be proportional to forward power.
Minimum power (zero watts) corresponds to 2.5 volts while maximum power
corresponds to 4.5 volts. This voltage is not temperature compensated and no effort is
made to calibrate this signal to an absolute power level. It is intended to provide a relative
indication of forward power and to discriminate between normal and cutback operation.

Zero volts on this line, when the PA is keyed, indicates the forward power is cutback.
This power cutback may be due to high reflected power or may be due to high PA
temperatures. This fault condition may indicate a problem with the PA or may indicate a
system problem external to the Power Amplifier. High VSWR may be due to a poor
antenna and high temperature may be due to a blocked cabinet vent. Zero volts on this
line, when the PA is keyed, does not indicate zero forward power. Zero volts indicates the
PA is protecting itself due to adverse conditions. If the adverse condition, either high
VSWR or high temperature is eliminated, the power will return to normal and the PWR
SENSOR voltage will rise above 2.5 volts.

8 LBI-38674L

CIRCUIT ANALYSIS

3.2.5.2 PA Key (Interface Connector pin 2)

This line is used to key and unkey the PA. UNKEY = 0 volt and KEY = 5 volts. The
driver of this line must be capable of supplying 5 volts at 1.0 mA. The appropriate key
sequence requires RF from the transmit synthesizer be input to the PA before the KEY
line is energized.

3.2.5.3 PA PWR Set (Interface Connector pin 3)

This line is used to set the RF Power Output of the PA. Minimum power output equals 4
volts and maximum power output equals 8 volts. The driver of this line must be capable
of supplying 8 volts at 1.0 mA.

3.2.5.4 Fil A+ (Interface Connector pin 6)

This line provides the filtered supply voltage for the Power Control. The driver of this
line must be capable of supplying 13.4 volts ±20% at 100 mA.

LBI-38674L 9

TROUBLESHOOTING

4.0 TROUBLESHOOTING

4.1 TROUBLESHOOTING GUIDE

SYMPTOM AREAS TO CHECK INDICATIONS

1. No Power or low Power at
Antenna Port.

2. No power at PA output port
and PA ALARM is OFF.

3. No power at PA output port
and PA ALARM is ON

4. Low power at PA output port
and PA ALRAM is OFF.

5. Low power at PA output port
and PA ALARM is ON.

1. Measure the transmitter output
power before the duplexer or
antenna switch (for simplex
mode).

2. Measure the transmitter output
power before the low pass
filter.

3. Measure the transmitter output
power before the optional
isolator at the PA output port.

Station is in receive mode.

1. No RF input to PA. Check
connection between PA and
TX

2. Check the logic or DC inputs to
the PA from the Interface
Board through J201.

a. J201-2 PA KEY 5volts during transmit

b. J201-3 POWER SET

c. J201-6 13.8 VF

3. Defective PA Replace PA

1. Low RF input to PA from TX
Synthesizer.

2. Check the voltage on J201­3(POWER SET).

3. Check the power supply
voltage on the collector of Q1,
Q2 and Q3

4. One of the two final PA
transistors (Q2 or Q3) is
defective.

Check for over temperature
and/or a high VSWR condition
due to a mismatch at the
output port.

The presence of power at this port
is an indication of a defective
duplexer, switch, or cables.

The presence of power at this port
is an indication of a defective filter
or cables.

The presence of power at this port
is an indication of a defective
isolator or cables.

TX Synthesizer should deliver a
minimum of 10 Mw

4 volts to 8 volts (4 volts
represents zero RF power)

13.8 Vdc ±20%

Power should be a minimum of 10
mW (10 dBm).

For minimal output power, this
voltage should be above 7 volts.

Voltage should be minimal 13.4
Vdc.

Replace the defective transistor.

The power control circuit protects
the PA by cutting back the power.
In case of a mismatch, refer to
symptom 1.

10 LBI-38674L

TROUBLESHOOTING

Table 1 - UHF Power Amplifier Voltage Chart

PARAMETER

(50 ohm, -30°C to +60°C)

SUPPLY VOLTAGE A+ 13.4 V ±20%

CONTROL VOLTAGE Vct1 0 - 12 V

FORWARD VOLTAGE Vf 3 - 7 V

REVERSE VOLTAGE Vr 2 - 6 V

POWER SENSE J201-1 2.5 - 4 V

PA KEY J201-2 5 V

POWER SET J201-3 4 - 8 V

13.8 VF J201-6 13.8 V ±20%

REFERENCE

SYMBOL

READINGS

(Volts DC)

Table 2 - UHF Power Amplifier Typical Voltage Readings

(50 Ohm, Room Temperature, 13.4 Vdc Supply Voltage, and Rated Output)

Frequency

Group Low Mid High

G3 450 MHz 460 MHz 470 MHz

G6 403 MHz 414 MHz 425 MHz

G7 425 MHz 437 MHz 450 MHz

G8 380 MHz 390 MHz 400 MHz

G9 470 MHz 482 MHz 494 MHz

Vct (Volts DC)

Vf (Volts DC)

G10 492 MHz 502 MHz 512 MHz

G11 410 MHz 420 MHz 430 MHz

G3 7 - 10 Volts 6 - 8 Volts 4 - 6 Volts

G6 6 - 8 Volts 6 - 8 Volts 6 - 8 Volts

G7 6 - 8 Volts 6 - 8 Volts 6 - 8 Volts

G8 6 - 8 Volts 6 - 8 Volts 6 - 8 Volts

G9 & G10 6 - 8 Volts 6 - 8 Volts 6 - 8 Volts

G11 6 - 8 Volts 6 - 8 Volts 6 - 8 Volts

G3 5 - 7 Volts 5 - 7 Volts 5 - 7 Volts

G6 6 - 8 Volts 6 - 8 Volts 6 - 8 Volts

G7 6 - 8 Volts 6 - 8 Volts 6 - 8 Volts

G8 6 - 8 Volts 6 - 8 Volts 6 - 8 Volts

G9 & G10 6 - 8 Volts 6 - 8 Volts 6 - 8 Volts

G11 6 - 8 Volts 6 - 8 Volts 6 - 8 Volts

Continued

LBI-38674L 11