Technalogix TAV250H Users Manual

TAV-250

TAV-250

ANALOG TV POWER AMPLIFIER

OPERATING

MANUAL

You’ve already unpacked it, haven’t you? You’ve unpacked it and

TAV-250

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

TAV-250

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

S

TANDARD 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

ISOLATOR...........................................................................................................IV-4

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

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

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

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

USER INTERFACE MODULE..................................................................................VI-1

OUPLER CONDITIONING MODULE .......................................................................VI-2

C

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

T

EMPERATURE SENSOR MODULE ........................................................................VI-4

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

EMOTE PORT ...................................................................................................VI-6

R

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

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

S

CHEMATICS....................................................................................................VI-10

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

TAV-250

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

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

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

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

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

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

UNPACKING AND INSPECTION.............................................................................VIII-6

LOCATION AND FUNCTION OF CONTROLS AND CONNECTORS (TAV-250 POWER

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

NITIAL HOOK UP ............................................................................................VIII-11

I

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

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

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

Section I - Safeguards

TAV-250

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

TAV-250

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

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

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

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

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

• a first-degree burn reddens the skin.

• a second-degree burn blisters the skin.

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

accompanied by respiratory paralysis.

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

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

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

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

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

I-2

Operating Safeguards

TAV-250

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

TAV-250

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 US per day plus air fare and meals.

II-1

To claim your rights under this warranty:

TAV-250

• 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

• 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

) for the RMA form (Service) and fill it out. Either fax it to us or email to us.

II-2

Section III - Overview

TAV-250

Standard Features

• Narrow output bandpass filter (if installed) allows adjacent channel operation

• Front panel Liquid Crystal Display (LCD) to monitor system parameters.

• 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

• 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

TAV-250

The TAV-250 power amplifier supplies a 250-watt peak video signal with an aural carrier level 10 to
13 dB below visual carrier (dBc) on any of the VHF television channels 2 through 13. Please note
that channel selection must be made at time of order, as the transmitter or translator is calibrated
and tested to the channel requested and is not field tuneable. The TAV-250 power amplifier is a
modular solid-state 250-watt broadcast amplifier utilizing readily available RF components wherever
possible, thus enhancing the serviceability of the equipment.

The TAV-250 is comprised of a 25 watt driver pallet in addition to a 400 watt final pallet that
provides 250 watts of peak visual power in addition to the aural carrier power.

The TAV-250 features ultra linear amplification with amplifier modules that are stable for high
reliability and long service life.

III-2

Block Diagram

TAV-250

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 gets preamplified using a driver pallet before the signal passes into
a final pallet for final amplification. The signal then passes through an isolator. Finally, the
signal gets monitored with a dual directional coupler before heading out to an antenna for
broadcast.

III-3

A=+40dB typ. low band VHF

TAV-250

A=+34dB typ. high band VHF

VHFTV25-VHF DRIVER

VHFTV400-VHF FINAL

Bandpass Filter

CIRCULATOR

U3

DIRECTIONAL COUPLER

Attenuation

RF INPUT RF OUT

V

V

V

TO WATTMETER

A=+18dB typ. low band VHF

AND ANTENNA

A=+15dB typ. high band VHF

50 OHM
TERMINATION

TAV-250 Block Diagram

Rev ID

Date: May 25, 2005 Page: 1 of 1

Specifications

TAV-250

The following specifications were taken with a Technalogix modulator/processor. Should a different
modulator or processor be used, specifications could vary. For this reason, we recommend that any
different modulator/processor be shipped to Technalogix so the system can be matched and set up
optimally. In addition, the audio/video ratio the input to the power amplifier needs to be –10 dB in
order for the software and LCD readout to be accurate.

RF Characteristics

Frequency range any specified VHF Channel 2 to 13
Frequency Response (one channel) ±0.5 dB
Frequency Stability ±250 Hz
Selectivity 60 dB (adjacent channel)
Minimum Input Level 0 dBmV
Rated Visual Output Power 250 Watts
Rated Aural Output Power 10% of peak visual power
IF Output Level +35 dBmV nominal
Input Impedance 75 Ohms
Output Impedance 50 Ohms
Harmonics > 60 dB below rated power
Predominant Intermodulation Distortion dBc = decibels below visual carrier

+ 920 kHz > -53 dBc

- 920 kHz > -53 dBc

+ 2.66 MHz > -53 dBc

- 2.66 MHz > -53 dBc
+ 5.42 MHz > -53 dBc
+ 7.16 MHz > -53 dBc

3rd Order Intermodulation Distortion

+ 4.5 MHz > -60 dBc
+ 9.0 MHz > -60 dBc

All others > -60 dBc

Spurious Emissions > -60 dBc

NTSC Video Characteristics

Input Level to modulator (for 87.5% modulation) 1.0 V
Differential Phase (at 87.5% modulation) ±2 Degrees
Differential Gain (at 87.5% modulation) 2%
Group Delay < ±40 nS
Video Group Delay Pre-emphasis Conforms to IC/FCC specifications
K-Factor 1.9% for 2T Pulse
Hum and Noise > 60 dB below rated power

PP

III-4

Aural Characteristics

TAV-250

Input Level for 25 kHz Deviation 0.3 V
Frequency Response (Standard Pre-emphasis) ±1 dB
Harmonic Distortion (25 kHz Deviation) < 1% 50 Hz to 15 kHz
Amplitude Modulation Noise > 50 dB
Frequency Modulation Noise > 60 dB
Intercarrier Stability ±250 Hz

Physical Characteristics

Power Requirements

Power Supply

115Vac, 11A or 230Vac, 5.3 Aac
Operating Temperature
Dimensions

Power Amplifier

W-19" flange (17” encl.) , D-25", H-8-3/4” (5U)

PP

0 - 50°C

III-5

Section IV – RF Components

TAV-250

Amplifier Pallets

The VHFTV-25 pallet is a two stage ultra linear class-A linear pallet. The VHFTV-25-L has a typical
gain of 40dB and the VHFTV-25-H has a typical gain of 34dB. These pallets draw no more than

3.25Adc 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
VHFTV-25 pallet by measuring the voltage drop across the current sense resistor found directly at
the DC power supply lead input to the pallet. This resistance is 0.01-ohms, providing a 10mV per
ampere ratio.

The final amplifier stage is comprised of a VHFTV-400-L or VHFTV-400-H amplifier pallet and
are characterized with typical gains of 18 dB (low band) or 16dB (high band) and maximum
drain currents of 11 A (low-band) or 14 A (high-band).

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

TAV-250

Technalogix Ltd.

25 Watt High Band VHF Pallet

PA25-VHF-H

S. Kazarian

November 12, 2001

B

B

TAV-250

Technalogix Ltd.

400 Watt High Band VHF Pallet

P400-VHF-H

R.S. McDonald

July 30, 2001

B

A

Filter

TAV-250

The passive bandpass filter rejects spurious and harmonic output products and passes the VHF
channel RF output. The cavity resonator uses aperture coupling and is a linear resonator design.
Typical insertion loss is 0.6 dB to 1.0 dB depending on channel frequency. Average roll off is –33
dBc at a point 4.5 MHz below the peak visual carrier frequency and –30 dBc 9.0 MHz above the
peak visual carrier frequency. The filter is DC grounded on both the input and output for additional
lightning protection.

Directional Coupler

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

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. Even though the flanged power resistor is rated for
only 150-watts, and there could potentially be 500-watts being reflected back into the circulator, the
software will recognize quickly that reflected power is present and turn the carrier off. This way,
there is instantaneous protection due to the isolator setup and long term protection due to the
software.

IV-4

Section V – Power Supply

TAV-250

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 30 Vdc nominally.

The power supply is a Cotek-800S-P. 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

TAV-250

800S-P □□□□ Series

Switching Power Supply

With PFC

User’s Manual

TAV-250

800S-P Series Switch Power Supplies

♦ Universal AC Input

♦ 0.98 Typical Power Factor

♦ Forced Current Sharing at Parallel Operation

♦ Power Failure Signal

♦ Remote Sense

♦ Remote ON / OFF control

♦ SC / OV / OL / OT Protection

♦ Programmable Output Voltage

Specification

Model

Input Voltage Range 90 ~ 260V AC, 47~63 Hz ( 90~170VAC reduce power see curve below )

Input Current (Typ.) 4.5A / 230 V AC

Inrush Current (Typ.)

Power Factor (Typ.) 0.98

800S -P009 800S-P012 800S-P015 800S-P018

RESULT A：42.0A

Efficiency 83% 84% 85% 85%

DC Output Voltage +9V DC +12V DC +15V DC +18V DC

Max.-Min.＞15% Adj. Typical adjustment by potentiometer

Output Voltage Adjustment

Ripple & Noise

Line & Load Regulation Less than 1%

Output Rated Current 88.8A 66.6A 53.3A 44.4A

Max Output Power 800W

Over Voltage Protection 110% ~ 135% ( variable “OVP” follows the adjustable DC output voltage )

Over Load Protection

Remote ON / OFF Control Compatible with a TTL signal to turn ON / OFF

Remote Sense Yes

Power Failure Signal Open Collector of NPN Transistor

Parallel Operation Yes

Setup , Rise , Hold Up Time

Temp. Coefficient

Working Temp., Humidity

Storage Temp., Humidity

Vibration 10 ~ 200Hz, 2g 10min./1 Cycle, Period of 60 min. for each axes

Current limiting 3 times (1.5”, 3.0”, 5.0”) then intelligent auto recovery

25% ~ 100% Adjustment by 1 ~ 5v DC external control

1%

before shutdown

RESULT A：12.4mS

±0.04% / ℃ ( 0 ~ 50℃)

0℃~+50℃ @100% Load, +65℃ @50% Load, 20% ~ 90% RH

-20℃~+85℃ 10%~95% RH

Safety Standards UL1950, TUV EN60950

EMC Standards EN55022, EN610000-4-2,3,4,5,6,8,11, EN61000-3-2,3, ENV50204

Leakage Current < 3.5mA / 240V AC

Cooling Power rating & temperature controlled fan

Dimension Weight ; Q’ty /

Carton

291 x 120 x 68 mm (L X W X H) / 2.3 Kgs ; 8 Sets / Ctn

1

TAV-250

800S-P Series Switch Power Supplies

♦ Universal AC Input

♦ 0.98 Typical Power Factor

♦ Forced Current Sharing at Parallel Operation

♦ Power Failure Signal

♦ Remote Sense

♦ Remote ON / OFF control

♦ SC / OV / OL / OT Protection

♦ Programmable Output Voltage

Specification

Model

Input Voltage Range 90 ~ 260V AC, 47~63 Hz ( 90~170VAC reduce power see curve below )

Input Current (Typ.) 4.5A / 230 V AC

Inrush Current (Typ.)

Power Factor (Typ.) 0.98

800S-P024 800S-P036 800S-P048 800S-P060

RESULT A：42.0A

Efficiency 88% 88% 89% 90%

DC Output Voltage +24V DC +36V DC +48V DC +60V DC

Max.-Min.＞15% Adj. Typical adjustment by potentiometer

Output Voltage Adjustment

Ripple & Noise

Line & Load Regulation Less than 1%

Output Rated Current 33.3A 22.2A 16.6A 13.3A

Max Output Power 800W

Over Voltage Protection 110% ~ 135% ( variable “OVP” follows the adjustable DC output voltage )

Over Load Protection

Remote ON / OFF Control Compatible with a TTL signal to turn ON / OFF

Remote Sense Yes

Power Failure Signal Open Collector of NPN Transistor

Parallel Operation Yes

Setup , Rise , Hold Up Time

Temp. Coefficient

Working Temp., Humidity

Storage Temp., Humidity

Vibration 10 ~ 200Hz, 2g 10min./1 Cycle, Period of 60 min. for each axes

Current limiting 3 times (1.5”, 3.0”, 5.0”) then intelligent auto recovery

25% ~ 100% Adjustment by 1 ~ 5v DC external control

1%

before shutdown

RESULT A：12.4mS

±0.04% / ℃ ( 0 ~ 50℃)

0℃~+50℃ @100% Load, +65℃ @50% Load, 20% ~ 90% RH

-20℃~+85℃ 10%~95% RH

Safety Standards UL1950, TUV EN60950

EMC Standards EN55022, EN610000-4-2,3,4,5,6,8,11, EN61000-3-2,3, ENV50204

Leakage Current < 3.5mA / 240V AC

Cooling Power rating & temperature controlled fan

Dimension Weight ; Q’ty / Carton 291 x 120 x 68 mm (L X W X H) / 2.3 Kgs ; 8 Sets / Ctn

2

TAV-250

Connector pin-out drawings

3

TAV-250

Output power vs. input voltage de-rating curve

Output power vs. ambient temperature de-rating curve

4

TAV-250

Mechanical drawings

5

Section VI – Monitor and Control System

TAV-250

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

VI-1

on their way from the power supply to the pallets. The DC enters through connector J101 from

TAV-250

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 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

TAV-250

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 opto­isolators 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

TAV-250

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

TAV-250

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

TAV-250

Circuit:

Revision:

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 2.7KΩ 0805 Yageo 9C08052A2701FKHFT

C162 1 CAPACITOR 1uF, 50V 0805 TDK Corporation C2012Y5V1H105Z

R132 1 RESISTOR 37.4KΩ 0805 Yageo 9C08052A3742FKHFT

R133 1 RESISTOR 3.3KΩ 0805 Yageo 9C08052A3301FKHFT

R134, R135, R136,

R137, R138, R139 6 RESISTOR 249KΩ 0805 Yageo 9C08052A2493FKHFT

R140, R141, R144
R145, R146, R147
R150, R151, R156 9 RESISTOR 10KΩ 0805 Yageo 9C08052A1002FKHFT

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

R152 1 RESISTOR 100Ω 0805 Yageo 9C08052A1000FKHFT

R119, R122, R125,

R128, R131, R153 6 RESISTOR 100KΩ 0805 Yageo 9C08052A1003FKHFT

R158 1 RESISTOR 430Ω 0805 Yageo 9C08052A4300FKHFT

R160 1 RESISTOR 1.4KΩ 0805 Yageo 9C08052A1401FKHFT

R161 1 RESISTOR 27KΩ 0805 Yageo 9C08052A2702FKHFT

R162 1 RESISTOR 6.2KΩ 0805 Yageo 9C08052A6201FKHFT

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

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

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

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

RN101 1 RESISTOR NETWORK 10KΩ SMT Panasonic EXB-A10P103J

F107 1

F108 1

L106, L107, L108,

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

User Interface Module

1.03

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

Y101 1 6.00 MHz CRYSTAL SMT Citizen HCM49-6.00

TAV-250

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 SW S-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

TAV-250

Circuit:

Revision:

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

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

U202 1

Coupler Conditioning

1.04

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%, 1kohm,
1/8W SMD 0805 Panasonic ERJ-6GEYJ102V

Resistor, thick film, 5%, 10kohm,
1/8W SMD 0805 Panasonic ERJ-6GEYJ103V
Resistor network, 10kohm, 8­resistors, 10-terminations, bussed,
5% SMD 2512 Panasonic EXB-A10P103J
Resistor network, 1kohm, 8­resistors, 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
IC, microcontroller, 16-bit, 16k X 8
program, 48 I/O, flash 64-QFP Texas Instruments MSP430F135IPM

VI-8

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

TAV-250

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, 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

VI-9

TAV-250

Circuit:

Revision:

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

R301 1

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

RF Conditioning

1.05

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, vertical PCB THT Amp (Tyco) 5556416-1

Printed circuit board, FR4, proto 2 or
equivalent - Alberta Printed Circuits PCB301
Resistor, thick film, 5%, 620ohm,
1W SMD 2512 Panasonic ERJ-1TYJ621U

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

PCB THT

(0.2") Wieland 25.350.3253.0

PCB End

Launch Johnson Components 142-0701-801

VI-10

VR303 1 Potentiometer, 200ohm SMT 5MM Murata PVG5A201C01R00

TAV-250

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

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

VI-11

TAV-250

Circuit:

Revision:

Designations Qty Description Package Manufacturer Mfg. Part Number

Temperature Sensor

1.02

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

VI-12

TAV-250

Circuit:

Revision:

Designations Qty Description Package Manufacturer Mfg. Part Number

TxNet

1.02

F601, F602, F603,

F604 4

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

J611 10

J602 1

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

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

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

VI-13

Insight System Schematics

TAV-250

The following pages contain the schematics for the Insight system.

VI-14

DC Supply Conditioning

TAV-250

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

GND IN

1

F106

TAC 58V

tbd

J101F

SMBJ30A TV
SMBJ48A FM

D111

Fuse Table

PA5-UHF 4 A

2 A

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

10 A

10 A/side

3 A

7.5 A/side

15 A

15 A/sideP750-FM

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

TAV-250

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

TAV-250

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

Pow-IN

Nav-IN

+3 Vdc

Sel-IN

Res-IN

GND

3

J103D

J103A

J103B

J103E

J103C

R140

10k

R146

10k

R141

10k

R147

10k

R143

R142

1k

1k

R1481kR149

1k

U109

MOCD211M

P1
P2
P3
P4 P5

U110

MOCD211M

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

TAV-250

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

RST

P58A0P59A1P60A2P61

P62

U112

MSP430F133

P22

P19

P20

P21

P23

P2 2

TCK

P57

P24

TMS

P56

P25

TDI

P55

P26

TDO

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

S101

7
6
5
4
3
2
1

CANterm1

CANterm2

RN101 10k

SCK

SOMI
SIMO
CAN CS

+3.3 Vdc

A. Sivacoe, N. Hendrickson

User Interface Module

Rev ID

B Insight Control System

Date: April 30, 2005 Page: 4 of 9

User Interface Module

TAV-250

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

TAV-250

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

IN

U117

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

Vin

LM2679

Gnd

Rads

R162

6.2k

+
C154

100uF

R160

1.4k

U119

Feedbk
Cboost

Vout

SoftStart

C162

1uF

S102

R161

C163

27k

0.01uF

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

TAV-250

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

P49

P50

P51

P52

P53

P54

P55

P56

P57

P58A0P59A1P60A2P61

P62

P63

P64

- 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

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

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

0.01uF

+5 Vdc

ATEN-Vcc
ATEN1
ATEN2

ATEN3
ATEN4
ATEN5

1

C208

0.01uH

J201a4
J201a2
J201a1
J201a3
J201a5
J201a7

L203

C209

0.01uF

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

TAV-250

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

C210

100uF

C211
100uF

P8

CANH

P7

CANL

P6
P5

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

TAV-250

+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

TAV-250

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

1 2

C225

0.01uF

FWD-OUT

RFL-OUT

D206B

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

TAV-250

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

TAV-250

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

TAV-250

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

TAV-250

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

TAV-250

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, within the 250-watt power amplifier enclosure,
there are two fans that each provide 170 cubic feet per minute (CFM) of air flow (into zero static
pressure). There is one fan mounted at the front of the heat sink and one mounted at the back end
of the heat sink. The fans are mounted at each end to produce the best cooling for the system and
are operating in a push-pull configuration to assist with heat dissipation. The fans are a 24Vdc
variety, so there are series dropping resistors to drop the higher power supply voltage down to a
safe level.

VII-1

Section VIII - Installation

TAV-250

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

Building Recommendations

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

Technalogix Ltd

.

VIII-1

Heating and Cooling Requirements

TAV-250

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

Technalogix Ltd

.

VIII-2

Electrical Service Recommendations

TAV-250

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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VIII-3

Antenna and Tower Recommendations

TAV-250

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 250-watt
unit will only deliver 125 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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VIII-4

Shelter Security

TAV-250

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

Technalogix Ltd

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VIII-5

Unpacking and Inspection

TAV-250

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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VIII-6

Location and Function of Controls and Connectors (TAV-250 Power Amplifier)

TAV-250

The following illustration depicts the location of the connectors when installing the 250-watt power
amplifiers (TAV-250).

Technalogix Ltd

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VIII-7

TAV-250

POWER - Tactile button to turn carriers on and off.
NAVIGATE - Tactile button to move between menu items, or to refresh the screen after it

has timed out.

SELECT- Tactile button to select menu item, or to refresh the screen after it has timed

out.

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

faults. The amplifier will come back on with the soft start feature.

RF IN – RF input from modulator or processor. BNC connector, 50 ohm.
RF OUT – 100-watt RF output. Connects to inline wattmeter (not supplied) and

antenna. N connector, 50 ohm.

REMOTE PORT - Port to monitor and control the amplifier externally. See “ Monitor and

Control” section for pin-out.

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

high current draw from switching power supply. The thermal circuit
breaker is a single pole configuration.

AC ON/OFF - AC rocker switch (SPST) to supply AC to the AC-DC switching power

supply

Technalogix Ltd

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VIII-8

TAV-250

Initial Hook Up

1. Ensure that the antenna has been swept and has a return loss of greater than 20dB (VSWR
= 1.2:1). This should be done before connecting the antenna cable to the transmitter output.

2. Check that your video source is present.

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

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

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

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

6. Plug power amplifier into AC mains.

7. Switch AC rocker switch to “on” position.

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

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

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

Technalogix Ltd

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VIII-9

TAV-250

Section IX - Operating Procedure

Assuming the previous installation instructions have been completed and cautions noted, and the
TAV-250 power amplifier is ready to receive a properly modulated video and audio signal, proceed
with the following steps to place the system in operation. The TAV-250 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 5U power amplifier enclosure into AC mains.

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

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

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

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

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

IX-1

TAV-250

10. The TAV-250 LCD shows the user the present status of the amplifiers. Adjust RF output power
to desired level (see Important RF Power Notice in previous section). Verify that the FWD
Power reads 80% to 100% on the filter enclosure - depending on signal content. The system is
set up for 250 watts peak visual power using the sync and blanking signal and should read 100
% FWD Power on the LCD under this condition only. The output power level can b e adjusted
using the modulator or processor’s RF output level adjust. Keep in mind that the system will
attenuateshould the forward RF output power level be exceeded.

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

12. Verify that the power supply reads approximately 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. The picture and sound quality should be
clean and sharp. If the output picture and sound quality is unsatisfactory, check the input
signals, connections to the antenna system, antenna and transmission line VSWR, and the
physical condition of the antenna.

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

IX-2

Section X – Maintenance and Troubleshooting

TAV-250

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

TAV-250

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)

X -2

TAV-250

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

TAV-250

for choosing

Technalogix Ltd.