Technalogix TAVD-500 User Manual

TAVD-500
POWER AMPLIFIER
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: 403.347.5400 Fax: 403.347.7444 URL: www.technalogix.ca Email: technical@technalogix.ca
sales@technalogix.ca
We truly appreciate that you have chosen us as your television broadcast system supplier. Happy viewing.
Table of Contents
SECTION I- SAFEGUARDS................................................................................................................. I-1
S
AFETY AND FIRST AID.................................................................................................................... I-2
OPERATING SAFEGUARDS ............................................................................................................... I-3
S
ECTION II - WARRANTY ................................................................................................................ II-1
S
ECTION III - OVERVIEW................................................................................................................. III-1
S
TANDARD FEATURES ...................................................................................................................III-1
PRINCIPLE OF OPERATION ............................................................................................................. III-2
B
LOCK DIAGRAM (TAVD-500)....................................................................................................... III-3
RF SIGNAL PATH...........................................................................................................................III-4
BLOCK DIAGRAM (TAVD-500)....................................................................................................... III-3
S
PECIFICATIONS ............................................................................................................................ III-5
S
ECTION IV - RF COMPONENTS......................................................................................................IV-1
A
MPLIFIER PALLETS ......................................................................................................................IV-1
SPLITTER/COMBINER .....................................................................................................................IV-4
DIRECTIONAL COUPLER .................................................................................................................IV-4
I
SOLATOR......................................................................................................................................IV-4
FILTER ..........................................................................................................................................IV-4
S
ECTION V - POWER SUPPLY SECTION ............................................................................................V-1
S
ECTION VI - MONITOR AND CONTROL SYSTEM ..............................................................................VI-1
C
ONTROL BOARD OVERVIEW (INSIGHT)..........................................................................................VI-1
USER INTERFACE MODULE .............................................................................................................VI-2
COUPLER CONDITIOING MODULE ....................................................................................................VI-3
RF
CONDITIONING MODULE ...........................................................................................................VI-3
TEMPERATURE SENSOR MODULE...................................................................................................VI-3
T
XNET MODULE.............................................................................................................................VI-3
EMOTE PORT...............................................................................................................................VI-4
R F
AULT SHUTDOWN.........................................................................................................................VI-5
B
ILL OF MATERIALS ......................................................................................................................VI-6
SCHEMATICS ...............................................................................................................................VI-12
S
ECTION VII - MECHANICAL SECTION ............................................................................................VII-1
S
ECTION VIII - INSTALLATION .......................................................................................................VIII-1
B
UILDING RECOMMENDATIONS.....................................................................................................VIII-1
HEATING AND COOLING REQUIREMENTS.......................................................................................VIII-2
E
LECTRICAL SERVICE RECOMMENDATIONS ..................................................................................VIII-3
A
NTENNA AND TOWER RECOMMENDATIONS .................................................................................VIII-4
SHELTER SECURITY.....................................................................................................................VIII-5
U
NPACKING AND INSPECTION.......................................................................................................VIII-6
L
OCATION AND FUNCTION OF CONTROLS AND CONNECTORS (TAVD-500 POWER AMPLIFIER).......VIII-7
L
OCATION AND FUNCTION OF CONTROLS AND CONNECTORS (COMBINER ENCLOSURE .................VIII-11
INITIAL HOOK UP……………………………………………………………………………………… VIII-13 S
ECTION IX - OPERATING PROCEDURE...........................................................................................IX-1
S
ECTION X - MAINTENANCE AND TROUBLESHOOTING.......................................................................X-1
T
ROUBLESHOOTING........................................................................................................................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.
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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 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.
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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.
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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 US per day plus air fare and meals.
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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
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.
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Terms & Conditions of Sale
Sales by Technalogix Ltd (“Seller”) are made only on the terms which are contained in this Terms and Conditions of Sale Policy. Seller hereby gives notice of its objection to any different or additional terms and conditions. All sales are expressly conditional upon Buyers’ assent to the terms and conditions set forth below. These terms and conditions may be modified or supplemented only by a written document sighed by the authorized representative of Seller. These terms and conditions supersede any prior and/or contemporaneous agreements or correspondence between Buyer and Seller. Any order received and accepted by Technalogix Ltd (Seller) shall be construed as an acceptance of Seller’s offer to sell its products to the purchaser (Buyer) in accordance with the terms and conditions of sale set forth herein. No waiver, whether express or implied, by Seller of any of the terms or conditions hereof shall be deemed a continuing waiver or trade custom between the parties, but shall apply solely to the instance to which the waiver is directed.
Ordering Information
All orders must be in writing and/or accompanied by a PO. 50% down payment is required with all orders. No orders are considered an order until the down payment has been paid.
Order Confirmation
A purchase order is not binding on Seller until Buyer has received Seller’s order confirmation or acknowledgement.
Pricing Policy
Prices for products do not include taxes or any additional charges. All prices are FOB shipping point and prices do not include freight/handling charges and insurance charges. All prices are in U.S. currency.
All prices published or quoted by Seller may be changed at any time without notice. Unless otherwise specified, written quotations expire thirty (30) days from the date issued and are subject to change or termination by notice during this period.
Taxes
Prices for all products do not include any sales, use, excise or other taxes. Buyer agrees to pay all applicable federal, state, and local taxes, duties and other fees on product and services ordered. If Buyer claims an exemption form any tax, Buyer shall submit to Seller the appropriate exemption certificates.
Shipping
Shipping is the responsibility of the Buyer. This includes all freight, custom and brokerage charges and duties.
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Terms of Payment
Seller will provide credit terms to Buyer at its discretion. Such terms are subject to change at all times. If credit is provided, Seller will invoice Buyer on the date the product is ordered. Such invoices will be due and payable net thirty (30) days from date of invoice, subject to credit approval. If credit is not established or maintained, terms shall be net cash on or prior to the Delivery Date. Seller reserves the right, at its sole discretion at any time to revoke any credit previously extended.
Past due accounts shall be charged two percent (2%) per month, or the highest rate permitted by Alberta law, whichever is less, and will be added to the outstanding balance. In the event Buyer defaults on payment, Buyer shall be liable for all collection cost, including reasonable attorney’s fees and costs.
Changes and Cancellation
Purchase orders that have been accepted by Seller may not be changed or cancelled, in whole or in part, without written consent of Seller. All changes must be include in a change order reflecting the purchase order number and submitted to the Seller. All other changes will not be accepted or acknowledged. Changes may affect delivery dates. Expenses incurred because of the changes shall be charged to the Buyer. Buyer will be liable for Seller’s costs incurred, plus a reasonable profit, for the portion of the work terminated, in accordance with generally accepted accounting principle, together with cancellation charges.
Orders for standard product may be changed by Buyer, with no penalty to the Buyer, provided that Buyer provides Technalogix notification at least 30 days prior to the scheduled ship date. Order changes received within 30 days of the scheduled ship date may be subject to an order change charge; a schedule detailing these charges will be forwarded to Buyer when Buyer’s change order is acknowledged. In no event can any aspect of the order be changed after product shipment has occurred.
Orders for custom product may be canceled by Buyer, provided that Buyer pays Seller for completed work allocated to Buyer’s order at the time of termination of the work at the unit selling price and all costs, direct and indirect for work-in-progress as well as costs resulting from cancellation and a reasonable profit therein. Specific cancellation charges will be dependent on the type of custom product ordered; a schedule detailing these charges will be forwarded to Buyer when Buyer’s cancellation is acknowledged. Orders for custom product are subject to a cancellation fee of up to 100% of the order, depending on the stage of completion of the order at the date the cancellation or revision is accepted.
Custom Products Policy
Custom items are not returnable; items other than “off the shelf” products are considered custom. Custom products, by their nature, are products and materials which have been altered, modified, cut, amended and customized to your order, and are not resalable or returnable.
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Orders for custom product are subject to a cancellation fee of up to 100% of the order, depending on the stage of completion of the order at the date the cancellation or revision is accepted.
Returns
The return of Products without a written authorization by Seller will not be accepted. Returns are accepted only with a valid Return Material Authorization (RMA) number for items to be returned. To receive authorization for Product return, please call customer service. There is a standard 25% restocking cost assessed on most returns.
All returned products must be unused, and in original condition. No refund or credit shall be given for damaged products.
We do not accept return packages without a valid RMA number and we do not accept postage­due or C.O.D. packages at any time for any reason.
Excusable Delay
Seller shall not be liable for any loss or damage resulting from any delay in delivery or failure to deliver which is due to any cause beyond Seller’s control, including, without limitation, acts of nature, unavailability of supplies or sources of energy, riots, wars, fires, floods, epidemics, lockouts, strikes and slowdowns, delays in delivery by supplies, or acts or omissions of the Buyer. The Buyer shall be liable for stage charges, including but not limited to all third party costs and expenses incurred by Seller, in holding or storing products for the Buyer or at the Buyer’s request.
Assignment
Buyer shall not assign any duties nor assign any order or any interest therein without the written consent of the Seller. Any such actual or attempted assignment shall entitle Seller to cancel the order upon written notice to Buyer.
Installation
Seller assumes no obligation to install any product sold or to place any products in working order at Buyer’s premises
Validity of Separate Clauses
If any provisions of this agreement shall be held invalid, illegal, or unenforceable, the validity, legality or enforceability of the remaining provisions shall not be affected or impaired thereby.
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Section III – Overview
Standard Features
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
All aluminium enclosure maintains power amplifier’s light weight
Simple design using commonly available parts ensures reliable operation
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Principle of Operation
The TAVD-500 power amplifier supplies a 500-watt (rms) 8VSB television signal 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 TAVD-500 power amplifier is a modular solid-state system comprised a TAVD­500 500-watt broadcast amplifier utilizing readily available RF components wherever possible, thus enhancing the serviceability of the equipment.
Each TAVD-500 is comprised of a VHFTV-25 and a VHFTV-200 driver pallet and (4) VHFTV-400 final pallets that are combined to create 500 watts (rms) 8VSB power. The amplifier modules are stable for high reliability and long service life.
The TAVD-500 features ultra linear amplification and individual channel RF output bandpass filtering.
The following block diagram illustrates the 500-watt system.
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FILTER
TAVD -50 0 AM PL IFI ER
Modulator or Processor
External power supply
RF Out
TAVD-500 BLOCK DIAGRAM
Date: May 21, 2009 Page: 1 of 1
Rev ID
TAVD-500 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 gets preamplified through the two driver pallets before the signal gets split into (4) signals for final amplification. The output of the (4) final amplifier pallets get combined and passes through an isolator. Finally, the signal passes through a dual directional coupler for monitoring purposes before heading out to the combiner/filter enclosure and then through to the antenna.
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VHFTV-200 Driver Pallet
VHFTV-25 Driver Pallet
A=-0.05 dB typical
A=-0.5dB t ypi cal
To W attmete r and Ant en n a
VHFTV-40 0H FINAL AMPLIFI ER PAL LET
VHFTV-40 0H FINAL AMPLIFI ER PAL LET
4 WAY SPL IIT ER
4 WAY COM BIN ER
RF INPUT RF OUT
Directional C
TERMINATION
50 OHM
ATTENUATION
TAVD-500 Power Amplifier Block Diagram
Date: May 21, 2009 Page: 1 of 1
Rev ID
Specifications
Electrical specifications that are specific to the unit are included with the shipment in addition to being kept on file at Technalogix.
Physical Characteristics
Power Requirements
Power Supply
Operating Temperature
220 VAC, 11 A
0 - 50°C
Dimensions
TAVD-500 Power Amplifier
Filter
Power Supply
W-19" flange (17” encl.), D-25-
W-19" flange (17” encl.), D-25-
W-19" flange (17” encl.), D-25-
¼", H-101/2”
(6U)
¼", H-8-¾”
(5U)
¼", H-5-1/4”
(3U)
AC
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Section IV – RF Components
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 36dB and the VHFTV-25-H has a typical gain of 34dB. These pallets draw no more than
3.5Adc 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 VHFTV-200 pallet is a two stage ultra linear class-A linear pallet. The VHFTV-200-L and –H pallets have a typical gain of 20dB and the VHFTV-200-H has a typical gain of 18dB. These pallets draw no more than 4 Adc total drain current (the exact bias and drain currents of your system are found in the spec sheet supplied with each manual).
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 17 A (low and high band) for 8VSB systems.
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.
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Filter
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. 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 while the 7/16” DIN connectors can handle over 3,000-watts peak.
Isolator
The power amplifier pallets are protected in part by the isolator located in the power amplifier enclosures. 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.
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Section V – Power Supply
Switching AC-DC power supplies are used to power the amplifier pallets, the control circuits, and all of the fans. The power supply is set at 30.0 Vdc nominally. All fans run off this same supply, though they pass through a series dropping resistor to lower the supply voltage, as the fans are 24Vdc.
The (2) power supplies found in the power supply enclosure are Mean Well RSP-1500-27. The switching power supplies are 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 (220Vac) is fed into the power supply enclosure via a filtered AC entry and then through a circuit breaker.
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Stock No. Model No. Output Tol. Effi.R&N
11231 11232 11233 11234 11235 11236
RSP-1500-5 RSP-1500-12 RSP-1500-15 RSP-1500-24 RSP-1500-27 RSP-1500-48
5V, 0~240A 12V, 0~125A 15V, 0~100A 24V, 0~63A 27V, 0~56A 48V, 0~32A
²2%
²1%
²1%
²1%
²1%
²1%
150mV 150mV 150mV 150mV 150mV 200mV
80% 87% 87% 90% 90% 91%
ƤUniversal AC input / Full range
ƤPF>0.98@115VAC; >0.95@230VAC
ƤUsing ZVS te chn ology to reduce power
dissipation
ƤHigh power d ens ity 8.3W/in
3
ƤBuilt-in 12V / 0. 1A auxiliary output
ƤAlarm signal output
ƤDC output vo lta ge adjustment 70~100%
by external r esi stor
ƤActive current sharing up to 6000W (3+1)
ƤBuilt-in remote sense f unc tion
ƤBuilt-in remote ON/OFF control
ƤProtections: Short circuit / Overload
Over voltage / Ove r temp.
ƤForced air c ool ing by built-in DC fan
Ƥ3 years w arrant y
AC input voltage range DC adjustment range Overload protection
Over voltage protection Setup, rise, hold up time Withstand voltage Working temperature Safety standards EMC standards
Packing
90~264VAC; 127~370VDC
-30~+10% rated output voltage 105%~135% constant current limiting , shut off after 5 sec. 115%~140% rated output voltage 1500ms, 100ms, 10ms at ful l load and 230VAC I/P-O/P:3KVAC, I/P-FG:1.5KVAC, 1 minute
-20~70OC (refer to output deratin g curve) UL60950-1, TUV EN60950-1 approved EN55022 class B conducted, EN610 00-3-2,3, EN61000-4-2,3,4,5,6,8,11, ENV50204
2.6kg ; 6pcs / 16.6kg / 1.75CUFT
1500W with PFC and Parallel Function1500W with PFC and Parallel Function
. . . .
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. . . . . . . . . . . . . . . . . . . . .
278x 127x 83.5 mm
CA SE: 943
²
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: User Interface, Coupler Conditioning, RF Conditioning, Temperature Sensor, and the TxNET modules. The operation of each module is outlined in the following sections.
For the TAUD-20-3 only, all three Power Amplifier chains are controlled by one User Interface Board and all three Power amplifiers are monitored on one LCD screen. In case of an alarm, the unit number and the fault will be displayed on the front panel (i.e. PA2 High Reflected Power). During the alarm situation only the error screen will be displayed while the other two units continue to run normally. The alarm buzzer will sound different on PA1, PA2 and PA3.
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.
Digital attenuation for input signal.
Temperature of the heat sink of the transmitter.
The time since the transmitter was last shut down.
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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 by two ICs, U113 and U114, and passes through a CAT5 cable attached to connector J106. The communication link with the Coupler Conditioning module allows the User Interface module to receive information about the forward 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 one amplifier enclosure, a second CAN connection will be present between the User Interface module (J105) 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 (6-position) from the power supply, and exits through J102 (10-position) 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 through U105, buffered by U106 through U108, and sent to the analog to digital converter integrated into the microcontroller. There are up to 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 forward 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 then filtered by LC networks. The analog signals are converted to digital by an analog-to-digital converter integrated into the microcontroller U202.
Technalogix Ltd TAVD-500 Transmitter
VI-2
Aside from taking readings from the coupler, the microcontroller on the coupler conditioning module also interfaces with the RF Conditioning module (through J201) and the Temperature Sensor (through J202). The microcontroller interfaces with the system 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 amplifier enclosures that are in the 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 U207 after it receives input from the microcontroller. The analog outputs are then buffered by U206 before being sent through J208 and J209 to the TxNET board. J208, along with J209, 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 U209 through U213.
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 J301 before it passes through a fixed attenuator (Pi-network) made up of R301, R302, and R303. The signal then passes through the digitally-controlled variable attenuator U302 before exiting through J303. The input control for the digital attenuator comes from the Coupler Conditioning module through J304. The input signals are passed through the opto-isolators U302, U303, and U304 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 U701 which, after it has taken a reading, relays the digital information to the Coupler Conditioning module through J702. Also passing through J702 is a driver disable signal coming from the Coupler Conditioning module. The Temperature Sensor module simply takes this signal and passes it through to a pad, where a wire connects it to the driver pallet.
Technalogix Ltd TAVD-500 Transmitter
VI-3
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. There is a high power version for systems that have more than one amplifier enclosure and a low power version, which does not have external enclosures aside from the modulator. 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 three straight through RJ45 connection pairs: J604 to J605, J606 to J607, and J608 to J609. These connections are only used on systems with multiple enclosures, to pass control signals between enclosures; otherwise a low power TxNET is used.
Technalogix Ltd TAVD-500 Transmitter
VI-4
Remote Port
The remote port allows external control of the transmission system via the DB25. The Power Amplifier enclosure does not include all the pins in the remote port like the Combiner/Filter enclosure. The overall functions of each pin on the remote port are indicated in the following table (see the Installation section for the specifics to each enclosure):
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
9 Reset2 11 High temperature flag3 12 High VSWR flag3 13 Amplifier overdriven flag3 14 +5Vdc 15 +3.3Vdc 16 Ground 17 Ground
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. All other pins are not to be connected. Please see the Installation section for the specific pins
that are used for each enclosure.
Technalogix Ltd TAVD-500 Transmitter
VI-5
Fault Shutdowns
On the LCD (Liquid Crystal Display) the following messages may appear:
The Amplifier overdrive shutdown is set to 115%. If the Amplifier is being overdriven (the RF output level is too high) the control system will automatically attenuate the RF input signal to the PA. It will continue attenuating this signal until the RF output is below 115% total power.
If Reflected Power has been detected at the output of the transmitter, the unit will shut down for 4 seconds. This occurs 5 times – If the fault is clear the PA enables itself. If the fault still exists after 5 times, the PA disables the carrier for 10 minutes and cycles until the fault clears. During the disable time (10 minutes) the unit will still alarm with a High Reflected message on the front panel.
Technalogix Ltd TAVD-500 Transmitter
VI-6
The control system monitors the temperature of a specific location of the heat sync. If this temperature exceeds a threshold the control system will turn the RF output level down until this temperature level is reached. The RF output level will automatically be brought back when it is safe to do so.
Technalogix Ltd TAVD-500 Transmitter
VI-7
Monitor and Control System (Insight) Bills of Materials
Technalogix Ltd TAVD-500 Transmitter
VI-8
Page 1
Item Designations Qty Bin # Description Package
1 U112 1
ICT 32001
IC MICROCONTROLLER 256 BYTE RAM 64QFP
2
C106, C107, C117, C118, C128, C129,
C141, C142, C148, C149, C163 11
CAP 14902
CAPACITOR 0.01 uF 50V 10% SMD 0805
3
C108-116, C119-127, C130-140, C143-
145, C161 33
CAP 17202
CAPACITOR 0.1uF 50V 10% SMD 0805
4 C146, C147 2
CAP 07202
CAPACITOR 33pF 50V 5% SMD 0805
5 R101, R104, R107 R110, R113 5
RES 5012
RESISTOR 2.7K SMD 0805
6 C162 1
CAP 19602
CAPACITOR 1uF, 50V SMD 0805
7 R132 1
RES 6492
RESISTOR 37.4K SMD 0805
8 R133 1
RES 5112
RESISTOR 3.3K SMD 0805
9
R140, R141, R144 R145, R146, R147
R150, R151, R156 9
RES 5802
RESISTOR 10K SMD 0805
10
R134, R135, R136, R137, R138, R139,
R142, R143, R148 R149, R154, R155 12
RES 4502
RESISTOR 1K SMD 0805
11 R152 1
RES 3212
RESISTOR 100 SMD 0805
12 R119, R122, R125, R128, R131, R153 6
RES 7042
RESISTOR 100K SMD 0805
13 R158 1
RES 4002
RESISTOR 430 SMD 0805
14 R160 1
RES 4662
RESISTOR 1.4K SMD 0805
15 R161 1
RES 6312
RESISTOR 27K SMD 0805
16 R162 1
RES 5512
RESISTOR 6.2K SMD 0805
17 R157 1
RES 1575
RESISTOR 4.7 SMD 2010
18
R117, R118, R120 R121, R123, R124
R126, R127, R129 R130 10
RES 0086
RESISTOR 0.006 1% 1W SMD 2512
19 R159 1
POT 0843
POTENTIOMETER 10K 4mm SMD
20
R102, R103, R105 R106, R108, R109
R111, R112, R114 R115 10
RES 2346
RESISTOR 20
1W SMD 2512
21 RN101 1
RES 5810
RESISTOR NETWORK 10K SMT
22 F107 1
FUS 2901
RESETTABLE FUSE, POLYFUSE, 2A SMD
23 F108 1
FUS 1651
RESETTABLE FUSE, POLYFUSE, .5A SMD
24 L106, L107, L108, L109, L110 5
IND 0221
INDUCTOR 0.01uH 1210
25 Y101 1
CLK 0002
6.00 MHz CRYSTAL SMT
26 U111 1
ICT 56001
IC SUPERVISOR 2.70V LOW SOT23
27 U114 1
ICT 12000
IC TXRX 3.3V CAN 8-SOIC
28 U113 1
ICT 12001
IC CAN CONTROLLER W/SPI 18-SOIC
29 U115 1
ICT 48003
IC REG SIMPLE SWITCHER TO-263-5
30 U116 1
SEM 69000
IC DARL TRANS ARRAY 16-SOIC
31 U117 1
ICT 48004
IC REG LINEAR LDO SOT223
32 U118 1
ICT 16000
IC VOLTAGE COMVERTER 8-SOIC
Bill of Materials
Modified: 08/03/06
Circuit: User Interface Module (TV) Revision: 1.03
CAP 22271
CAP 07202
SEM 29006
SEM 29005
SEM 09005
SEM 09010
SEM 14001
SEM 24000
R219
POT 0841
ICT 32033
ICT 12000
SEM 69000
ICT 04003
ICT 18000
ICT 46001
SWT 4003
SWT 0001
CON 31502
PCB 129
Bill of Materials - ASY129A Circuit: Coupler Conditioning (D-Attn) Revision: 1.10 Modified: 12/1/08
Item Designations Qty Bin # Description Package
C201, C202, C203,
1
C208, C209, C210,
C212, C214-C223
2 C204, C211, C213 3 3 C205 1 4 C206, C207 2
L201, L202, L203,
5
L204, L205, L206,
6 D201 1 7 D202, D203, D204 3 8 D205 1 9 D206 1
10
11 D211 1 12 D212 1
13
14 R210 1
15
16 R215, R217 2
17
18 RN202, RN204 2
19 VR201, VR202 2
20 U201 1
21 U202 1 22 U203 1
23 U204 1
24 U205 1 25 U206 1 26 U207 1 27 U208 1
28
29 K201 1
30 Y201 1
31 S201 1
32
33 J205 1
34 J206, J207 2
35 1
L207, L208
D207, D208, D209,
D210
R201, R203, R205,
R206, R207, R209,
R213
R212, R216, R218,
RN201, RN203,
RN205 3
U209, U210, U211,
U212, U213
J201, J202, J203,
J204, J208, J209
17
8 IND 0221 Inductor, 0.01uH, Imax=0.45A, DCR=0.13 omhs SMD 1210
4
7 RES 0002 Resistor, thick film, 5%, 0ohm, 1/8W SMD 0805
4 RES 4502 Resistor, thick film, 5%, 1kohm, 1/8W SMD 0805
5
6
CAP 14902
CAP 17202
SEM 09008
RES 3292
RES 4872
RES 5810
RES 4510
ICT 56001
ICT 12001
ICT 36001
CLK 0001
CON 45020
CON 31521
Capacitor, ceramic, 0.01uF, 50Vdc, +/-20% SMD 0805
Capacitor, ceramic, 0.1uF, 50Vdc, +/-20% SMD 0805 Capacitor, Tantalum, 10uF 16V SMD 3528 Capacitor, ceramic, 33pF, 50Vdc, 5% SMD 0805
Diode Low ESD Protection 5.0V SOD 323 Diode Low ESD Protection 3.3V SOD 323 Diode, LED, Green SMD 0603 Diode, LED, Red SMD 0603
Diode, LED, Yellow SMD 0603
Diode, rectifier, 200V, 1A SMA Diode, zener, dual, 10V SOT-23
Resistor, thick film, 5%, 120ohm, 1/8W SMD 0805
Resistor, thick film, 5%, 2.15k, 1/8W SMD 0805 Resistor network, 10kohm, 8-resistors, 10-terminations, bussed, 5% SMD 2512 Resistor network, 1kohm, 8-resistors, 10-terminations, bussed, 5% Potentiometer, 10kohm, 11-turn, 5mm, top SMT IC, supervisor, 2.7V, internal pull-up resistor, open drain, active low IC, microcontroller, 16-bit, 16k X 8 program, 48 I/O, flash 64-QFP IC, CAN transceiver, 3.3V SOIC-8 IC, CAN controller, industrial temp, 3 transmit buffers, 2 receive buffers IC, buffer, Darlington, array SOIC-16 IC, op-amp, dual, single supply SOIC-8 IC, DAC, dual, 8-bit, serial SOIC-8 IC, voltage reference, 2.50V, +/- 0.2% SOT-23
IC, optoisolator, dual, transistor o/p, Vceo=30V SOIC-8
Relay, SPST, 4.5Vdc coil, SMT SMT
Crystal, 6.000MHz SMT
Switch, DIP, 7-position, SPST SMD 0.1"
Connector, modular, female, 8-position, vertical, Shielded Through Hole
Connector, header, IDC, 0.1" spacing, 14-pos Through Hole
Header, recept. 4pos, dual row, pass thru
Printed circuit board, FR4, rev 1.10 -
SMD 2512
SOT-23
18-SOIC
CAP 22271
CAP 07202
SEM 29006
SEM 29005
SEM 09005
SEM 09010
SEM 14001
R219
POT 0841
ICT 12000
SEM 69000
ICT 04003
ICT 18000
ICT 46001
SWT 4003
SWT 0001
CON 31502
PCB 129
Bill of Materials - ASY129B Circuit: Coupler Conditioning (V-Attn) Revision: 1.10 Modified: 12/1/08
Item Designations Qty Bin # Description Package
C201, C202, C203,
1
C208, C209, C210,
C212, C214-C223
2 C204, C211, C213 3 3 C205 1 4 C206, C207 2
L201, L202, L203,
5
L204, L205, L206,
6 D201 1 7 D202, D203, D204 3 8 D205 1 9 D206 1
10
11 D211 1 12 D212 1
13
14 R210 1
15
16 R215, R217 2
17
18 RN202, RN204 2
19 VR201, VR202 2
20 U201 1
21 U202 1 22 U203 1
23 U204 1
24 U205 1 25 U206 1 26 U207 1 27 U208 1
28
29 K201 1
30 Y201 1
31 S201 1
32
33 J205 1
34 J206, J207 2
35 1
L207, L208
D207, D208, D209,
D210
R202, R208, R209,
R213,
R212, R216, R218,
RN201, RN203,
RN205 3
U209, U210, U211,
U212, U213
J201, J202, J203,
J204, J208, J209
17 CAP 14902 Capacitor, ceramic, 0.01uF, 50Vdc, +/-20% SMD 0805
8 IND 0221 Inductor, 0.01uH, Imax=0.45A, DCR=0.13 omhs SMD 1210
4
4
4 RES 4502 Resistor, thick film, 5%, 1kohm, 1/8W SMD 0805
5
6
CAP 17202
SEM 09008
SEM 24000
RES 5802
RES 3292
RES 4872
RES 5810
RES 4510
ICT 56001
ICT 32033
ICT 12001
ICT 36001
CLK 0001
CON 45020
CON 31521
Capacitor, ceramic, 0.1uF, 50Vdc, +/-20% SMD 0805 Capacitor, Tantalum, 10uF 16V SMD 3528 Capacitor, ceramic, 33pF, 50Vdc, 5% SMD 0805
Diode Low ESD Protection 5.0V SOD 323 Diode Low ESD Protection 3.3V SOD 323 Diode, LED, Green SMD 0603 Diode, LED, Red SMD 0603
Diode, LED, Yellow SMD 0603
Diode, rectifier, 200V, 1A SMA Diode, zener, dual, 10V SOT-23
Resistor, thick film, 5%, 0ohm, 1/8W SMD 0805
Resistor, thick film, 5%, 120ohm, 1/8W SMD 0805
Resistor, thick film, 5%, 2.15k, 1/8W SMD 0805 Resistor network, 10kohm, 8-resistors, 10-terminations, bussed, 5% SMD 2512 Resistor network, 1kohm, 8-resistors, 10-terminations, bussed, 5% Potentiometer, 10kohm, 11-turn, 5mm, top SMT IC, supervisor, 2.7V, internal pull-up resistor, open drain, active low IC, microcontroller, 16-bit, 16k X 8 program, 48 I/O, flash 64-QFP IC, CAN transceiver, 3.3V SOIC-8 IC, CAN controller, industrial temp, 3 transmit buffers, 2 receive buffers IC, buffer, Darlington, array SOIC-16 IC, op-amp, dual, single supply SOIC-8 IC, DAC, dual, 8-bit, serial SOIC-8 IC, voltage reference, 2.50V, +/- 0.2% SOT-23
IC, optoisolator, dual, transistor o/p, Vceo=30V SOIC-8
Relay, SPST, 4.5Vdc coil, SMT SMT
Crystal, 6.000MHz SMT
Switch, DIP, 7-position, SPST SMD 0.1"
Connector, modular, female, 8-position, vertical, Shielded Through Hole
Connector, header, IDC, 0.1" spacing, 14-pos Through Hole
Header, recept. 4pos, dual row, pass thru
Printed circuit board, FR4, rev 1.10 -
SMD 2512
SOT-23
18-SOIC
CAP 15702
CAP 14902
CAP 17202
SEM 09005
IND 0832
RES 0002
ICT 50003
ICT 36001
SWT 0016
CON 64532
CON 57017
CON 45020
TRM 0006
PCB 0009
Bill Of Materials - ASY 0009B
Circuit: Revision: Modified:
RF Conditioning (DC Filter, VHF)
1.12 1-Dec-08
Item Designations Qty Bin # Package
1 C301 2 C302, C305 3 C303 1 4
5 6 7
8
9
10
11 U301 1 12 13 14 15 16 17 18 PCB 1
D302
D303, D304, D305,
D306, D307
L301 1 R301 1
R304, R309, R310,
R315, R316, R319
R305, R306, R311,
R312, R317
R307, R308, R313,
R314, R318
U302, U303, U304
S301
J303
J301, J302
J304
C304
1 2
1
5 SEM 09008 Diode, LED, yellow, Vf=2.0V SMD 0603
6 RES 4502 Resistor, thick film, 1%, 1k, 1/8W SMD 0805
5 RES 4582 Resistor, thick film, 1%, 1.2k, 1/8W SMD 0805
5 RES 5802 Resistor, thick film, 1%, 10k, 1/8W SMD 0805
3 1 1 2 1 1
Capacitor, ceramic, 0.022uF, 50Vdc, +/-10% Capacitor, ceramic, 0.01uF, 50Vdc, +/-10% SMD 0805 Capacitor, ceramic, 0.1uF, 50Vdc, +/-20% SMD 0805 Diode, LED, green, Vf=2.1V
Inductor, 0.1uH, 5% (VHF only) SMD 1008 Resistor, thick film, 0-ohm, 1/8W SMD 0805
IC, 5 Bit,Digital attenuator, LSB 1 dB w/Driver 20-SSOP IC, optoisolator, dual, transistor o/p, Vceo=30V Switch dip low pro, 1 pos Gold Connector, high rel socket, 2mm, SMM series Connector, SMA, female,PCB vertical mount Connector, 8-8 mod jack, shielded Trimmer, variable, 9pF-90pF, 50V Printed circuit board, FR4, 0.031", 1oz -
SMD 0805
SMD 0603
SOG.050/8B
7188VSANF(THT)
SMD
CAP 15702
CAP 14902
CAP 17202
SEM 09005
RES 0002
ICT 50003
ICT 36001
CON 57017
CON 45020
PCB 0009
Bill Of Materials - ASY0009A
Circuit: Revision: Modified:
RF Conditioning (no DC filter)
1.12 1-Dec-08
Item Designations Qty Bin # Package
1 C301 2 C302, C305 3 C303 1 4
5 6
7
8
9
10 U301 1 11 12 13 14 PCB 1
D302
D303, D304, D305,
D306, D307
R301 1
R304, R309, R310,
R315, R316, R319
R305, R306, R311,
R312, R317
R307, R308, R313,
R314, R318
U302, U303, U304
J301, J302
J304
1 2
1
5 SEM 09008 Diode, LED, yellow, Vf=2.0V SMD 0603
6 RES 4502 Resistor, thick film, 1%, 1k, 1/8W SMD 0805
5 RES 4582 Resistor, thick film, 1%, 1.2k, 1/8W SMD 0805
5 RES 5802 Resistor, thick film, 1%, 10k, 1/8W SMD 0805
3 2 1
Capacitor, ceramic, 0.022uF, 50Vdc, +/-10% Capacitor, ceramic, 0.01uF, 50Vdc, +/-10% SMD 0805 Capacitor, ceramic, 0.1uF, 50Vdc, +/-20% SMD 0805 Diode, LED, green, Vf=2.1V
Resistor, thick film, 0-ohm, 1/8W SMD 0805
IC, 5 Bit,Digital attenuator, LSB 1 dB w/Driver 20-SSOP IC, optoisolator, dual, transistor o/p, Vceo=30V Connector, SMA, female, PCB vertical mount Connector, 8-8 mod jack, shielded Printed circuit board, FR4, 0.031", 1oz -
SMD 0805
SMD 0603
SOG.050/8B
7188VSANF(THT)
CAP 15702
CAP 14902
CAP 17202
SEM 09005
IND 0831
RES 0002
ICT 50003
ICT 36001
SWT 0016
CON 64532
CON 57017
CON 45020
TRM 0006
PCB 0009
Bill Of Materials - ASY 0009C
Circuit: Revision: Modified:
RF Conditioning (DC Filter, UHF)
1.12 1-Dec-08
Item Designations Qty Bin # Package
1 C301 2 C302, C305 3 C303 1 4
5 6 7
8
9
10
11 U301 1 12 13 14 15 16 17 18 PCB 1
D302
D303, D304, D305,
D306, D307
L301 1 R301 1
R304, R309, R310,
R315, R316, R319
R305, R306, R311,
R312, R317
R307, R308, R313,
R314, R318
U302, U303, U304
S301
J303
J301, J302
J304
C304
1 2
1
5 SEM 09008 Diode, LED, yellow, Vf=2.0V SMD 0603
6 RES 4502 Resistor, thick film, 1%, 1k, 1/8W SMD 0805
5 RES 4582 Resistor, thick film, 1%, 1.2k, 1/8W SMD 0805
5 RES 5802 Resistor, thick film, 1%, 10k, 1/8W SMD 0805
3 1 1 2 1 1
Capacitor, ceramic, 0.022uF, 50Vdc, +/-10% Capacitor, ceramic, 0.01uF, 50Vdc, +/-10% SMD 0805 Capacitor, ceramic, 0.1uF, 50Vdc, +/-20% SMD 0805 Diode, LED, green, Vf=2.1V
Inductor, 0.01uH, 10% (UHF only) SMD 0805 Resistor, thick film, 0-ohm, 1/8W SMD 0805
IC, 5 Bit,Digital attenuator, LSB 1 dB w/Driver 20-SSOP IC, optoisolator, dual, transistor o/p, Vceo=30V Switch dip low pro, 1 pos Gold Connector, high rel socket, 2mm, SMM series Connector, SMA, female,PCB vertical mount Connector, 8-8 mod jack, shielded Trimmer, variable, 9pF-90pF, 50V Printed circuit board, FR4, 0.031", 1oz -
SMD 0805
SMD 0603
SOG.050/8B
7188VSANF(THT)
SMD
ICT 52000
TRM 0006
CAP 17202
CAP 08402
IND 0832
CON 31525
CON 45021
SWT 0016
PCB 180
Modified: 11/13/08
Bill of Materials - ASY 180B Circuit: Temperature Sensor (DC Filter VHF) Revision: 1.10
Item Designations Qty Bin # Description Package
1 3 4 C704 1 5 C705 1 6 L701 1 7 J701 1 8 J702 1 9 S701 1
10 1
U701 C701
1 1
IC, temperature sensor, SPI 8-MSOP TRIMMER CAPACITOR, 9-90pF THT CAPACITOR 0.1uF, 50V, 10% SMD 0805 CAPACITOR 100pF, 50V, 10% SMD 0805 INDUCTOR, 0.1uH, 10%, 175mA, 0.80ohm SMD 0805 CONNECTOR, header, 0.1", 3-position SMD CONNECTOR, modular, jack, 8-8 R/A, shielded SWITCH, 1-position, SPST SMD PRINTED CIRCUIT BOARD, FR4, 0.062"
ICT 52000
CAP 17202
CAP 11502
CAP 08402
PCB 180
Modified: 11/13/08
Bill of Materials - ASY 180A Circuit: Temperature Sensor (no DC filter) Revision: 1.10
Item Designations Qty Bin # Description Package
1 2 C702, C704 2 3 C703 1 4 C705 1 6 J702 1 CON 45021 7 1
U701
1
IC, temperture sensor, SPI 8-MSOP CAPACITOR 0.1uF, 50V, 10% SMD 0805 CAPACITOR 0.001uF (1000pF), 50V, 10% SMD 0805 CAPACITOR 100pF, 50V, 5% SMD 0805 CONNECTOR, modular, jack, 8-8 R/A, shielded PRINTED CIRCUIT BOARD, FR4, 0.062"
ICT 52000
TRM 0006
CAP 17202
CAP 08402
IND 0831
CON 31525
CON 45021
SWT 0016
PCB 180
Modified: 11/13/08
Bill of Materials - ASY180C Circuit: Temperature Sensor (w/ DC Filter UHF) Revision: 1.10
Item Designations Qty Bin # Description Package
1 2 3 C704 1 4 C705 1 5 L701 1 6 J701 1 7 J702 1 8 S701 1 9 1
U701 C701
1 1
IC, temperature sensor, SPI 8-MSOP TRIMMER CAPACITOR, 9-90pF THT CAPACITOR 0.1uF, 50V, 10% SMD 0805 CAPACITOR 100pF, 50V, 10% SMD 0805 INDUCTOR, 0.01uH, 10%, 540mA, 180mohm SMD 0805 CONNECTOR, header, 0.1", 3-position SMD CONNECTOR, modular, jack, 8-8 R/A, shielded SWITCH, 1-position, SPST SMD PRINTED CIRCUIT BOARD, FR4, 0.062"
Bill of Materials: ASY 206 Circuit: TxNET LP Revision: 1.10 Modified:12/1/08
Item Designations Qty Bin # Description Package
1 F601, F602, F603, F604 4 FUS 0801 Fuse, resettable, Ihold=0.14A, Itrip=0.34A, Vmax=60V SMD
2 J601, J603 2 CON 45020 Connector, 8-8 mod jack, shielded 7188VSANF(THT)
3 J602 1 CON 21000 Connector, D-sub, 25 position, female, vertical, PCB mount THT
4 PCB 1 PCB 206 PCB, FR4, 0.062", red solder mask, white silk screen
Insight System Schematics The following pages contain the schematics for the Insight system.
Technalogix Ltd TAVD-500 Transmitter
VI-23
DC Supply Conditioning
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
User Interface Module
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
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
1
D111
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
1.03 (ii) Insight Control System
Date: November 13, 2008 Page: 1 of 6
User Interface Module
Current Monitoring
R117
0.012
V1 Cond V1 Out
C108
0.1uF
C113
0.1uF
R118
0.012
U101
INA168
R120
0.012
R121
0.012
U102
INA168
R119 100k
R122
100k
U106A
OPA2340UA
U106B
OPA2340UA
+
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
U107A
U107B
+
C120
0.1uF
+
C121
0.1uF
C125
0.1uF
U103
INA168
R125
C119
0.1uF
R126
0.012
V4 Cond V4 Out
C124
0.1uF
R127
0.012
U104
INA168
100k
R128 100k
OPA2340UA
OPA2340UA
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
1.03 (ii) Insight Control System
Date: November 13, 2008 Page: 2 of 6
Voltage/Current Monitoring
V5 Cond
C130
0.1uF
R129
0.012
R130
0.012
U105
INA168
User Interface Module
+
R131 100k
U108A
OPA2340UA
C129
0.01uF
C131
0.1uF
L108
0.01uH
C128
0.01uF
C132
0.1uF
C133
0.1uF
J102E
C134
0.1uF
+3.3 Vdc
V5 Out
I5 Buff
U108B
+
R135
1k
C136
0.1uF
R136
1k
C137
0.1uF
R137
1k
C138
0.1uF
R138
1k
C139
0.1uF
R139
1k
C140
0.1uF
Vin
I1 Buff I1 ADC
I2 Buff I2 ADC
I3 Buff I3 ADC
R132
37.4k - TV
68.1k - FM R133
3.3k
OPA2340UA
R134
1k
C135
0.1uF
V1 ADC
I4 ADC I4 Buff
I5 ADC I5 Buff
Membrane Switch Inputs
+3 Vdc
R140
R141
10k
R147
10k
R1421kR143
1k
R149
R148
300
Pow-IN
Nav-IN
+3 Vdc
Sel-IN
Res-IN
GND
J103D
J103A
J103B
J103E
J103C
10k
R146
10k
3
1k
MOCD211M
U109
MOCD211M
U110
R144
10k
R150
10k
R145
10k
R151
10k
A. Sivacoe, N. Hendrickson
User Interface Module
Rev ID
1.03 (ii) Insight Control System
Date: November 13, 2008 Page: 3 of 6
Pow-uPC
Nav-uPC
Sel-uPC
RESET
User Interface Module
Microcontroller
I1 ADC
I2 ADC
I3 ADC
I4 ADC
I5 ADC
V1 ADC
C146 30pF
C147 30pF
0.01uH
C141
0.01uF
Y101
6.00MHZ
L109
C142
0.01uF
C144
0.1uF
C145
tbd
C143
0.1uF
U111
MCP130-450
Vcc Reset
GND
P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 P11 P12 P13 P14 P15 P16
P60
P61
P62
P63
P64
MSP430F133/5
P17
P18
P19
P20
P21
RESET +3.3 Vdc
TCK
TMS
TDI
TDO
CAN CLK
LED1
Buzzer
BkLtCtrl
Pin15LCD
J104
LED A
LED K
U112
P50
P51
P52
P53
P54
P55
P56
P57
P58
P59
P48 P47 P46 P45 P44 P43 P42 P41 P40 P39 P38 P37 P36 P35 P34 P33
P22
P23
P24
P25
P26
P27
P28
P29
P30
P31
P32 P49
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
Pow-uPC
Nav-uPC
Sel-uPC
- DIP SWITCH 7,6,5 SET ID
- DIP SWITCH 2 SETS CALIBRATION MODE
- DIP SWITCH 1 ENABLES CAN BUS TERMINATION
S101
7
1
P14
6
P13
2
5
P12
3
4
4
P11
3
5
P10
2
6
P9
1
7
RN101 10k
CANterm1
CANterm2
P1 P2 P3 P4 P5 P6 P7 P8
+5 Vdc
Pin3LCD
SCK
SOMI
SIMO
CAN CS
+3.3 Vdc
A. Sivacoe, N. Hendrickson
4
User Interface Module
Rev ID
1.03 (ii) Insight Control System
Date: November 13, 2008 Page: 4 of 6
User Interface Module
CAN and Programmer Interface
+3.3Vdc
C148
0.01uF
CAN CLK
L110
0.01uH
U113
P1 P2 P3 P4 P5 P6 P7 P8 P9 P10
MCP2510
C149
0.01uF
P18 P17 P16 P15 P14 P13 P12 P11
U114
P1 P2 P3 P4 P5
SN65HV232
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
CANH-1
CANH-2
CANL-1
CANL-2
CANterm1
CANterm2
RESET
+5Vdc
+3.3Vdc
RESET RESET-2
P8 P7 P6
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
1.03 (ii) Insight Control System
Date: November 13, 2008 Page: 5 of 6
User Interface Module
Power Supplies
VgenCond
LED1
Buzzer
BkLtCtrl
+5 Vdc
+ C150
100uF
R156
10k
C152
10uF
10V tantalum
U115
LM2576S-5.0
U116
P1 P2 P3 P4 P5 P6 P7 P8 P9
ULN2003
P16 P15 P14 P13 P12 P11 P10
U117
LM1117MP-3.3
IN
OUT
COM
30BQ060
SML-LX1206GW
D116
S1D-13
L111
100uH
D114
D113
Green
G6L-1F 5Vdc
RL101
Littlefuse 1812L
C153
100uF
F107
Littlefuse 1812L
+
C151
1000uF
R155
1k
BZ101
F108
R154
tbd
R157
4.7
R158
430
D117
+3.3V LED
D115
+5V LED
+5 Vdc
Pin15LCD
+3.3 Vdc
VgenCond
C154
100uF
C156
22uF
U118
P1
+
C157
22uF
P2 P3 P4 P5
LM2660M
C158
22uF
C161
0.1uF
P8 P7 P6
C155
100uF
R160
1.4k
LM2576
R162
6.2k
+
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
1.03 (ii) Insight Control System
Date: November 13, 2008 Page: 6 of 6
Coupler Conditioning Module
Microcontroller
U201
L201
0.01uH
MCP130-450
Vcc Reset
GND
DVcc
P1
A3
P2
A4
P3
A5
P4
A6
P5
A7
P6 P7
Xin
P8
Xout
P9 P10 P11
P1 0
P12
P1 1
P13 P14 P15 P16
CAR DOWN
CAR UP
CAR OFF
CAR ON
SOFT RES
C201
0.01uF
L202
0.01uH
C203
0.01uF
AVcc
P64
P17
AVss
DVss
P62
P63
MSP430F149
P18
P19
P20
TCK
TMS
TDI
TDO
CAN CLK
P50
P51
P52
P53
P29
P30
P31
P28
SIMO0
SOMI0
UCLK0
PSU
LED 3
TEMP
LED 4
U202
P32 P49
P48 P47 P46 P45 P44 P43 P42 P41 P40 P39 P38 P37 P36 P35 P34 P33
MCLK
- DIP SWITCH 3,2,1 SET ID
- DIP SWITCH 7 ENABLES CAN TERMINATION
S201
1 2 3
4 5 6 7
DIP SW7
91348
7
RN201 10k
J202
2
4
3
8
TDO
TDI
TMS
TCK
Reset
P54
P55
P56
P57
P58A0P59A1P60A2P61
P21
P23
P24
P25
P26
P27
P22
P2 2
1
VSWR
LED 5
OVERDRV
LED 6
+3.3 Vdc RESET
FWD-POW
RFL-POW
C202
0.01uF
DRVR DIS
LED 1
LED 2
C204
0.1uF
C205 10uF
+
C206 33pF
C207 33pF
C208
0.01uF
Y201
6.00MHZ
0.01uF
L203
0.01uH
C209
+5 Vdc
ATEN-Vcc
ATEN1
SCK
ATEN2
SOMI
ATEN3
ATEN4
DAC2 CS
ATEN5
SIMO
GROUND
J201 4
R201
1
R202
1
R203
2
R204
2
R205
3
R206
5
6
R207
7
R208
7
8
CANterm2
CANterm1
+3.3 Vdc
DAC CS
SCK
SOMI
SIMO
CAN CS
TMP VCC
TMP SCK
TMP SO
TMP CS
TMP GND
1
A. Sivacoe
Coupler Conditioning
Rev ID
1.10 Insight Control System
Date: November 13, 2008 Page: 1 of 4
CAN and Programmer Interface
+5Vdc
Coupler Conditioning Module
C210
0.01uF
C211
0.1uF
D201
J203
J204
4
4
+5V-1
+5V-2
+3.3Vdc
CAN CLK
+3.3Vdc
C214
0.01uF
0.01uH
0.01uF
C215
U204
P1
P18
P2
P17
P3
P16
P4
P15
P5
P14
P6
P13
P7
P12
P8
P11
P9 P10
MCP2510
C212
0.01uF
J203
J204
C213
0.1uF
RESET RESET-1
GND Vcc
D202
R209
0
U203 J203
D
P1 P2 P3
R
P4 P5
SN65HV232
P8
CANH
P7
CANL
P6
R210
100
J203
J204
J203
J204
J203
J204
J204
6
6
2
2
1L204
1
8
8
7
7
+3.3V-1
+3.3V-2
GND-1
GND-2
RESET-2
CANH-1
CANH-2
CANL-1
CANL-2
CANterm1
CANterm2
RESET
SCK
SIMO
SOMI
CAN CS
TDO
TDI
TMS
TCK
2
JTAG
J205
+3.3Vdc
A. Sivacoe
Coupler Conditioning
Rev ID
1.10 Insight Control System
Date: November 13, 2008 Page: 2 of 4
Coupler Input
+5Vdc
+3.3 Vdc
FWD GND
FWD+3.3
FWD+5V
FWD In
RFL GND
RFL+3.3
RFL +5V
RFL In
J206
J206
J206
J206
J207
J207
J207
J207
Coupler Conditioning Module
4
3
2
1
4
3
2
1
D203
D204
L205
0.01uH
C216
0.01uF
L206
0.01uH
C218
0.01uF
C217
0.01uF
C219
0.01uF
FWD-POW
RFL-POW
Interface
+3.3 Vdc
DRVR DIS
LED 1
LED 2
LED 3
LED 4
LED 5
LED 6
U205
P1 P2 P3 P4 P5 P6 P7 P8 P9
ULN2003
P16 P15 P14 P13 P12 P11 P10
RN202
RN202
1k
7 10
D205 D207 D208 D209
RN202
RN202
1k
1k
6 10
1 10
D206 D210
RN202
1k
1k
2 10
3 10
RN202 1k
4 10
D211
R2111kR212
K201
R2130R214 0
A. Sivacoe
1k
+5 Vdc
0.01uF
C220
L207
0.01uH
C221
0.01uF
J202
7
DISABLE
3
Coupler Conditioning
Rev ID
1.10 Insight Control System
Date: November 13, 2008 Page: 3 of 4
RF Power Output
+5 Vdc
SIMO
SCK
DAC CS
Remote Access Port
C222
0.01uF
L208
0.01uH
U207
P1 P2 P3 P4 P5
TLV5625
P8 P7 P6
C223
0.01uF
LM4040-2.5
U208
R216 1k
R217
2.15k
R215
2.15k
+
+
VR201
U206B LM358
VR202
U206A LM358
10k
10k
1 3
1 2
FWD-OUT
D212A
RFL-OUT
D212B
+3.3 Vdc
+5 Vdc
VSWR
OVERDRV
TEMP
PSU
RFL-OUT
FWD-OUT
RN204
1k
RN204
1k
MOCD211M
CAR OFF
MOCD211M
U210
U212
RN203
10k
RN203
10k
RN204 1k
10 9
10 8
MOCD211M
RN204
1k
10 6
10 7
RN203 10k
10 6
10 7
RN203 10k
10 9
10 8
J208
8 7 6 5 4 3 2 1
J209
1 2 3 4 5 6 7 8
10 1
10 4
10 8
RN 203 10k
RN 203 10k
RN 205 10k
10 2
10 3
10 9
RN 203 10k
RN 203 10k
RN 205 10k
10 4
10 2
RN 204 1k
RN 204 1k
R 218 1k
RN 204 1k
10 3
RN 204 1k
10 1
R219 1k
U209
MOCD211M
U211
MOCD211M
U213
10 3
10 7
RN 205 10k
RN 205 10k
RN 205 10k
10 4
RN 205 10k
10 6
RN 205 10k
10 2
CAR ON
CAR UP
CAR DOWN
SOFT RES
RESET
4
A. Sivacoe
Coupler Conditioning
Rev ID
1.10 Insight Control System
Date: November 13, 2008 Page: 4 of 4
Digital Attenuation
RF 2
RF OUT
J301
J302
R301
RF Conditioning
U301
J1
N/C
GND
R303R302
CTL1
GND
CTL2
GND
CTL4
GND
CTL8
GND
CTL16
GND
Vss GND GND J2 Vcc
C2 C1
C301
C303
CTL 1dB
CTL 2dB
CTL 4dB
CTL 8dB
CTL 16dB
C302
Opto-Isolation
Ext 5Vdc
1dB in
2dB in
8dB in
4dB in
J304
4
D301
J304
1
2
J304
5
3
S301
R304
D302
J303
C305
R305 R306
R311 R312
L301
U302
P1 P2 P3 P4 P5
U303
P1 P2 P3 P4 P5
C304
P8 P7 P6
R308R307
P8 P7 P6
R314R313
D303 D304
R309 R310
D306D305
CTL 1dB
CTL 2dB
CTL 8dB
CTL 4dB
16dB in
16dB in
J304
7
R317
J304
8
1
U304
P1 P2 P3 P4 P5
R316R315
P8 P7 P6
R318
D307
R319
CTL 16dB
A. Sivacoe
RF Conditioning
Rev ID
1.12 Insight Control System
Date: November 4, 2008 Page: 1 of 1
+3.3Vdc
TMP Vcc
TMP CS
L701
J701
S701
2J702
8J702
C701
TMP SO
TMP SCK
TMP GND
Disable
U701
3J702
4J702
1J702
7J702
P1 P2 P3 P4 P5
LM70CIMM
J703
P8 P7 P6
Disable
C702
C703
From CTRL To amp pallet
C704
C705
1
A. Sivacoe
Temperature Sensor Board
Rev ID
1.10 Insight Control System
Date: June 4, 2007 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
3
4
5
7
8
1J603
2
3
4
5
6
7
8
F601
F602
F603
F604
13 12 11 10
J602
9 8 7 6 5 4 3 2 1
25 24 23 22 21 20 19 18 17 16 15 14
1
TxNET
Rev ID
1.10 LP
Date: July 16, 2008 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
TxNET
Rev ID
1.10 HP
Date: July 16, 2008 Page: 1 of 1
Section VII – Mechanical Section
The heat sinks allow the amplifiers to operate at a cooler temperature and prevent overheating, which helps the longevity of the entire system. Each 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 sinks, within the 500-watt power amplifier enclosure, there are six fans that each provide 170 cubic feet per minute (CFM) of air flow (into zero static pressure). There are three fans mounted at the front of the heat sink and three mounted at the back end of the heat sink. The fans are mounted side-by-side 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.
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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.
The TAVD-5000 contains (3) DC ball bearing fans in each PA (push-pull configuration) and (2) fans in each of the combiner/filter and power supply enclosure.
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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.
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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 ther e is a 3 dB line loss in the cable between your unit’s output and the transmitting antenna, a 1,000-watt unit will only deliver 500 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.
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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.
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Location and Function of Controls and Connectors (TAVD-500 Power Amplifier)
The following illustration depicts the location of the connectors when installing the 500-watt power amplifier.
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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 – 500-watt (rms) RF output. Connects to combiner/filter enclosure. N
connector, 50 ohm.
REMOTE PORT - Port to monitor and control the amplifier externally. See “ Monitor and
Control” section for pin-out. Power amplifier has fault alarms only and filter/combiner has fault alarms and controls.
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Location and Function of Controls and Connectors (Filter Enclosure)
The following illustration depicts the location of the connectors when installing the filter enclosure.
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RF IN - RF inputs (500-watts each) from the power amplifier. N female connector,
50 ohm.
RF OUT – 500-watt (rms) RF output. Connects to inline wattmeter (not supplied) and
antenna. 7/16”DIN female connector, 50 ohm.
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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 amplifiers at this time. Because of the characteristics of transistor 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. Hook up the PA out to the Filter in.
8. Connect the RF Output on the filter enclosure to the wattmeter directly (no cable in between) and then the output of the inline wattmeter to the transmitting antenna cable.
9. Plug power supply into AC mains (220 Vac, single phase).
10. Leave the AC rocker switch to “off” position.
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Section IX - Operating Procedure
Assuming the previous installation instructions have been completed and cautions noted, and the TAVD-500 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 TAVD-500 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. With the PA output loaded, plug the 3U power supply enclosure into 220V AC mains.
5. Switch AC rocker switch to “ON” position.
6. Verify that the power amplifier fans are all 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.
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10. The TAVD-500 LCDs show 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 400 to 500 Watts on the PA enclosure. 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.
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.
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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.
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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 31 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
Correction
Fault
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
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Install EMI/RFI filter in AC line
and power amplifier share a common ground
frequency of interfering signal (spectrum analyzer may be required)
Symptom Possible
Correction
Fault
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
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Thank you
for choosing
Technalogix Ltd.
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