Technalogix TAUD-40, TAV-25 User Manual

TAUD-40

POWER AMPLIFIER

NEW

ADVENTURES

IN

BROADCASTING

Technalogix

You’ve already unpacked it, haven’t you? You’ve unpacked it and
plugged it in and turned it on and fiddled with the knobs. No?
Okay, good. Please take a few minutes to read the manual and
familiarize yourself with your new Technalogix power amplifier.

We believe that this manual, and of course our equipment, should
be everything you need to get on the air with superb broadcast
quality video. We understand that a capable and confident user
will get the most out of our product and we have made every
attempt to educate readers of all technical levels. If there is
something that is not clear, or you require further information,
please do not hesitate to contact us and we’ll be glad to help out.

Technalogix Ltd.
#4, 8021 Edgar Industrial Place
Red Deer, Alberta, Canada
T4P 3R3
Phone: [phone]
Fax: [phone]
URL: www.technalogix.ca
Email: [e-mail]

[e-mail]

We truly appreciate that you have chosen us as your television
broadcast system supplier. Happy viewing.

Table of Contents

SECTION I- SAFEGUARDS...............................................................................................I-1

SAFETY AND FIRST AID.....................................................................................................I-2

OPERATING SAFEGUARDS ................................................................................................I-3

SECTION II - WARRANTY ..............................................................................................II-1

SECTION III - OVERVIEW..............................................................................................III-1

STANDARD FEATURES....................................................................................................III-1

PRINCIPLE OF OPERATION..............................................................................................III-2

BLOCK DIAGRAM.............................................................................................................III-3

SPECIFICATIONS..............................................................................................................III-5

SECTION IV - RF COMPONENTS................................................................................ IV-1

AMPLIFIER PALLETS....................................................................................................... IV-1

DIRECTIONAL COUPLER.................................................................................................IV-4

I SOLATOR .......................................................................................................................IV-4

FILTER............................................................................................................................ IV-4

SECTION V - POWER SUPPLY SECTION......................................................................V-1

SECTION VI - MONITOR AND CONTROL SYSTEM....................................................... VI-1

CONTROL BOARD OVERVIEW (INSIGHT)........................................................................VI-1

USER I NTERFACE MODULE............................................................................................VI-1

COUPLER CONDITIONING MODULE ................................................................................ VI-2

RF CONDITIONING MODULE ..........................................................................................VI-3

TEMPERATURE SENSOR MODULE................................................................................. VI-4

TXNET MODULE.............................................................................................................. VI-5

REMOTE PORT...............................................................................................................VI-6

FAULT SHUTDOWN.........................................................................................................VI-7

BILL OF MATERIALS....................................................................................................... VI-8

SCHEMATICS ................................................................................................................VI-10

SECTION VII - MECHANICAL SECTION......................................................................VII-1

SECTION VIII - INSTALLATION..................................................................................VIII-1

BUILDING RECOMMENDATIONS....................................................................................VIII-1

HEATING AND COOLING REQUIREMENTS ....................................................................VIII-2

ELECTRICAL SERVICE RECOMMENDATIONS................................................................VIII-3

ANTENNA AND TOWER RECOMMENDATIONS...............................................................VIII-4

SHELTER SECURITY .....................................................................................................VIII-5

UNPACKING AND I NSPECTION......................................................................................VIII-6

LOCATION AND FUNCTION OF CONTROLS AND CONNECTORS (TAV-100 POWER

AMPLIFIERS).................................................................................................................VIII-7

INITIAL HOOK UP........................................................................................................VIII-11

SECTION IX - OPERATING PROCEDURE ..................................................................... IX-1

SECTION X - MAINTENANCE AND TROUBLESHOOTING...............................................X-1

TROUBLESHOOTING ........................................................................................................X-2

Section I - Safeguards

General Safeguards

This section is written as a general guide to keep all 5 fingers on your hand and is intended for those having
previous knowledge and experience with these kinds of equipment. It is not intended to contain a complete
statement of all safety precautions, which should be observed by personnel using this or other electronic
equipment.

DOCUMENTATION - Read, retain and follow instructions before operating the equipment. There is a
lot of useful information in the manual, and besides, we spent a lot of time writing it!

ENVIRONMENT - To reduce the risk of fire or electric shock, do not expose this equipment to rain,
moisture, or rye and sodas at the company Christmas party. Refer all servicing to qualified service
personnel.

SERVICING - Do not attempt to service this equipment yourself as opening or removing covers can
result in a warm tingly feeling and will void the warranty. Refer all servicing to qualified service
personnel.

I-1

Safety and First Aid

Personnel engaged in the installation, operation, maintenance, or servicing of electronic equipment are exposed
to the hazard of high voltage. It is imperative that all safety regulations and precautions are consistently
observ ed. Knowledge of first aid procedures is recommended. The following information is presented as a
reference only.

• At all times, avoid placing any part of the body in series between ground and circuit points, whether power is
on or off.

• Dangerous voltage may be present in equipment even though power is off. Do not open the cabinet. Refer
servicing to qualified service personnel.

• It is the duty of all personnel to be prepared to give adequate emergency first aid treatment and thereby
prevent avoidable loss of life.

• There are three principle degrees of burns, recognizable as follows:

• a first-degree burn reddens the skin.

• a second-degree burn blisters the skin.

• a third degree burn chars the flesh and frequently places the victim in a state of shock accompanied

by respiratory paralysis.

• Respiratory paralysis can cause death by suffocation within seconds. It is imperative that the approved
methods of artificial respiration are initiated immediately and continue until the victim’s breathing is normal.

• A muscular spasm of unconsciousness may render the victim unable to break free of the electric power. If
this is the case, turn the power off immediately.

DO NOT TOUCH THE VICTIM OR YOU MAY SHARE THE SAME PREDICAMENT.

• If the power cannot be turned off immediately, very carefully loop a dry rope, article of clothing, length of
strong cloth or a rolled-up newspaper around the victim and pull the victim free of the power source.
Carefully avoid touching the victim or clothing.

• Once free of the power source, the victim must be placed in a reclining position and covered with a
blanket or newspapers to keep warm. At the first opportunity, enlist help in summoning a doctor. If a
doctor cannot be summoned, transport the victim to the doctor or a hospital. Be sure the victim is kept
well covered and warm while awaiting professional treatment.

I-2

Operating Safeguards

It is a known fact that our broadcast transmitters and translators enjoy 50-ohm load impedances. So much
so, that it is imperative you maintain 50-ohm impedances throughout your system. In return, your equipment
will provide you with maximum power transfer to the antenna and decreased reflected power heading back
towards the amplifier pallets, reducing the amount of magic smoke that gets let out of the power amplifier.
Before anything is turned on, ensure that there is a 50-ohm path from the output of each stage to the input
of the next, all the way to the antenna.

In addition to maintaining proper 50-ohm impedances throughout the signal chain, it is also important,
whenever possible, to make sure the RF drive going to the input of the power amplifier is removed before
turning on or turning off the DC power supply. This is because all of the RF transistors used in the individual
amplifier pallets are fabricated with LDMOS (Laterally Diffused Metal Oxide Semiconductor) technology.
Nice and linear yes, but they do not like to make any RF power when their supply voltages are not within a
specific range. When you first turn your power amplifier on or off, the DC power supply’s output voltage may
take a while to stable out to a safe operating voltage. Ten seconds wait before applying the RF drive will
ensure no issues arise.

Our power amplifiers are designed to reliably generate a specific RF output power. Failing to adhere to
overdriven amplifier warnings can decrease the reliability of your system, and frankly, makes our repair
department busy and grumpy. If you need to transmit to a little larger coverage, you are better off increasing
antenna gain, and more importantly, antenna height above average terrain. On TV and FM broadcast
frequencies, insufficient antenna height puts an upper limit on your range, regardless of power levels, as the
distance from your antenna to the radio horizon is limited.

I-3

Section II - Warranty

Our legalese is straightforward. It is simply designed to give you peace of mind and helps you resist the
temptation to have your electronics friend try to repair your Technalogix product.

Technalogix Ltd. products have been completely tested and found to meet specifications and be in
proper operating condition. They are warranted to be free from defects in materials and workmanship
for a period of one year from the date of shipment. If the system becomes damaged in shipment and
there are obvious signs of damage to the outside of the packaging, notify your courier immediately
before that courier walks out the door.

Technalogix Ltd. will not be liable for damages of whatever nature arising out of or in connection with
the equipment or its use thereof. Technalogix does not assume responsibility for injury or damage
resulting from the practices of untrained or unqualified personnel in the handling of this equipment.

Technalogix Ltd. warranty does not include:

• misuse, neglect or accident.

• incorrect wiring and /or improper installation.

• unauthorized repairs, modifications or use in violation of instructions issued by Technalogix.

• incidental or consequential damages as a result of any defect.

• reshipment cost or insurance of the unit or replacement units or parts.

• acts of nature or terrorism.

Technalogix agrees, at our option, to remedy warranted defects or furnish a new part in exchange for
any part of a unit which, under normal installation, use and service, becomes defective. The user will
pay for transportation costs to and from the repair center. If you require technical service on the site,
the cost to you will be $800.00 per day plus air fare and meals.

II-1

To claim your rights under this warranty:

• Contact Technalogix and describe the problem in as much detail as possible. See troubleshooting
section in this manual. If a solution cannot be found at this time, it may be determined that the unit
will have to be returned to Technalogix for repair, once a Return Materials Authorization (RMA)
number is provided. Please look under our web site (www.technalogix.ca) for the RMA form
(Service) and fill it out. Either fax it to us or email to us.

• Package equipment carefully for prepaid shipment to Technalogix. Include a written description of
the problem experienced, a copy of the original invoice establishing warranty status, and the RMA.

Technalogix reserves the right to make revisions in current production of the equipment and assumes
no obligation to incorporate these changes in earlier models.

Shipping Address:
Technalogix Ltd.

ATTN: RMA#
#4, 8021 Edgar Industrial Place
Red Deer, Alberta, Canada
T4P 3R3
Ph: 403.347.5400
Made in Canada, returned for repairs

II-2

Section III - Overview

Standard Features

• No sync compression to ensure power amplifier is digital compatible

• Narrow output bandpass filter allows adjacent channel operation

• Front panel Liquid Crystal Display (LCD) to monitor forward and reflected RF power, and DC

voltage

• Microcontroller-based monitoring and control ensures amplifier will never be overdriven and high
VSWR will not damage amplifier

• AC circuit breaker on back panel to eliminate replacement of fuses

• RF/EMI filtering on AC entry plug

• All aluminium enclosure maintains power amplifier’s light weight

• Simple design using commonly available parts ensures reliable operation

• Predominate and third-order intermodulation distortion exceeds Industry Canada and FCC

specification.

III-1

Principle of Operation

The TAUD-40 power amplifier supplies a 130-watt P1dB peak video signal with an aural carrier level
10 to 13 dB below visual carrier (dBc) on any of the UHF television channels 14 through 69. Please
note that channel selection must be made at time of order, as the transmitter or translator is calibrated
and tested to the channel requested and is not field tuneable. The TAUD-40 power amplifier is a
modular solid-state 100-watt broadcast amplifier utilizing readily available RF components wherever
possible, thus enhancing the serviceability of the equipment.

The TAUD-40 is comprised of a UHFTV-10 driver and a UHFTV-150 final amplifier. The unique zero
sync compression technology ensures digital ready operation.

The TAUD-40 features ultra linear amplification and individual channel RF output bandpass filtering.
The amplifier modules are stable for high reliability and long service life.

III-2

Block Diagram

The RF signal enters through the RF Input connector on the power amplifier enclosure from the
modulator or processor. It then passes through an RF attenuator to limit the output power level of
the power amplifier and to help buffer any transients that may come into the power amplifier. After
attenuation, the signal is amplified through the UHFTV-10 driver and UHFTV-150 final pallet before
the signal passes through an isolator (circulator with load) and a bandpass filter. Finally, the
amplified signal passes through a dual directional coupler for monitoring purposes. After the
directional coupler, the signal exits the power amplifier enclosure before heading out to an antenna
for broadcast.

III-3

A=-0.4dB to -0.6dB

TO WATTMETER
AND ANTENNA

A=-0.05dB typ.

A=-0.4dB typ.

Attenuator

Adjustable A=+38dB min
to +49 dB max

UHFTV-150

V

CIRCULATOR

RF OUT

UHFTV-10

RF INPUT

V

V

COUPLER

DIRECTIONAL

Bandpass Filter

TERMINATION

50-OHM

TAUD-40 Block Diagram

Date: June 27, 2005 Page: 1 of 1

Rev ID

TAUD Series

Transmission Performance 1

Adjustable

Gain
TAUD-10 38 dB 35 W 35 W 13 W min 7 W min 6 W min 6 W min
TAUD-20 38-49 dB 70 W 65 W 23 W min 13 W min 12 W min 12 W min
TAUD-40 38-49 dB 130 W 125 W 45 W min 26 W min 23 W min 23 W min
TAUD-80 50-61 dB 300 W 250 W 89 W min 53 W min 47 W min 45 W min

* The data modulation power levels take into account worst case trajectory overshoot and peak to average ratio.

Actual power output level may be higher.

VSWR protected RF output into open (internal isolator installed)
Input Return Loss min -16dB
Output Return Loss min -18dB
Spurious Emissions >60dBc
Harmonic Suppression >60dBc
Intermodulation Products >53dBc (red field, aural carrier inserted, no pre-correction)

P1dB

Minimum

Electrical Characteristics

Simple RF Connectivity BNC for RF Input and test point, N for RF output
Universal AC Input 88-264Vac, 47-63 Hz

EMI Filtered max AC Power TAUD-10 3.6Aac at 115Vac, 1.8Aac at 230Vac at 25W ps
TAUD-20 4Aac at 115Vac, 2Aac at 230Vac at 50W ps
TAUD-40 7Aac at 115Vac, 3.5Aac at 230Vac (TAUD-40) at 100W ps
TAUD-80 6Aac at 230Vac at 250W ps

TAUD Series Issue 1.02 September 29, 2005

digital power amplifiers

• Liquid Crystal Display Front
panel monitoring

• Internal Bandpass filter

• Remote monitoring 25-pin

interface Connection

• Internal RF isolator
protection

• 2-Stage amplification

• Class A Driver, Class A/B

Final

• Made in North America

Peak Sync

Output

Output *

QPSK

16-QAM
Output *

64-QAM
Output *

Page 1 of 2

256-QAM

Output *

TAUD Series

5W

RF INPUT

RF OUT

PUT RF

50W

BANDPASS

RF

digital power amplifiers

Physical Characteristics

Lightweight Enclosure 40 lbs (TAUD-10, TAUD-20), 45 lbs (TAUD-40), 50 lbs (TAUD-80)
Minimal rack space 3U (TAUD-10, TAUD-20, TAUD-40), 5U (TAUD-80)
Operating temperature 0 to +45°C
Humidity 90% non-condensing
Built in components UHF bandpass filter and RF isolator included

1

Due to continuous product improvements, Technalogix reserves the right to change specifications without notice.

Internal View

Typical Block Diagram

CONDITIONING

TAUD Series Issue 1.02 September 29, 2005

DRIVER

FINAL

ISOLATOR

FILTER

Page 2 of 2

Section IV – RF Components

Amplifier Pallets

The UHFTV -10 pallet is a two stage ultra linear class-A linear pallet. It has an adjustable gain of 26dB
to 37dBand draws no more than 5.o Adc total drain current (the exact bias and drain currents of your
system are found in the spec sheet supplied with each manual). The quiescent and drain currents can
be measured on the UHFTV-10 pallet by measuring the voltage drop across the current sense resistor
found directly at the DC pow er supply lead input to the pallet. This resistance is 0.01-ohms, providing a
10mV per ampere ratio.

The UHFTV -150 pallet used in the driver and final amplification stages use LDMOS (Laterally Diffused
Metal Oxide Semiconductor) technology. LDMOS technology offers higher gain, efficiency and linearity
over standard MOSFET and Bipolar devices. LDMOS transistors have the added advantage of not
having BEO (Beryllium Oxide) in their construction. The UHFTV -150 amplifier pallets have a typical
gain of 13 dB and draw no more than 14Adc (again, the exact bias and drain currents of your system
are found in the spec sheet supplied with each manual). Currents for these pallets must be measured
with an ammeter in series with the power supply lead. Temperature compensated biasing helps ensure
steady operating levels over wide temperature ranges.

Each of the amplifier pallets is connectorized. All amplifier pallets must have the transistor drain
voltages reach at least 26Vdc before the RF drive is applied.

IV-1

Isolator

The power amplifier pallets are protected in part by the isolator located in the filter enclosure. It is
actually made up of a circulator and 50-ohm dump resistor. The circulators’ specifications include an
insertion loss of less than 0.2dB with an isolation rating better than 20dB. Any reflected power gets
dumped into the flanged power resistor. This way, there is instantaneous protection due to the isolator
setup and long term protection due to the software.

Filter

The passive bandpass filter rejects spurious and harmonic output products and passes the UHF
channel RF output. The cavity resonator uses aperture coupling. Typical insertion loss is 0.3 dB to 0.6
dB depending on channel frequency. Average roll off is –33 dBc at a point 4.5 MHz below the peak
visual carrier frequency and –30 dBc 9.0 MHz above the peak visual carrier frequency. The filter is DC
grounded on both the input and output for additional lightning protection.

Directional Coupler

The Technalogix dual directional couplers provide DC voltages proportional to forward and reflected
RF power monitoring. These analog voltages are converted for processing using analog-to-digital
converters and provide the control system with valuable data for monitoring purposes. The directional
couplers installed in the power amplifier and filter enclosures have peak detection circuits on the
forward RF power side of the coupler and average detection circuits on the reflected RF power side of
the coupler. This is to allow the end user to set power in a ma nner that is more independent of
modulation and closer to a true tip-of-sync meter. Hence the readings of the displays in the power
amplifier system are peak for forward and average for reflected. Output power should be set following
the operating procedure found elsewhere in this manual. The directional coupler has a typical
insertion loss of 0.5dB and its Type N connectors can handle 1,500 watts peak.

IV-4

Section V – Power Supply

Switching AC-DC power supplies are used to power the amplifier pallets, the control circuits, and all of
the fans. There is (1) power supply used to generate the necessary current for the amplifier pallets, set
to 31.0 Vdc nominally.

The power supply is a Lambda SWS600-36. This switching power supply is fully protected against
short circuit and output overload. Short circuit protection is a cycling type power limit. The internal AC
fuse is designed to blow only on a catastrophic failure in the unit – the fuse does not blow on overload
or short circuit. The thermal shutdown automatically recovers when the power supply chassis cools
down.

AC is fed into the enclosure via a filtered EMI AC entry. It is then current limited with a resettable circuit
breaker before passing through a rocker switch. This switch turns the AC on and off to the switching
power supply.

V-1

SWS300/600 Series

3055 Del Sol Blvd • San Diego, CA 92154 • 1-800-LAMBDA-4

 Meets IEC61000-4  Greater reliability
 Global safety Approvals  Supports Global Use
 Power Factor Corrected  Supports Global Use
 Level B EMI  Assists System Compliance

Feature Benefit

Factory Automation Process Control, NC-Machining,

Automotive, Packaging Equipment,
Materials Handling,
Chemical Processing, Robots

Test & Measurement Burn-in & Test, Automated, Detection

Test, Instrumentation, Measurement

Automated Service Vending Machines, Elevators,

Video Gaming, Point of Sale Equipment

 Low Cost
 Active Power Factor Correction
 Universal Input (85 - 265VAC)
 Input Transient Protected IEC61000-4
 SEMI F47 Certified (208VAC Input)

Key Market Segments & Applications

SWS Features and Benefits

Single Output General Purpose Power Supplies

MODEL SWS300 SWS600
ITEMS
Input Voltage range (1) - 85 - 265VAC (47 - 63Hz) or 120 - 370VDC
Inrush Current (115 / 230VAC) A 20 / 40
Power Factor - Meets EN61000-3-2
Input Current (100/200VAC) A 3.6 / 1.8A 7.2 / 3.6A
Temperature Coefficient - <0.02%/°C
Overcurrent Protection -- >105%, Constant current style
Overvoltage Protection V 3.3V: 4.1-5.3V, 5V: 6.25-7.25V, 12V: 13.8-16.8V

15V: 18.7-22.5V, 24V: 30-34.8V, 36V: 41.4-50.4V, 48V: 60-69.6V
Overtemperature Protection - Yes, cycle AC to reset
Hold Up Time (Typ) ms 20ms at 115/230VAC
Leakage Current (max) mA SWS300: 0.75mA , SWS600: 1.5mA
Remote Sense - None Yes
Parallel Connection - None Yes
Remote On/Off - None Yes, >4.5V to shutdown
Power Fail Signal - None Yes, open collector output
LED Indicator - Green LED = On
Operating Temperature - -10 to +65°C (See table for derating - model specific)
Storage Temperature °C -30 to +85°C
Humidity (non-condensing) - 30 - 90% RH operating, 10 - 95%RH non operating
Cooling - Internal fan
Withstand Voltage - I/P to Grnd 2kVAC, I/P to O/P 3kVAC, O/P to Grnd 500VAC, O/P to CNT 100VAC for 1 min
Isolation Resistance - >100M at 25C & 70%RH, Output to Ground 500VDC
Vibration (non operating) - 10 - 55Hz (sweep for 1 min)19.6m/s

2

constant X, Y, Z 1 hour each plane)
Immunity - EN61000-4-2, -3, -4, -5, -6, -8, -11
Safety Agency Approvals - UL60950, CSA60950, EN60950, EN50178, CE Mark, SEMI F47 (208VAC)
Conducted & Radiated EMI - EN55011 / EN55022-B, FCC Class B
Recommended EMI Filter - MC1206 MC1210
Weight (Typ) g 950 2000
Size (WxHxD) in 2.05 x 4.01 x 7.8" 3.62 x 4.72 x 7.48"
Warranty yrs Two Years

Specifications

Notes: (1) Derate linearly to 85% load from 115VAC to 85VAC input (derate to 90% load for SWS600-3 & -5)

SWS300/600 Series

3055 Del Sol Blvd • San Diego, CA 92154 • 1-800-LAMBDA-4

Revision A4: Mar 2005

RWS 15W & 30W Single Output, High Reliability
JWS, JWS-P & JWT 50-600W Single & Triple Output, High Reliability
SWS 50-150W Single Output
ZWS 5-240W PCB style Single Output

Other Lambda Industrial Products

SWS300 100% 91.6% 83.3% 50%
SWS600 100% 85% 70% 55%

Additional derating required when operating SWS600 with side
ventilation holes blocked - see installation manual.

Model 50°C 55°C 60°C 65°C

Derating

/CO2 Double sided conformal coating

Suffix Descriptor

Options

-V

AC(N)

FG( )

AC(L)

-V

-V

+V

+V

+V

60¡0.524

150¡0.5 21.5

SEE NOTE B

198¡1

13MAX

SEE NOTE B

6.5 30¡0.5

52¡1

16155¡0.5

(12.1)

15

(19.6)

(8.5)

9.5 8.2

(95)

H D K

102¡1

TERMINAL COVER

SEE NOTE A

VR FOR Vadj.

LED

9-M3.5

(18.1)

INPUT: 100-240VAC ~ 4.4A

50/60Hz

N

L

-V-V-V

MADE IN CHINA

OUTPUT: 5 V 55 A

+V +V+V

H

V ADJ

BAR CODE

SWS300- 5

SWS300 Outline Drawing

SEE NOTE "C"

(Tapped at the bottom chassis)

(Tapped on both sides)

SEE NOTE "C"

SEE NOTE "C"

(Tapped on both sides)

NAME

PLATE

Hole at the opposite chassis

++

+

NAME

PLATE

150¡0.5

70¡0.5

120¡1

7-M3.5

92¡1

8-M4

50¡0.5

21

(21)

(25)

25

(20)

20

10

100¡0.5

190¡1

(10)

(20)

150¡0.5

20

5MAX

AIR FLOW

21

34

11

9.5

21MAX

15MAX

(72)

7.5

10

(73)

(16.5)

9.0

8.2

( )

TOG

PC

PF

CNT

N

L
AC

-S

+S

- -

H

V.ADJ

ON

SWS600 Outline Drawing

Model Selector

SWS300-3 3.3V 2.97-3.96V 55 40 20 120 67/70
SWS300-5 5V 4.5-6V 55 40 20 120 75/78
SWS300-12 12V 9.6-13.2 26 96 48 120 77/80
SWS300-15 15V 13.2-18V 21 120 48 120 79/83
SWS300-24 24V 20-28.8 13 120 48 150 80/84
SWS300-36 36V 28.8-40V 8.7A 180 72 200 82/85
SWS300-48 48V 40-57.6 6.7 240 96 240 82/85
SWS600-3 3.3V 2.97-3.96V 100 (2) 40 20 100 69/71
SWS600-5 5V 4.5-6V 100 (2) 40 20 100 74/77
SWS600-12 12V 9.6-13.2 50 96 48 120 78/81
SWS600-15 15V 13.2-18V 40 120 48 120 80/83
SWS600-24 24V 20-28.8 25 120 48 150 81/84
SWS600-36 36V 28.8-40V 16.7 180 72 200 81/85
SWS600-48 48V 40-57.6 12.5 240 96 240 82/85

Max Load Line Ripple

Adjust Curr. Reg Reg Noise Eff.(3)

Model Voltage Range (A) (mV) (mV) (mV) (typ)%

Notes:

(2) Peak rating of 120A for 10s
(3) 115/230VAC

For Additional Information, please visit

www.lambdapower.com/products/sws-series.htm

Section VI – Monitor and Control System

Control System Overview (Insight)

The Insight control system is used for a variety of functions, the most important of which is ensuring
that the transmitter continues to operate in a safe manner. The control system also allows the user
to monitor and control the transmitter from both the front panel and the remote access port.

Five modules comprise the Insight control system. These modules work together to provide all the
functions of the control system. The modules are: the user interface module, the coupler condition
module, the RF conditioning module, the temperature sensor module, and the TxNET module. The
operation of each module is outlined in the following sections.

User Interface Module
The primary function of the user interface module is, as the name suggests, providing the user

interface for the control system. This circuit board is mounted to the front panel of the transmitter,
directly behind the LCD display. The membrane switch on the front panel is also connected to the
user interface module. These components together provide the user with the ability to monitor the
transmitter from the front panel.

The following parameters can be monitored from the front panel:

• Forward (incident) power at the transmitter output.

• Reflected (reverse) power at the transmitter output.

• DC voltage of the transmitter power supply.

• DC current for each pallet in the transmitter.

• Temperature of the heat sink of the transmitter.

• The time since the transmitter was last shut down.

The hardware of the user interface module is based around a microcontroller (U112). This
microcontroller interfaces directly with the LCD and the membrane switch to provide output and
receive input from the user. The microcontroller also communicates with the coupler conditioning
board over a controller area network (CAN) bus. This communication is facilitated be two ICs, U113
and U114, and passes through a CAT5 cable attached to connector J105. The communication link
with the coupler conditioning module allows the user interface module to receive information about
the foreword power, reflected power, and temperature of the transmitter, as well as relay
commands from the user to the rest of the system. If the transmitter includes more than on
amplifier module, a second CAN connection will be present between the user interface module
(J106) and the TxNET board to facilitate communication between enclosures.

Other elements of the user interface module are also controlled by the microcontroller. A buzzer
(BZ101), a status LED (D113), and a relay to control the backlight of the LCD (RL101), are all
controlled through a buffer (U116). In order for the user interface module to monitor the current
draw of each pallet in the system, the DC supply wires pass through the user interface module on
their way from the power supply to the pallets. The DC enters through connector J101 from the
power supply, and exits through J102 to go to the pallets. As the current passes through shunt
resistors (R117, R118, R120, R121, R123, R124, R126, R127, R129, R130), the voltage drop is

VI -1

monitored by U101 to U105, buffered by U106 to U108, and sent to the analog to digital converter
integrated into the microcontroller. There are five circuits for which the current is monitored by this
system.

As the DC supply passes through the user interface module, it undergoes filtering to ensure that
the supply to the pallets is as clean as possible. Each of the five circuits passes through a network
of transient voltage suppressors, capacitors, and inductors. Each connection is also fused at the
input to insure an over-current condition does not persist. The fuses are a replaceable mini blade
type fuse with a 42V voltage rating, and a current rating depending on application.

Coupler Conditioning Module
The coupler conditioning module serves to monitor the output of the directional coupler which

provides a voltage proportional to the foreword and reflected power at the output of the transmitter.
The coupler conditioning module also interfaces with each of the other boards in the control
system, acting as the hub of communications for the system. Lastly, the coupler conditioning board
sends and receives signals through the remote access port, via the TxNET board.

The analog signals produced by the coupler for forward and reflected power are passed onto the
coupler conditioning module by connectors J206 and J207 respectively. Each signal is filtered by
CLC networks, and buffered and amplified by the op-amp U214. The level of the forward signal
can be adjusted by VR201, and the reflected signal by VR202. These two potentiometers can be
used to fine tune the power readings of the transmitter if they go out of calibration. The analog
signals are converted to digital by an analog-to-digital converter integrated into the microcontroller
U202.

Aside from taking readings from the coupler, the microcontroller on the coupler conditioning
module also interfaces with the RF conditioning module (through J201A) and the temperature
sensor (through J201B). The microcontroller interfaces with the CAN bus using U203 and U204.
Through the CAN bus, the coupler conditioning board is able to communicate with the user
interface module, and any other amplifiers that are in the system. The CAN bus is connected
through J201C, and J201D if there are multiple amplifiers in the transmitter system.

The last task of the coupler conditioning board is to send and receive remote access signals to and
from the TxNET board. Two analog outputs, proportional to forward and reflected power and
produced by the digital-to-analog converter U212 after it receives input from the microcontroller.
The analog outputs are then buffered by U211 before being sent through J203 to the TxNET
board. J203, along with J204, also bring the digital inputs and outputs from the TxNET board to the
coupler conditioning module. The digital signals are then connected to the microcontroller through
the opto-isolators U205, U206, U207, U208, and U209.

VI -2

RF Conditioning Module

The RF conditioning board is located at the RF input of the amplifier. Its main function is to act as
a variable attenuator, so that the control system can add attenuation to the input of the amplifier in
order to limit the output power of the transmitter. The RF signal comes in to the RF conditioning
module through J302 before it passes through a manually variable attenuator made up of R305,
VR303, and R307. The signal then passes through the digitally-controlled variable attenuator
U302 before exiting through J303. The input for the digital attenuator comes from the coupler
conditioning module through J304. The input signals are passed through the opto-isolators U303,
U304, and U305 before being sent to the digital attenuator. In total, five control signals go to the
digital attenuator, allowing for attenuations of up to 31dB in 1dB steps.

Temperature Sensor Module

The temperature sensor module is a small board mounted to the main heatsink of the amplifier.
The main purpose of the temperature sensor module is to take temperature readings of the
heatsink. The temperature sensor IC is U1 which, after it has taken a reading, relays the digital
information to the coupler conditioning module through J1. Also passing through J1 is a driver
disable signal coming from the coupler conditioning module. The temperature sensor module
simply takes this signal and passes it through to J2, where it is connected to the driver pallet.

TxNET module

The TxNET module is simply a passive board that acts as an interface between the wiring on the
inside of the amplifier enclosure and connections on the outside of the enclosure. The DB-25
connector for the remote port (J602) is attached to the TxNET module. The signals travelling
through this port are connected to the coupler conditioning module through J601 and J603. The
TxNET module also includes up to four straight through RJ45 connections: J604 to J605, J606 to
J607, J608 to J609, and J610 to J611. These connections are only used on systems with multiple
enclosures, to pass control signals between enclosures.

VI -3

Remote Port

The remote port allows external control of the transmission system via the DB25. The functions of
each pin on the remote port are indicated in the following table:

Pin Number Description

1 Ground
2 Forward power sample1
3 Reflected power sample1
4 Carrier off2
5 Carrier on2
6 Increase carrier level (level must have been decreased) 2
7 Decrease carrier level (1dB increments) 2
8 Soft reset2

9 Reset2
10 Power supply fault flag3
11 High temperature flag3
12 High VSWR flag3
13 Amplifier overdriven flag3
14 +5Vdc
15 +3.3Vdc
16 Ground
17 Ground
18 N/C
19 N/C
20 N/C
21 N/C
22 N/C
23 N/C
24 N/C
25 N/C

Notes: 1. Analog output with voltage ranging from 0 to 5Vdc.

2. TTL level digital input, active on rising edge.

3. TTL level digital output, active high.

VI -4

Fault Shutdowns

On the LCD (Liquid Crystal Display) the following messages may appear:

If you see this message, the system has been driven to a power level higher than it is rated for.
This message will likely only appear momentarily, before the amplifier will add attenuation at its
input to bring the output power to a safe level.

This message indicates that excessive reflected power has been detected at the output of the
transmitter. Periodically, the amplifier will cycle on, and re-check for reflected power. If high
reflected power continues, the transmitter will eventually shut down completely.

This message indicates that the transmitter is experiencing unsafe internal temperatures. Output
power is reduced until a safe temperature is reached.

VI -5

Monitor and Control System (Insight) Bills of Materials

Circuit: User Interface Module

Revision: 1.03

Designations Qty Description Package Manufacturer Mfg. Part Number

U112 1

C106, C107, C117,
C118, C128, C129,
C141, C142, C148,

C149, C163 11 CAPACITOR 0.01 uF 50V 10% 0805 Yageo 08052R103K9B20D

C108-116, C119-

127, C130-140,

C143-145, C161 33 CAPACITOR 0.1uF 50V 10% 0805 Yageo 08052R104K8B20D

C146, C147 2 CAPACITOR 33pF 50V 5% 0805 Panasonic ECJ-2VC1H330J

R101, R104, R107

R110, R113 5 RESISTOR 2.7K? 0805 Yageo 9C08052A2701FKHFT

C162 1 CAPACITOR 1uF, 50V 0805 TDK Corporation C2012Y5V1H105Z
R132 1 RESISTOR 37.4K? 0805 Yageo 9C08052A3742FKHFT
R133 1 RESISTOR 3.3K? 0805 Yageo 9C08052A3301FKHFT

R134, R135, R136,

R137, R138, R139 6 RESISTOR 249K? 0805 Yageo 9C08052A2493FKHFT
R140, R141, R144

R145, R146, R147
R150, R151, R156 9 RESISTOR 10K? 0805 Yageo 9C08052A1002FKHFT

R142, R143, R148
R149, R154, R155 6 RESISTOR 1K? 0805 Yageo 9C08052A1001FKHFT

R152 1 RESISTOR 100? 0805 Yageo 9C08052A1000FKHFT

R119, R122, R125,

R128, R131, R153 6 RESISTOR 100K? 0805 Yageo 9C08052A1003FKHFT

R158 1 RESISTOR 430? 0805 Yageo 9C08052A4300FKHFT
R160 1 RESISTOR 1.4K? 0805 Yageo 9C08052A1401FKHFT
R161 1 RESISTOR 27K? 0805 Yageo 9C08052A2702FKHFT
R162 1 RESISTOR 6.2K? 0805 Yageo 9C08052A6201FKHFT

R157 1 RESISTOR 4.7? 2010 Panasonic ERJ-12ZYJ4R7U
R117, R118, R120
R121, R123, R124
R126, R127, R129

R130 10 RESISTOR 0.006? 1% 1W 2512 Vishay WSL25126L000FEA

R159 1 POTENTIOMETER 10K? 4mm SMD Bourns 3314G-1-103E
R102, R103, R105
R106, R108, R109
R111, R112, R114

R115 10 RESISTOR 20? 1W 2512 Panasonic ERJ-1TYJ200U

RN101 1 RESISTOR NETWORK 10K? SMT Panasonic EXB-A10P103J

F107 1

F108 1

IC MICROCONTROLLER 256 BYTE
RAM 64QFP Texas Instruments MSP430F135IPM

RESETTABLE FUSE, POLYFUSE,
2A SMD Raychem MINISMDC200-2
RESETTABLE FUSE, POLYFUSE,
.5A SMD Raychem MINISMDC050-2

VI -6

L106, L107, L108,

L109, L110 5 INDUCTOR 0.01uH 1210 TDK NLV32T-010J-PF

Y101 1 6.00 MHz CRYSTAL SMT Citizen HCM49-6.00

U111 1 IC SUPERVISOR 2.70V LOW SOT23 Microchip Technology MCP130T-270I/TT

U114 1 IC TXRX 3.3V CAN 8-SOIC Texas Instruments SN65HVD232D

U113 1 IC CAN CONTROLLER W/SPI 18-SOIC Microchip Technology MCP2510-I/SO

U115 1 IC REG SIMPLE SWITCHER TO-263-5 National Semiconductor LM2576HVS-5.0

U116 1 IC DARL TRANS ARRAY 16-SOIC Texas Instruments ULN2003ADR

U117 1 IC REG LINEAR LDO SOT223 National Semiconductor LM1117MP-3.3

U118 1 IC VOLTAGE COMVERTER 8-SOIC National Semiconductor LM2660M

U109, U110 2 OPTOCOUPLER DUAL CHANNEL 8-SOIC Fairchild Semiconductor MOCD211M

U101, U102, U103

U104, U105 5 IC CURRENT MONITOR SOT23-5 Texas Instruments INA168NA
U106, U107, U108 3 IC OP AMP SINGLE SUPPLY 8-SOIC Texas Instruments OPA2340UA
D101, D103, D105

D107, D109, D111 6 DIODE TVS 30V D0214AA Crydom SMBJ30A
D102, D104, D106

D108, D110 D113,

D115, D117 8 DIODE LED GREEN 1206 Lumex SML-LX1206GC-TR

D114 1 DIODE SCHOTTKY SMC International Rectifier 30BQ060
D116 1 DIODE RECTIFIER 1A 200V SMA Diodes Inc. S1D-13
D118 1 DIODE SCHOTTKY 5A 50V SMC Diodes Inc. B550C-13 or B550C-13F
C152 1 CAPACITOR 10uF 16V TANTALUM 3528 Kemet T491B106K016AS

C156-160 5 CAPACITOR 22uF 35V TANTALUM D (SMT) Kemet T495D226K035ASE300

S101 1 SWITCH DIP 7 POSITION SMT 0.1" CTS 219-7MST
S102 1 HEADER 3POS 0.1" Through Hole AMP/Tyco 640452-3

RL101 1 RELAY SPST 5VDC SMT Omron G6L-1F-DC5

L101, L102, L103,

L104, L105 5 INDUCTOR 1.3uH SMT Panasonic ETQ-P6F1R3LFA

C153, C154, C155 3 CAPACITOR 100uF, 10V D (SMT) Panasonic ECE-V1AA101SP

U119 1 IC REG SIMPLE SWITCHER TO-263-7 Texas Instruments LM2679S-ADJ

C101, C102, C103,

C104, C105, C150 6 CAPACITOR 100uF 63V G (SMT) Panasonic ECE-V1JA101P

BZ101 1 BUZZER SMT CUI Inc. CT-1205C

J107 1 CONNECTOR 14POS HEADER Through Hole AMP/Tyco 103308-2
J108 1 CONNECTOR SCREW TERMINAL Through Hole Keystone 7701

J105,J106 2

F101, F102, F103,

F104, F105, F106 6

J103 1 CONNECTOR 5POS HEADER Through Hole AMP/Tyco 3-644695-5
J102 1 CONNECTOR, 2 PART 0.3" 10POS Through Hole Weiland 25.390.4053.0
J101 1 CONNECTOR 2 PART 0.3" 6POS Through Hole Weiland 25.390.3653.0
L111 1 INDUCTOR 150uH S6 Talema SWS-2.0-150
L112 1 INDUCTOR 33uH 5A 260kHz Through Hole Pulse P0849NL
J104 1 16 POST HEADER Through Hole Samtec TSW-116-18-T-S

C151 1 CAPACITOR 1000uF, 10V G (SMT) Panasonic ECE-V1AA102P

CONNECTOR MODULAR JACK 8
VERTICAL Through Hole AMP/Tyco 5556416-1

FUSE AND FUSE HOLDER 42V
MINI Through Hole Littelfuse

02970xx.WXNV and
01530008Z

VI -7

Circuit: Coupler Conditioning

Revision: 1.04

Designations Qty Description Package Manufacturer Mfg. Part Number

C201, C203, C204,
C205, C208, C209,
C212, C213, C214,
C215, C216, C217,
C218, C219, C220,
C221, C222, C223,
C224, C225, C226,

C227, C228, C229 24

C202 1

C206, C207 2

C210, C211 2

D201, D202 2

D203, D204 2 Diode, LED, red, 2.0V SMD 1206 Lumex SML-LX1206IW-TR

D205 1 Diode, rectifier, 200V, 1A SMA Diodes Inc. S1D-13
D206 1 Diode, zener, dual, 10V SOT -23 Diodes Inc. AZ23C10-7-F

J201 1

J202 1

J203, J204 2

J205 1

J206, J207 2

K201 1 Relay, SPST, 5Vdc coil, SMT SMT Omron G6L-1F-DC5
L201, L202, L203,
L204, L205, L206,
L207, L208, L209,

L210, L211, L212 12

R201 1

R203, R204, R207,
R208, R211, R212,
R213, R214, R217,
R218, R219, R220,
R221, R222, R223,

R224 16 Resistor, thick film, 5%, 1kohm, 1/8W SMD 0805 Panasonic ERJ-6GEYJ102V

R205, R206, R209,

R210, R215, R216 6

RN201, RN202,

RN204 3

RN203 1

S201 1 Switch, DIP, 7-position, SPST SMD 0.1" CTS 219-7MST

U201 1

Capacitor, ceramic, 0.01uF, 50Vdc,
+/-20% SMD 0805 Kemet C0805C103K5RACTU
Capacitor, ceramic, 0.1uF, 50Vdc,
+/-20% SMD 0805 Yageo America C0805C104M5UACTU
Capacitor, ceramic, 33pF, 50Vdc,
5% SMD 0805 Panasonic ECJ-2VC1H330J
Capacitor, electrolytic, 100uF, 10V,
+/-20% SMD 'D' Panasonic ECE-V1AA101SP
Diode, TVS, 5.0Vdc, 600W,
unidirectional SMB General Semiconductor SMBJ5.0A-13

Connector, modular, female, 4-port,
8-position, rt. angle Through Hole AMP/Tyco 557562-1
Connector, header, IDC, 0.1"
spacing, 14-pos Through Hole AMP/Tyco 103308-2
Connector, modular, female, 8­position, vertical Through Hole AMP/Tyco 5556416-1
Connector, header, 3-position, 0.1",
square post Through Hole AMP/Tyco 644695-3
Connector, header, vertical, 3-pos,

0.1" spacing Through Hole Molex 22-02-2035

Inductor, 0.01uH, Imax=0.45A,
DCR=0.13 omhs SMD 1210 KOA KL32TE010K
Resistor, thick film, 5%, 100ohm,
1/8W SMD 0805 Panasonic ERJ-6GEYJ101V

Resistor, thick film, 5%, 10kohm,
1/8W SMD 0805 Panasonic ERJ-6GEYJ103V
Resistor network, 10kohm, 8-resistors,
10-terminations, bussed, 5% SMD 2512 Panasonic EXB-A10P103J
Resistor network, 1kohm, 8-resistors,
10-terminations, bussed, 5% SMD 2512 Panasonic EXB-A10P102J

IC, supervisor, 2.7V, internal pull-up
resistor, open drain, active low SOT-23 Microchip Technology MCP130T-270I/TT

VI -8

U202 1

U203 1 IC, CAN transceiver, 3.3V SOIC-8 Texas Instruments SN65HVD232D

U204 1

U205, U206, U207,

U208, U209 5

U210 1 IC, buffer, Darlington, array SOIC-16 Texas Instruments ULN2003ADR

U211, U214 2 IC, op-amp, dual, single supply SOIC-8 Texas Instruments OPA2340UA

U212 1 IC, DAC, dual, 8-bit, serial SOIC-8 Texas Instruments TLV5625CD

U213 1

VR201, VR202 2

Y201 1 Crystal, 6.000MHz SMT Citizen HCM49-6.00

IC, microcontroller, 16-bit, 16k X 8
program, 48 I/O, flash 64-QFP Texas Instruments MSP430F135IPM

IC, CAN controller, industrial temp, 3
transmit buffers, 2 receive buffers 18-SOIC Microchip Technology MCP2510-I/S0

IC, optoisolator, dual, transistor o/p,
Vceo=30V SOIC-8 Fairchild MOCD211M

IC, voltage reference, 2.50V, +/-

0.2% SOT -23 National Semiconductor LM4040BIM3-2.5
Potentiometer, 2kohm, 11-turn,
5mm, top SMT Murata PVG5A202C01R00

Circuit: RF Conditioning

Revision: 1.05

Designations Qty Description Package Manufacturer Mfg. Part Number

C301, C306, C311 3

C302, C303, C305,

C312, C320 5

C304 1

C307, C308, C310 3

C309 1

C313, C314, C315,
C316, C317, C318,

C319 4 DNS SMD 0805

D301 1 Diode, TVS, 30V, 600W SMB Diodes Inc. SMBJ30A-13

D302 1 Diode, LED, green, Vf=2.2V SMD 1206 Lumex SML-LX1206GW-TR

D303, D304, D305,

D306, D307 5 Diode, LED, red, Vf=2.0V SMD 1206 Lumex SML-LX1206IW-TR

D308 1 Diode, ultrafast SOT -23 Fairchild Semiconductor MMBD914

D309, D310 2 DNS TO-92

F301 1

J301 1

J301 1

J302, J303 2

J304 1
L301 1 Inductor, 0.01uH 1210 TDK NLV32T-010J-PF

PCB301 1

Capacitor, ceramic, 0.1uF, 50Vdc,
+/-20% SMD 0805 Yageo America C0805C104M5UACTU

Capacitor, ceramic, 0.01uF, 50Vdc,
+/-20% SMD 0805 Kemet C0805C103M5RACTU
Capacitor, ceramic, 0.022uF, 50Vdc,
+/-10% SMD 0805 Panasonic ECJ-2VB1H223K
Capacitor, ceramic, 1000pF, 50Vdc,
+/-10% SMD 0805 Kemet C0805C102K5RACTU
Capacitor, ceramic, 330pF, 50Vdc,
+/-10% SMD 0805 Panasonic ECJ-2VC1H331J

Fuse, resettable, miniSMD, Ihold =

0.14A, Itrip = 0.34A Fuse-miniSMD Littelfuse MINISMDC014-2
Connector, terminal block, header,
2-position, straight
Connector, terminal block, plug, 2­position, straight - Wieland 25.340.3253.0
Connector, SMA, PCB End Launch,
50-ohms
Connector, modular, female, 8­position, vert ical PCB THT Amp (Tyco) 5556416-1

Printed circuit board, FR4, proto 2 or
equivalent - Alberta Printed Circuits PCB301

PCB THT

(0.2") Wieland 25.350.3253.0

PCB End

Launch Johnson Components 142-0701-801

VI -9

R301 1 Resistor, thick film, 5%, 620ohm, 1W SMD 2512 Panasonic ERJ-1TYJ621U

R302, R303 2 DNS

R304, R312, R313,

R318, R319, R322 6

R305, R307 2

R308, R309, R314,

R315, R320 5

R310, R311, R316,

R317, R321 5

R323 1 Resistor, 100ohm, 1/8W SMD 0805 Yageo America 9C08052A1000FKHFT

R324 1 Resistor, 3.3ohm, 1/8W SMD 0805 Yageo America 9C08052A3R32FGHFT

R325, R326, R327,

R328, R329 5 DNS SMD 0805

VR301 1 Potentiometer, 5kohm SMD 5MM Murata PVG5A502C01R00
VR302 1 DNS SMD 5MM
VR303 1 Potentiometer, 200ohm SMT 5MM Murata PVG5A201C01R00

S301 1

U301 1

U302 1 IC, digital attenuator, 5-bit, 1dB LSB SSOP-20 Skyworks (Alpha) AA110-85

U303, U304, U305 3

U306 1 Directional coupler Mini-Circuits DBTC-20-4

U307 1 IC, power detector TSSOP-16 Analog Devices AD8362ARU

U308 1

U309 1 DNS TO-243

Resistor, thick film, 5%, 1.0kohm,
1/8W SMD 0805 Yageo America 9C08052A1001JLHFT
Resistor, thick film, 1%, 130ohm,
1/8W SMD 0805 Yageo America 9C08052A1300FKHFT

Resistor, thick film, 5%, 1.2kohm,
1/8W SMD 0805 Yageo America 9C08052A1201JLHFT

Resistor, thick film, 5%, 10kohm,
1/8W SMD 0805 Panasonic 9C08052A1002JLHFT

Switch, DIP, 5-position, SPST, gold
finish, sealed
IC, voltage regulator, 5V output,
500mA TO-252 National Semiconductor LM78M05CDT

IC, optoisolator, dual, transistor o/p,
Vceo=30V SOIC-8 Fairchild MOCD211M

DNS (replace with two 0805 0ohm
resistors)

CTS 219-5

SMD CTS Corporation 219-5MST

Circuit: Temperature Sensor

Revision: 1.02

Designations Qty Description Package Manufacturer Mfg. Part Number

C701 1 CAPACITOR 0.1uF 50V 10% 0805 Yageo 08052R104K8B20D

J701 1
J702 1 TERMINAL SCREW VERTICAL PC MNT Keystone 8191

U701 1 IC DIG TEMPERATURE SENSOR 8-MSOP National Semiconductor LM70CIMM-3

CONN MOD JACK 8-8 R/A PCB
50AU SMT Molex 44144-0003

Circuit: TxNet

Revision: 1.02

Designations Qty Description Package Manufacturer Mfg. Part Number

F601, F602, F603,

F604 4

Fuse, resettable, Ihold=0.14A,
Itrip=0.34A, Vmax=60V SMD Tyco MINISMDC014-2

VI -10

J601, J603, J604,
J605, J606, J607,
J608, J609, J610,

J611 10

Connector, modular, jack, 8­position, vertical, PCB mount Tyco 5556416-1

J602 1

Connector, D-sub, 25 position,
female, vertical, PCB mount Kycon K85-BD-25S-R

VI -11

Insight System Schematics

The following pages contain the schematics for the Insight system.

VI -12

DC Supply Conditioning

User Interface Module

V1 Input

V2 Input

V3 Input

V4 Input

V5 Input

J101A

J101B

J101C

J101D

J101E

F101

TAC 58V

see table

SMBJ30A TV
SMBJ48A FM

F102

TAC 58V

see table

SMBJ30A TV
SMBJ48A FM

F103

TAC 58V

see table

SMBJ30A TV
SMBJ48A FM

F104

TAC 58V

see table

SMBJ30A TV
SMBJ48A FM

F105

TAC 58V

see table

SMBJ30A TV
SMBJ48A FM

Vin

D101

D103

D105

D107

D109

+

C101
100uF
63V

+

C102
100uF

63V

+

C103
100uF
63V

+

C104
100uF
63V

+

C105
100uF
63V

R101

2.7k TV

4.87k FM

D102
Green
SML-LX1206GW

R104

2.7k TV

4.87k FM

D104
Green
SML-LX1206GW

R107

2.7k TV

4.87k FM

D106
Green
SML-LX1206GW

R110

2.7k TV

4.87k FM

D108
Green
SML-LX1206GW

R113

2.7k TV

4.87k FM

D110
Green
SML-LX1206GW

L101

ETQ-P6F1R3LFA

R102

20

R103

20

L102

ETQ-P6F1R3LFA

R105

20

R106

20

L103

ETQ-P6F1R3LFA

R108

20

R109

20

L104

ETQ-P6F1R3LFA

R111

20

R112

20

L105

ETQ-P6F1R3LFA

R114

20

R115

20

V1 Cond

V2 Cond

V3 Cond

V4 Cond

V5 Cond

F106

TAC 58V

tbd

SMBJ30A TV
SMBJ48A FM

GND IN

J101F

Fuse Table

PA5-UHF 4 A

P50-UHF
P150-UHF
U60LD UHF
U200LD UHF
P350-FM

1

2 A
3 A
10 A
10 A/side
3 A

7.5 A/side
15 A
15 A/sideP750-FM

D111

PA25-VHF-L
PA25-VHF-H

P200-VHF-H
P400-VHF-L
P400-VHF-H

5 APA10-UHF
15 AP200-VHF-L
15 A
15 A/side
10 A/side

VgenCond

A. Sivacoe, N. Hendrickson

User Interface Module

Rev ID

B Insight Control System

Date: April 30, 2005 Page: 1 of 9

User Interface Module

Current Monitoring

R117

0.012

V1 Cond V1 Out

C108

0.1uF

C113

0.1uF

R118

0.012

3

U101

5

INA168

R120

0.012

R121

0.012

3

U102

5

INA168

4

1

2

2

R119

100k

4

1

R122
100k

OPA2340UA

OPA2340UA

U106A

U106B

+

C109

0.1uF

+

C107

0.01uF

C110

0.1uF

C114

0.1uF

L106

0.01uH

C111

0.1uF

C115

0.1uF

C106

0.01uF

J102A

C112

0.1uF

J102B

C116

0.1uF

+3.3 Vdc

I1 Buff

V2 Out V2 Cond

I2 Buff

L107

0.01uH

C118

0.01uF

R123

0.012

R124

0.012

3

U103

5

INA168

C119

0.1uF

R126

0.012

V4 Cond V4 Out

C124

0.1uF

R127

0.012

3

U104

5

INA168

4

1

2

2

R125
100k

4

1

R128
100k

OPA2340UA

OPA2340UA

U107A

U107B

+

C120

0.1uF

+

C121

0.1uF

C125

0.1uF

C122

0.1uF

C126

0.1uF

C117

0.01uF

J102C

C123

0.1uF

J102D

C127

0.1uF

+3.3 Vdc

V3 Out V3 Cond

I3 Buff

I4 Buff

2

A. Sivacoe, N. Hendrickson

User Interface Module

Rev ID

B Insight Control System

Date: April 30, 2005 Page: 2 of 9

Voltage/Current Monitoring

V5 Cond

3

5

C130

0.1uF

R129

0.012
R130

0.012

U105

INA168

2

User Interface Module

L108

0.01uH

C129

0.01uF

4

1

R131
100k

OPA2340UA

U108A

+

C131

0.1uF

C128

0.01uF

C132

0.1uF

C133

0.1uF

J102E

C134

0.1uF

+3.3 Vdc

V5 Out

I5 Buff

U108B

+

R135
249k

C136

0.1uF

R136
249k

C137

0.1uF

R137
249k

C138

0.1uF

R138
249k

C139

0.1uF

R139
249k

C140

0.1uF

Vin

I4 Buff I4 ADC

I5 Buff I5 ADC

R132

37.4k - TV

68.1k - FM
R133

3.3k

OPA2340UA

R134

249k

C135

0.1uF

V1 ADC

I1 ADC I1 Buff

I2 ADC I2 Buff

I3 ADC I3 Buff

Membrane Switch Inputs

+3 Vdc

R143

R142

R141

R140

10k

Pow-IN

Nav-IN

+3 Vdc

Sel-IN

Res-IN

GND

3

J103D

J103A

J103B

J103E

J103C

10k

R146

10k

R147

10k

1k

1k

R1481kR149

U109

MOCD211M

P1
P2
P3
P4 P5

U110

MOCD211M

1k

P1
P2
P3
P4 P5

P8
P7
P6

P8
P7
P6

R144

10k

R150

10k

R145

10k

R151

10k

Pow-uPC

Nav-uPC

Sel-uPC

RESET

A. Sivacoe, N. Hendrickson

User Interface Module

Rev ID

B Insight Control System

Date: April 30, 2005 Page: 3 of 9

User Interface Module

Microcontroller

U111

L109

0.01uH

+3.3 Vdc RESET

C141

0.01uF

C142

0.01uF

C143

0.1uF

I1 ADC

I2 ADC

I3 ADC

I4 ADC

MCP130

Vcc

Reset

GND

TCK
TMS
TDI

TDO

CAN CLK

LED1
Buzzer
BkLtCtrl

I5 ADC

V1 ADC

Pow-uPC

Nav-uPC

Sel-uPC

C146
30pF

C147
30pF

Y101

6.00MHZ

C144

0.1uF

C145

tbd

DVcc

A3
A4
A5
A6
A7

Xin

Xout

P1 0
P1 1

P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
P11
P12
P13
P14
P15
P16

DVss

AVcc

P63

P64

P17

P18

AVss

TCK

RST

P58A0P59A1P60A2P61

P62

U112

MSP430F133

P22

P19

P20

P21

P23

P2 2

TMS

P57

P24

TDI

P56

P25

TDO

P55

P26

P54

P27

P52

P53

P29

P28

SIMO0

P50

P51

P30

P31

SOMI0

UCLK0

P49

P32

P48
P47
P46
P45
P44
P43
P42
P41
P40
P39
P38
P37
P36
P35
P34
P33

MCLK

J104

Pin15LCD

LED A

LED K

LCD D7
LCD D6
LCD D5
LCD D4
LCD D3
LCD D2
LCD D1
LCD D0

LCD E
LCD R/*W
LCD RS
LCD Vo

LCD Vdd

LCD Vss

+5 Vdc
Pin3LCD

- DIP SWITCH 7,6,5 SET ID

- DIP SWITCH 2 SETS CALIBRATION MODE

- DIP SWITCH 1 ENABLES CAN BUS TERMINATION

CANterm1

CANterm2

S101

SCK

SOMI
SIMO
CAN CS

7
6
5
4
3
2
1

+3.3 Vdc

A. Sivacoe, N. Hendrickson

User Interface Module

RN101 10k

Rev ID

B Insight Control System

Date: April 30, 2005 Page: 4 of 9

User Interface Module

CAN and Programmer Interface

+3.3Vdc

C148

0.01uF

TXCAN
RXCAN

CAN CLK

OSC1

Vss

L110

0.01uH

P1
P2
P3
P4
P5
P6
P7
P8
P9
P10

MCP2510

C149

0.01uF

U113

P20
P19
P18
P17
P16
P15
P14
P13
P12
P11

Vdd
RESET
CS
SO
SI

SCK

SN65HV232

D

P1

GND

P2

Vcc

P3

R

P4

U114

P8
P7
P6
P5

CANH
CANL

+5Vdc

+3.3Vdc

R152

100

J105D
J106D

J105F
J106F

J105E
J106E

J106A

J105H
J106H

J105G
J106G

+5V-1
+5V-2

+3.3V-1
+3.3V-2

GND-1
GND-2

RESET-2 RESET

CANH-1
CANH-2

CANL-1
CANL-2

CANterm1

CANterm2

RESET

SCK
SIMO

SOMI

CAN CS

TDO

TDI
TMS
TCK

R153
100k

J107

JTAG header

+3.3Vdc

5

A. Sivacoe, N. Hendrickson

User Interface Module

Rev ID

B Insight Control System

Date: April 30, 2005 Page: 5 of 9

User Interface Module

Power Supplies

VgenCond

LED1
Buzzer
BkLtCtrl

+5 Vdc

+
C150

100uF

R156

10k

C152

10uF

10V tantalum

U115

LM2576S-5.0

Feedbk

Vin

Vout

Gnd

On/Off

U116

ULN2003

P1
P2
P3
P4
P5
P6
P7
P8 P9

LM1117MP-3.3

U117

IN

COM

P16
P15
P14
P13
P12
P11
P10

OUT

30BQ060

SML-LX1206GW

D116

S1D-13

L111

100uH

D114

D113

Green

G6L-1F 5Vdc

RL101

Littlefuse 1812L

+

C151

1000uF

R155

1k

F108

Littlefuse 1812L

C153

100uF

F107

BZ101

R154

tbd

R157

4.7

R158

430

D117

+3.3V LED

D115

+5V LED

+5 Vdc

Pin15LCD

+3.3 Vdc

VgenCond

C156

22uF

C157
22uF

+

P8
P7
P6

C155

100uF

C158

22uF

U118

LM2660M

C161

0.1uF

P1
P2
P3
P4P5

LM2679

Vin

Gnd

Rads

SoftStart

R162

6.2k

+
C154

100uF

R160

1.4k

U119

Feedbk
Cboost

Vout

C162

1uF

S102

R161

C163

0.01uF

27k

D118

DIODE

L112
33uH

R159

10k 40%

C159
22uF

C160

22uF

J108

Pin3LCD

FanOut

6

A. Sivacoe, N. Hendrickson

User Interface Module

Rev ID

B Insight Control System

Date: April 30, 2005 Page: 6 of 9

Microcontroller

Coupler Conditioning Module

U201

MCP130

+3.3 Vdc RESET

Vcc

Reset

GND

TCK
TMS
TDI

TDO

C201

0.01uF

C202

0.1uF

L201

0.01uH

C203

0.01uF
L202

0.01uH

FWD-POW

RFL-POW

C204

0.01uF

C205

0.01uF

CAN CLK

TDO

TDI

TMS

TCK

RST

AVss

DVss

AVcc

P54

P55

P56

P57

P58A0P59A1P60A2P61

P62

P63

P64

P53

P52

P51

P50

P49

- DIP SWITCH 3,2,1 SET ID

- DIP SWITCH 7 ENABLES CAN
TERMINATION

S201

1
2
3
4
5
6
7

RN201 10k

CANterm1
CANterm2
+3.3 Vdc

DRVR DIS
LED1
LED2

C206
33pF

C207
33pF

Y201

6.00MHZ

DVcc

Xin

Xout

P1 0
P1 1

A3
A4
A5
A6
A7

P1
P2
P3
P4
P5
P6
P7
P8
P9
P10
P11
P12
P13
P14
P15
P16

P17

P18

P19

U202

MSP430F133

P22

P20

P21

P23

P24

P25

P26

P27

P28

P29

P30

P31

P32

P48
P47
P46
P45
P44
P43
P42
P41
P40
P39
P38
P37
P36
P35
P34
P33

MCLK

C208

0.01uF
L203

0.01uH

C209

0.01uF

+5 Vdc

ATEN-Vcc
ATEN1
ATEN2

ATEN3
ATEN4
ATEN5

J201a4
J201a2
J201a1
J201a3
J201a5
J201a7

1

P2 2

SIMO0

SOMI0

UCLK0

PSU
TEMP
VSWR
OVERDRV

SOFT RES
CAR ON
CAR OFF
CAR UP
CAR DOWN

DAC CS
SCK

SIMO
CAN CS

J201b2

J201b4

J201b3

J201b8
J201b1

TMP VCC
TMP SCK
TMP SO
TMP CS
TMP GND

N. Hendrickson, A. Sivacoe

Coupler Conditioning

Rev ID

1.04 Insight Control System

Date: June 17, 2005 Page: 1 of 4

SOMI

Coupler Conditioning Module

CAN and Programmer Interface

L204

+3.3Vdc

CAN CLK

C212

0.01uF

0.01uH

C213

0.01uF

U204

MCP2510

+5Vdc

+3.3Vdc

GND
Vcc

U203

SN65HV232

D

P1
P2
P3

R

P4 P5

C210

100uF

C211
100uF

P8

CANH

P7

CANL

P6

D201

D202

R201

100

J201c4
J201d4

J201c6
J201d6

J201c2
J201d2

J201c1

J201c8
J201d8

J201c7
J201d7

+5V-1
+5V-2

+3.3V-1
+3.3V-2

GND-1
GND-2

RESET-1 RESET

CANH-1
CANH-2

CANL-1
CANL-2

CANterm1

CANterm2

RESET

SCK
SIMO

SOMI

CAN CS

TDO

TDI
TMS
TCK

J202

JTAG header

N. Hendrickson, A. Sivacoe

+3.3Vdc

2

Coupler Conditioning

Rev ID

1.04 Insight Control System

Date: June 17, 2005 Page: 2 of 4

Remote Access Port

+5 Vdc

OVERDRV
VSWR

R203

1k

U206

MOCD211M

P1
P2
P3
P4 P5

R204
1k

P8
P7
P6

R205

10k

Coupler Conditioning Module

R206
10k

1

RN
202
10k

2

RN
202
10k

3

RN
203
1k

MOCD211M

P1
P2
P3
P4 P5

1

RN
203
1k

U205

P8
P7
P6

9

RN
202
10k

8

RN
202
10k

+3.3 Vdc

CAR OFF
CAR ON

TEMP
PSU

RFL-OUT
FWD-OUT

+3.3 Vdc

DRVR DIS

LED1

LED2

R207

1k

U208

MOCD211M

P1
P2
P3
P4 P5

R208
1k

U210

ULN2003

P1
P2
P3
P4
P5
P6
P7
P8 P9

P8
P7
P6

P16
P15
P14
P13
P12
P11
P10

R209

10k

R210
10k

R2111kR212

D203

1k

D204

D205

K201

J203

1
2
3
4
5
6
7
8

R213

1k

J204

8
7
6
5
4
3
2
1

+5 Vdc

C214

0.01uF

4

3

RN
202
10k

RN
204
10k

3

RN
202
10k

2

RN
204
10k

L205

0.01uH

0.01uF

8

RN
203
1k

7

RN
203
1k

C215

MOCD211M

P1
P2
P3
P4 P5

4

RN
203
1k

MOCD211M

P1
P2
P3
P4 P5

6

RN
203
1k

U207

U209

J201

b7

P8
P7
P6

P8
P7
P6

7

6

RN

RN

202

202

10k

10k

1

RN
204
10k

DISABLE

CAR DOWN
CAR UP

SOFT RES
RESET

3

J205

N. Hendrickson, A. Sivacoe

Coupler Conditioning

Rev ID

1.04 Insight Control System

Date: June 17, 2005 Page: 3 of 4

RF Power Output

Coupler Conditioning Module

+5 Vdc

SIMO
SCK
DAC CS

Coupler Input

+5Vdc

FWD-GND

FWD-5V

FWD-IN

J206A

J206B

J206C

L207

0.01uH

C218

0.01uF

L209

0.01uH

C222

0.01uF

C216

0.01uF

TLV5625

P1
P2
P3
P4 P5

C219

0.01uF

C223

0.01uF

L206

0.01uH

U212

P8
P7
P6

C217

0.01uF

R219

1k

LM4040-2.5

R217

1k

+

U214A
OPA2340UA

U213

R214

1k

L208

0.01uH

C220

0.01uF

R218

1k

R215

VR201

10k

R216

10k

C221

0.01uF

OPA2340UA

+

+

U211B

OPA2340UA

+3.3 Vdc

L210

0.01uH

C224

0.01uF

U211A

D206A

1 3

C225

0.01uF

FWD-OUT

RFL-OUT

D206B

1 2

FWD-POW

RFL-GND

RFL-5V

RFL-IN

J207A

J207B

J207C

L211

0.01uH

C226

0.01uF

C227

0.01uF

R223

1k

+

R221

1k

U214B
OPA2340UA

R220

1k

L212

R222

1k

VR202

R224

1k

0.01uH

C228

0.01uF

N. Hendrickson, A. Sivacoe

Coupler Conditioning

C229

0.01uF

RFL-POW

4

Rev ID

1.04 Insight Control System

Date: June 17, 2005 Page: 4 of 4

PSU In

Ground

J301

1

J301

2

F301

D301

R301

R302

R303

C301

U301

IN

COM

OUT

L301

+5 Vdc

R304

C302 C303

D302

RF OUT

Ext 5Vdc

2dB in
1dB in

J303

J304 4

J304 2
J304 1

RF 2

S301

1

S301
2

R308 R309

Alpha 110-85

P1
P2
P3
P4
P5
P6
P7
P8
P9
P10 P11

U303

P1
P2
P3
P4 P5

P8
P7
P6

U302

P20
P19
P18
P17
P16
P15
P14
P13
P12

CTL 1dB
CTL 2dB
CTL 4dB
CTL 8dB
CTL 16dB

C304

C305

+5 Vdc

C306

+5 Vdc

CTL 2dB
CTL 1dB

R311R310

R312 R313

8dB in
4dB in

16dB in

J304 5
J304

J304 7

D303 D304

S301

3

3

S301
4

R314 R315

U304

P1
P2
P3
P4 P5

P8
P7
P6

CTL 8dB
CTL 4dB

R317R316

R319R318

D306D305

S301
5

U305

P1
P2
P3
P4 P5

P8
P7
P6

D308

R321R320

R322

D307

A. Sivacoe, N. Hendrickson

Shutdown

CTL 16dB

RF Conditioning Module

Rev ID

1.04 Insight Control System

Date: Sept. 19, 2005 Page: 1 of 2

U306

DBTC-20-4

RF 1 RF 2

RF IN

DIR. COUPLER

J302

R305 R307

V

VR303

C307

V

R323

C308

U307

AD8362

P1
P2
P3
P4
P5
P6
P7
P8 P9

P16
P15
P14
P13
P12
P11
P10

DIP16

U308

SAGE WIRE -HCT2

C309

C310

C312

C320

R324

C311

RF 1

+5 Vdc

Shutdown

VR301

PSU In

C317

U309

78L20

IN

COM

OUT

HYBRID COUPLE

C313

D309

C315

R327

R329 R328

VR302

C318 C319

C314

R326R325

D310

C316

A. Sivacoe, N. Hendrickson

RF Conditioning Module

Rev ID

1.04 Insight Control System

Date: Sept. 19, 2005 Page: 2 of 2

Temperature Sensor

DRV DIS
TMP SO
TMP SCK
TMP GND
TMP VCC
TMP CS

J1G

J1C

J1D
J1A

J1B

J1H

C1

1uF

U1

LM70

P1
P2
P3
P4 P5

P8
P7
P6

J2

TMP VCC

1

N. Hendrickson, A. Sivacoe

Temperature Sensor Board

Rev ID

1.02 Insight Control System

Date: May 8, 2005 Page: 1 of 1

PSUflag
RFL samp
TEMPflag
FWD samp
VSWRflag
ODRVflag
ground

CAR on
CAR off
CAR up
+5 Vdc
CAR down
+3.3 Vdc
Soft RES
RESET

1J601
2

F601

3
4

F602

5
7
8

1J603
2

13
12
11
10

9
8
7
6
5
4
3
2
1

J602

25
24
23
22
21
20
19
18
17
16
15
14

3
4

F603

5
6

F604

7
8

IN 1
IN 2
IN 3
IN 4
IN 5
IN 6
IN 7
IN 8

IN 1
IN 2
IN 3
IN 4
IN 5
IN 6
IN 7
IN 8

IN 1
IN 2
IN 3
IN 4
IN 5
IN 6
IN 7
IN 8

1J604
2
3
4
5
6
7
8

1J606
2
3
4
5
6
7
8

1J608
2
3
4
5
6
7
8

1J605
2
3
4
5
6
7
8

1J607
2
3
4
5
6
7
8

1J609
2
3
4
5
6
7
8

OUT 1
OUT 2
OUT 3
OUT 4
OUT 5
OUT 6
OUT 7
OUT 8

OUT 1
OUT 2
OUT 3
OUT 4
OUT 5
OUT 6
OUT 7
OUT 8

OUT 1
OUT 2
OUT 3
OUT 4
OUT 5
OUT 6
OUT 7
OUT 8

IN 1
IN 2
IN 3
IN 4
IN 5
IN 6
IN 7
IN 8

1J610
2
3
4
5
6
7
8

1J611
2
3
4
5
6
7
8

OUT 1
OUT 2
OUT 3
OUT 4
OUT 5
OUT 6
OUT 7
OUT 8

TxNET

Rev ID

1.02

Date: Dec. 5, 2005 Page: 1 of 1

Section VII – Mechanical Section

The heat sink allows the amplifiers to operate at a cooler temperature and prevents overheating,
which helps the longevity of the entire system. The heat sink has hollow fins, which help dissipate
the heat from the amplifiers faster than a conventional serrated or corrugated fin.

In addition to the cooling effects of the heat sink, there is a fan that provides 110 cubic feet per
minute (CFM) of air flow (into zero static pressure).

VII-1

Section VIII - Installation

This section contains installation recommendations, unpacking, inspection, and installation instructions
for the power amplifier. We are sure that you are chomping at the bit to install your new system, so we
recommend that you read the following sections very carefully.

Building Recommendations

The quality of the building is of great importance if you are to expect long life and continued
performance from the power amplifier. The building must be clean, dry, temperature controlled and
secure. Don’t forget to allow space in the building for any additional racks to house test equipment, a
workbench area, line regulating transformers, ladders, equipment and parts storage, first aid kit,
emergency generator if used, as well as heating and cooling devices that may be unique to your
installation. A sloping roof will tend to develop leaks less rapidly. The building should be well roofed
with good material. The cooling load will be lowered with reflective or light colored roofing material.

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Heating and Cooling Requirements

The environment’s temperature will contribute greatly to the length of the power amplifier’s life.
Technalogix recommends that the building’s filtered air intake must have capacity for all air-flow in the
building plus an additional 20%. Keep the intake below the roofline to avoid intake of solar heated air.
Please ensure that the intake and exhaust areas are on the same side of the building to avoid
pressure differentials during windy conditions. Also, do not position intake near exhaust’s preheated
air. If air conditioning is required to cool the shelter, discuss the situation with a qualified HVAC
technician. Under average conditions, 12,000 BTUs will cool approximately 500 square feet to a
comfortable level.

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Electrical Service Recommendations

Technalogix recommends that a qualified, licensed local electrician be consulted for the required
electrical service. We suggest local electricians because:

• The personnel knows the local codes

• The personnel can be on site readily

• You are apt to get better overall support if you give what business you can to local suppliers

Technalogix recommends that proper AC line conditioning and surge suppression be provided on the
primary AC input to the power amplifier. All electrical service should be installed with your national
electrical code in your area, any applicable provincial or state codes, and good engineering practice.
Special consideration should be given to lightning protection of all systems in view of the vulnerability
of most transmitter or translator sites to lightning. Lightning arrestors are recommended in the service
entrance. Straight and short grounds are recommended. The electrical serviced must be well
grounded. Do not connect the unit to an open delta primary power supply, as voltage fluctuations could
harm the unit. Branch your circuits. Do not allow your lights, your workbench plugs, and your
transmitting or translating equipment to operate on one circuit breaker. Each transmitter or translator
should have its own circuit breaker, so a failure in one does not shut off the whole installation.

Technalogix Ltd.

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Antenna and Tower Recommendations

Your preliminary engineering workgroup should establish your antenna and tower requirements, both
for receiving and transmitting antennas. Construction of sturdy, high quality antenna/tower systems will
pay off in terms of coverage of your service area, the overall quality and saleability of your radiated
signal, and reduced maintenance expenses. Technalogix provides complete turnkey antenna systems
if needed. If your site is serving as a translator, your receiving antenna should be in line of sight to the
originating station all year round. The foliage will change with season. Transmitting antennas can
enhance or seriously impair the transmitter/translator output.

The selection, routing, and length of coaxial cable are extremely important in the installation. If there is
a 3 dB line loss in the cable between your unit’s output and the transmitting antenna, a unit will only
deliver 50 watts to the antenna. Buy the best cable you can obtain, route it via the shortest way to the
antenna, and keep it straight. Do not form it into sharp bends on its way. Do not use any more cable
fittings for the installation than absolutely necessary. All cautions here apply equally to all coaxial
cables in the system - input and output.

Pay attention to radial ice accumulation when designing the transmission system. It is not uncommon
for at least an inch of ice to build up on the tower and antenna. This in turn significantly increases the
weight, cross section, and wind loading of the system.

Attaching the transmission line to the tower is crucial to maintain a safe and reliable operation. Nylon
wire ties and electrical tape will breakdown in the sunlight and ultimately fail, creating a potentially
dangerous situation. It is important to use proper clamps and hoisting grips and also ensure that the
transmission line is grounded to the tower in several locations. When high currents flow through the
tower in the event of lightening strikes, some of that current will through the outer conductors of the
transmission lines. Due to the resistance difference between the steel tower and copper transmission
line, a significant voltage can be developed, often resulting in arcing between the outer jacket and
outer conductor, thus pitting the conductor.

Preventative maintenance is crucial in ensuring that safety is maintained. Specifically, check that
transmission line grounds are tight and are not missing any hardware. Frequently inspect support
clamps or spring hangers. Consider investing in an ice break, if you haven’t already done so, as
shards of falling ice can damage the transmission line – and if it is going to happen, it will happen at an
important time. Check the tower light photocells and conduit.

The better-known tower manufacturers offer complete technical and safety documentation with their
towers. Be sure that you have this information as it regards wind loading, guying, etc. The best­designed antenna system will function poorly if shortcuts and compromises are used during installation.
Follow the manufacturer’s instructions exactly, along with any engineering data prepared for the site.
Be absolutely safe and certain about this aspect as human lives may be at stake.

Technalogix Ltd.

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Shelter Security
The FCC requires that the transmitter or translator be secure from entry or control by unauthorized

persons, and that any hazardous voltages or other dangers (including most tower bases) be protected
by locks or fences as necessary to protect personnel and prevent unauthorized tampering or
operation. Security of the building further implies that it be secure from wildlife. Use sturdy construction
materials, including sheet metal if necessary. Holes around conduit, cable, and other similar entry
points should be stuffed with steel wool and caulked to prevent entry of wildlife. Other features of
security for your shelter may include its location with respect to the prevailing wind conditions. A
location leeward of some natural topographical feature will prevent wind damage and snowdrifts. Check
the soil runoff conditions that may slow or hasten wind or water erosion and other concerns that may
be unique to your location.

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Unpacking and Inspection

Check the outside of the container. Carefully open the container and remove the power amplifier.
Retain all packing material that can be reassembled in the event that the equipment must be returned
to the factory.

Exercise care in handling equipment during inspection to prevent damage due
to rough or careless handling.

Visually inspect the enclosure of the power amplifier for damage that may have occurred during
shipment. Check for evidence of water damage, bent or warped chassis, loose screws or nuts, or
extraneous packing material in connectors or fan failures. Inspect all connectors for bent connector
pins. If the equipment is damaged, a claim should be filed with the carrier once the extent of the
damage is assessed. Technalogix cannot stress too strongly the importance of immediate careful
inspection of the equipment and subsequent immediate filing of the necessary claims against the
carrier if necessary. If possible, inspect the equipment in the presence of the delivery person. If the
equipment is damaged, the carrier is your first area of recourse. If the equipment is damaged and must
be returned to the factory, phone for a return authorization. Claims for loss or damage may not be
withheld from any payment to Technalogix, nor may any payment due be withheld pending the outcome
thereof. Technalogix cannot guarantee the carrier’s performance.

Technalogix Ltd.

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Location and Function of Controls and Connectors (TAUD-40 Power Amplifier)

The following illustration depicts the location of the connectors when installing the power amplifier
(TAUD-40).

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POWER - Tactile button to turn carriers on and off.
NAVIGATE - Tactile button to open menu and move cursor in menu. When the screen has

timed out, this button is also used to refresh the screen

SELECT- Tactile button to select item in menu or to refresh screen after it has been

timed out

RESET - Tactile button to reset microcontroller in control board. Also clears existing

faults. Individual control board with reset comes back on with soft start feature.
RF IN – RF input from modulator or processor. BNC connector, 50 ohm.
RF OUT – 500-watt RF output. Connects to RF IN on filter enclosure. 7/16” din connector,

50 ohm.
AC IN – AC input to switching power supply.
AC BREAKER – Resettable circuit breaker is used to protect against inrush currents and

high current draw from switching power supply. The thermal circuit breaker

is a single pole configuration.
AC ON/OFF - AC rocker switch (SPST) to supply AC to the AC -DC switching power supply

REMOTE PORT - The transmitter can be controlled and monitored by the remote port. See

“Monitor and Control System” section for details.

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Initial Hook Up

1. Ensure that the antenna has been swept and has a return loss of greater than 20dB (VSWR =

1.2:1). This should be done before connecting the antenna cable to the transmitter output.

2. Check that your video source is present.

3. Place the transmitter/translator in its permanent location near a receptacle supplying required
AC voltage.

DO NOT APPLY AC POWER AND TURN ON POWER TO THE TRANSMITTER /
TRANSLATOR AT THIS TIME SINCE THE RF OUTPUT MUST BE PROPERLY
LOADED BEFORE OPERATION.

4. Place an appropriate AC power line protector, conditioner, and/or surge suppressor across the
AC supply line.

5. Hook up the modulator or processor as shown in their respective manuals for a transmitter or
translator. Do not connect the modulated signal from the RF OUT on the modulator or
processor to RF IN on the power amplifier at this time. Because of the characteristics of
LDMOS devices, the RF drive should not be connected to the power amplifier until after the
power supply and bias voltages are present and stable.

6. Ensure that modulator or processor RF output level is turned down as far as possible.

7. Ensure that the audio modulation is set to 100% with the audio signal supplied, as described in
the appropriate modulator/processor manual (will be factory set).

8. Ensure that the video modulation level is set to 87.5% with the video signal supplied, as
described in the appropriate modulator/processor manual (will be factory set).

9. Connect the transmitting antenna cable to the RF OUT N-type connector on the power
amplifier enclosure RF output.

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Section IX - Operating Procedure

Assuming the previous installation instructions have been completed and cautions noted, and the
TAUD-40 power amplifier is ready to receive a properly modulated video and audio signal, proceed
with the following steps to place the system in operation. The TAUD-40 power amplifier has been
factory aligned for channel frequency (per system specification), signal levels and optimum
performance.

IT IS HIGHLY RECOMMENDED THAT YOU RUN YOUR SYSTEM INTO A DUMMY LOAD BEFORE
INSTALLING TO MAKE SURE THERE ARE NO DAMAGES CAUSED IN SHIPPING AND THE UNIT IS
RUNNING PROPERLY

1. Do not apply RF drive signal to the power amplifier at this time.

2. Verify that all control and RF cables are tight and properly seated in or on the mating connector.

3. Plug the modulator or processor into AC mains.

4. Plug the 3U power amplifier enclosure into AC mains.

5. Switch AC rocker switch to “ON” position.

6. Verify that the power amplifier enclosure’s fan is on.

7. Ensure that the modulator/processor is turned on and set up according to its instructions. Depress
the POWER tactile button to turn the unit on.

8. The internal soft start circuitry will turn the bias voltages off until the power supply to the amplifier
pallets is fully stable. The message on the LCD indicates when the soft start is running. Once
complete, the Forward and Reflected Power and Power Supply readings will appear on the LCD in
the filter and power amplifier enclosures.

9. After the soft start is complete, apply the RF drive signal (which still should be turned down)
between the modulator or processor and the power amplifier RF In. This ensures that the RF drive
signal is applied only after the power supply is stable and the bias voltages are applied to the
amplifier.

IX-1

10. The TAUD-40 LCD shows the user the present status of the amplifiers. Adjust RF output power to
desired level (see Important RF Power Notice in previous section). Verify that the FWD Power
reads 100% or less - depending on signal content. The output power level can be adjusted using
the modulator or processor’s RF output level adjust. Keep in mind that the system will shut down
should the forward RF output power level be exceeded.

11. Ideally, the RFL Power should read zero. However, should a high VSWR be detected, the system
will automatically shut down and cycle as previously described. This is also shown as a percentage
of rated forward power.

12. Verify that the power supply reads approximately 30 Volts DC (see supplied final inspection sheet
for factory settings of power supply levels) on the LCD of the power amplifier.

13. Look at the transmitted output using a suitable monitor. If the signal quality is unsatisfactory, check
the input signals, connections to the antenna system, antenna and transmission line VSWR, and
the physical condition of the antenna.

If reception problems are encountered, and the quality of transmission is satisfactory, the difficulty is
often with the receiving antenna or with obstructions in the path between the transmitter/translator and
receiver.

IX-2

Section X – Maintenance and Troubleshooting

Periodic Maintenance

If your unit employs a filter on the air inlet for the fans, the filter should be cleaned every 30 days. If the
equipment is operated in a severe dust environment, the filters on the inlet fan may need to be cleaned
more regularly. Turn the system off and unplug all of the AC inlet cords. The filter can be lifted off the
fan and cleaned using an air compressor at low pressure. While the filter is out, clean the fan blades
themselves with a small brush. The fans themselves do not need lubrication.

The interior of the cabinets should be cleaned and inspected annually. Turn the system off and unplug
all of the AC inlet cords. Remove the top lid by unscrewing the 6-32 machine screws.

Use extreme caution when working near the AC input terminal. The power
amplifier and power supply store hazardous capacitances and voltages.

Using either compressed air or a brush with soft bristles, loosen accumulated dust and dirt and then
vacuum the interior of the cabinet. Complete a visual inspection of the interior, making sure there are
no loose connections or discolorations on any components from heat. Nothing inside the power
amplifier enclosure exceeds a temperature that is not comfortable to the touch under normal operating
conditions, so any signs of discoloration indicate potential damage.

All modular components inside the enclosure are attached to aluminium mounting plates for easy
removal and replacement. Ensure that plates are secured and the mounting hardware is tight.

X -1

Troubleshooting

The first and most important aspect of troubleshooting anything is to be systematic. Note where you
have looked and what you found.

Look first for the obvious.

• Make a physical inspection of the entire facility. Are all necessary connections properly made? Do
you see any signs of obvious damage within the equipment?

• Is the AC power ‘ON’ to the site and the equipment? (Check fuses and circuit breakers if
necessary.)

• Are all the switches in the correct operating position?

• Is the input signal present?

• Check LCD readings for presence of forward and reflected power and 30 V DC supply levels.

The above is an aid in determining the fault if some aspect of the system is not operating. The
following table deals with quality of operation:

Symptom Possible Fault Correction

Horizontal bars in picture (may
roll either way depending on
phase)
Ensure modulator/processor

Diagonal lines in picture Interference Install EMI/RFI filter in AC line
Determine source and

AC grounding / AC interference Install EMI/RFI filter in AC line

and power amplifier share a
common ground

frequency of interfering signal
(spectrum analyzer may be
required)

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Symptom Possible Fault Correction

Weak output or picture Low level input signal Verify presence and level of

input signal

Low output power Verify power amplifier output

with wattmeter and dummy load
Incorrect modulation depth Adjust to meet specification
High reflected power Incorrect load Ensure amplifier connected to

transmission line
Ensure correct antenna

impedance (50 ohms)
Check antenna tuning and

VSWR. Verify correct cable for

transmission line length
Check all cables for visible

damage (kinks, nicks or cuts)
Check all connectors for poor

connections, water or corrosion
Check alignment of antenna
Check for physical damage of

antenna, including ice build-up

X -3

Thank you

for choosing

Technalogix Ltd.