Technalogix TM100 User Manual

TM-100

BROADCAST MODULATOR

OPERATING

MANUAL

Technalogix

1

TABLE OF CONTENTS

1.0 SAFEGUARDS ..................................................................................................................... 2

General Safeguards................................................................................................................2

Safety and First Aid .................................................................................................................3

2.0 WARRANTY........................................................................................................................ 4

3.0 DESCRIPTION AND SPECIFICATIONS.................................................................................... 5

General Description................................................................................................................5

Available Options....................................................................................................................6

Specifications..........................................................................................................................6

Video Conditioning Module.....................................................................................................9

4.0 INSTALLATION .................................................................................................................... 9

Building Recommendations....................................................................................................9

Heating and Cooling Requirements........................................................................................9

Electrical Service Recommendations...................................................................................10

Antenna and Tower Recommendations...............................................................................10

Shelter Security.....................................................................................................................11

Unpacking and Inspection ....................................................................................................12

Location and Function of Controls and Connectors.............................................................13

5.0 OPERATING PROCEDURE.................................................................................................. 15

Preliminary Hook -up.............................................................................................................15

Setup and Operation.............................................................................................................15

Transmitter Hookup ..............................................................................................................18

6.0 BILL OF MATERIALS, SCHEMATICS, AND PCB OVERLAYS ................................................ 20

Agile Logic Board..................................................................................................................20

Agile Output Amplifier Board ................................................................................................25

Audio Video Modulator Board ............................................................................................... 28

Digital Up converter Board....................................................................................................37

750 MHz Down Converter Board..........................................................................................43

Power Supply Board.............................................................................................................49

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1.0 SAFEGUARDS

General Safeguards

This section is written as a general guide 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.

To reduce the risk of fire or electric shock, do not expose this equipment to rain or
moisture. Do not open the cabinet. Refer servicing to qualified personnel.

1. READ INSTRUCTIONS - All safety, installation, and operating instructions should be
read before the equipment is operated.

2. RETAIN INSTRUCTIONS - The safety and operating instructions should be retained
for future reference.

3. FOLLOW INSTRUCTIONS - All safety, installation, and operating instructi ons should
be followed.

4. GROUNDING AND POLARIZATION - The TM-100 Modulator is equipped with a
three prong grounded power plug. Do not remove the ground prong from the plug.
Do not use an AC receptacle where the plug blades cannot be fully inserted.

5. SERVICING - Do not attempt to service this equipment yourself as opening or
removing covers may expose you to dangerous voltage or other hazards and will
void the warranty. Refer all servicing to qualified service personnel.

6. DAMAGE REQUIRING SERVICE - Unplug this equipment and refer servicing to
qualified service personnel under the following conditions:

• if the power cord or plug is damaged.

• if liquid has been spilled or objects have fallen into the equipment.

• if the equipment has been exposed to rain or water.

• if the equipment does not operate normally by following the operating

instructions. Adjust only those controls covered by the operating instructions. An
improper adjustment may result in damage and will often require extensive work
by a qualified technician to restore the equipment to its normal operation.

• if the equipment has been dropped or the cabinet has been damaged.

• if the equipment exhibits a distinct change in performance.

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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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2.0 W ARRANTY

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.

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 God.

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.

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.

• Package equipment carefully for prepaid shipment to Technalogix. Include a

written description of the problem experienced and a copy of the original
invoice establishing warranty status.

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

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3.0 DESCRIPTION AND SPECIFICATIONS

General Description

The high output modulator eliminates the need for preamplifiers prior to the
power amplifier system. The modulator processes baseband audio and video
information to provide an IF output consisting of a visual IF carrier at 45.75 MHz,
using amplitude modulation, and an aural IF carrier at 41.25 MHz, using
frequency modulation. An internal upconverter translates the modulator circuitry’s
IF carriers to VHF and UHF television frequencies. All operating controls are
located on the front panel, as described in a later section. An aural loop through
is provided to properly set transmitter power.

Standard Features

• Totally microprocessor controlled with self-diagnostic monitoring.

• Selectable output channels:

§ Standard Broadcast VHF 2 – 13, UHF 14 – 60, T7 – T13

§ HRC channels 1 through 118

§ ±10 kHz offsets

• SAW filtered IF designed for adjacent channel operation.

• + 60 dBmV output using low distortion hybrid amplifiers.

• Synthesized oscillators – crystal referenced phase locked.

• Bar graph modulation and digital LED readout.

• Internal switch selects standard or HRC output.

• Surface mount technology construction.

• RF muted during tuning.

• Optional aural sub-carrier and baseband audio input

• Phase lock loop FM audio.

• BTSC stereo compatible.

• External separate audio/video and composite IF loop-through.

• RS-232 control option (daisy -chain capable)

• Sound carrier level adjustable –10 dB to –20 dB.

• Video delay predistortion network meets FCC 73.687.

• High stability TCXO, ± 250 Hz

• Non -volatile memory retains channel selection after power loss.

• Video Detection turns off carrier in event of loss of video.

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Available Options

• 4.5 MHz sub carrier and baseband audio inputs.

• Dual RS-232 control with daisy chain capabilities that allow for remote

control by PC workstation.

HRC Output Frequency Set:
This Technalogix frequency agile product can be set for HRC frequency output.

This feature is controlled by an internal dip switch assembly, DS-1. The switch is
located near the right front corner (with the panel facing you) between the test
point and the output converter module. DS-1 is clearly marked on the PCB.
Switch #3 placed in the OFF position switches the output frequency to HRC on
all channels. The switch is normally set to ON at the factory.

Specifications

RF Characteristics

Frequency range 7 to 750 MHz
Frequency Response (one channel) ±0.5 dB
Frequency Stability ±250 Hz
RF Output Level +60 dBmV max
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

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NTSC Video Characteristics

Input Level to modulator (for 87.5%
modulation)
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

Aural Characteristics

Input: 50 Hz – 15 KHz 0 dBm (0.8V)
Impedance 600 ohms, balanced
Frequency Response +/- 1.0 dB
Frequency Tolerance, +/- 500 Hz 4.5 MHz
Frequency Deviation +/- 25 KHz
Harmonic Distortion 1% max
Preemphasis (mono) 75 µs

Internally Defeatable

IF Section

Output Impedance 75 ohms, unbalanced
Video IF level + 37 dBmV, +97 dBµV
Audio IF Level +22 dBmV

Adjustable +82 dBµV

Return Loss > 14 dB
IF Frequency, Video Carrier 45.75 MHz
IF Frequency, Audio Carrier 41.25 MHz
Video Sound Spacing + 4.5 MHz
Vestigial side-band width 0.05 MHz
Second IF Frequency 945.75 MHz

Physical Characteristics

Power Requirements 100-130, 210-230 VAC, 50/60 Hz
Operating Temperature

Weight 12 lbs
Dimensions (modulator only) W-19", D-14 ", H 1.75”, 1U -high

0 - 50°C

1.0 VPP

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Video Conditioning Module

The TM-100 modulator includes a separate circuit board called the Video
Conditioning Module. The baseband video signal passes into the modulator,
through a group delay filter, and onto the video conditioning Module circuit board.
This module accomplishes two processes:

1. Sync Stretch. Allows the user to adjust the sync level to maintain the
proper level. Adjustment is made via potentionmeter VR2 and can be
made through the ventilation holes in the modulator lid without having to
remove the lid. Potentionmeter VR1 adjusts the video modulation level
and must be made by either removing the lid and adjusting VR1 or by the
Video Modulation adjust on the front panel of the modulator. The sync
stretch is powered by +5Vdc brought in to the connector and –5Vdc,
which is generated on board by U1.

2. Video Detect. Turns off the 24Vdc supply to the final amplifier in the TM­100 in the event of missing video input. The power supply for the final
amplifier (+24Vdc) is routed through a relay on the circuit board. In the
event of a missing video signal, the relay contact is opened and the
+24Vdc is disconnected from the final amplifier.

The input and output impedance of the Video Conditioning Module is 75-ohms
and video connections are made via RCA connectors. The video Conditioning
Module can be bypassed, if necessary

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4.0 INSTALLATION

This section contains installation recommendations, unpacking, inspection, and
installation instructions for the Technalogix TM-100 Modulator. Carefully read all
material in this section prior to installation. Also read and review operating
procedures later in this section.

Building Recommendations

The quality of the building is of great importance if you are to expect long life and
continued performance from the modulator. The building must be clean, dry,
temperature controlled and secure. The modulator takes up a single 1-U high
space on a 19” rack. 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.

Heating and Cooling Requirements

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

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Electrical Service Recommendations

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

• The personnel knows the local codes

• The personnel can be on site readily

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

to local suppliers

Technalogix recommends that proper AC line conditioning and surge
suppression be provided on the primary AC input to the power amplifier. All
electrical service should be installed with your national electrical code in your
area, any applicable provincial or state codes, and good engineering practice.
Special consideration should be given to lightning protection of all systems in
view of the vulnerability of most transmitter 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 off of one circuit breaker.
Each transmitter should have its own circuit breaker, so a failure in one does not
shut off the whole installation.

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. Transmitting antennas can enhance or seriously impair the
transmitter output. It is assumed that one has been selected prior to system
installation, but the best-designed 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.

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The selection, routing, and length of coaxial cable is 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 500 watt unit will only deliver 250 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.
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. Be absolutely safe and certain about this
aspect as human lives may be at stake.

Shelter Security

The FCC requires that the transmitter 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
modulator. 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 modulator 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.
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

The following illustrations depict the location of the installation connectors when
installing the power amplifier with a modulator or processor.

FRONT

BACK

Audio Deviation – Allows user to control extent of audio deviation. Original
factory setting at 25 KHz deviation using standard pre-emphasis curve.

Audio/Video Display Select - Provides a graphical representation of audio
deviation and visual modulation levels on an LED bar graph. The switch selects
between audio deviation or visual modulation.

Video Modulation -- Allows user to control extent of video modulation. Original
factory setting at 87.5% video modulation with 1.0 Volt peak to peak baseband
input video signal.

Frequency Offset Select – Toggles between +10 KHz, 0KHz, and –10 KHz
frequency offset.

Aural Carrier Level - Allows user to set aural carrier level relative to visual carrier
level. Modulator is factory tested at –10 dBc (decibels below visual carrier).

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Output Select – Selects the desired channel of operation. If you require a lower
channel than the one currently displayed, push the toggle switch down. The
channels will change one at a time as many times as you press the switch.
Holding the select switch in the up or down position will “scan” to the desired
channel. It is normal for the frequency lock LED to turn off during and for a few
seconds after, changing channels. The switch must be held up or down initially
for three seconds. This helps to ensure that no accidental channel changes will
occur.

Output Level – Sets visual carrier output level.
RF Out Test Point – Provides a sample of the RF output level which is 20 dB

below the actual value. RF test point is only a relative indicator of the actual RF
output level and may vary. All RF operating measurements should be made at
the RF output of the unit.

RF Output - Modulated Audio/ Video output capable of +60 dBmV levels using
built in low distortion hybrid amplifiers.

RS-232 Ports – Set up for optional RS-232 control option.
Combined IF Input/ Output – 45.75 MHz visual carrier and 41.25 MHz audio

carrier intermediate frequency signal loop.

Audio Input/ Ouput Loop – Available for baseband audio processing.
Video Input/ Output Loop - Available for baseband video processing.
Video In – Connection for 1.0 Volt peak to peak video source.
Balanced Baseband Audio In – Used to connect a 1 Volt peak to peak baseband

audio signal. For balanced input connection, connect 1 audio input lead to the
left terminal on the connector and the other audio input lead to the right terminal.
For an unbalanced input connection, connect one audio input lead to the left
terminal on the connector and the other audio input lead to the centre terminal.
Center terminal is chassis ground.

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5.0 OPERATING PROCEDURE

Preliminary Hook-up

1. Terminate modulator into a 50 ohm load before applying power.

2. Connect the power cord of the Technalogix TM-100 agile modulator to a
proper electrical source as indicated on the back of the unit

3. Observe the front panel. If power is applied and present, the red power
LED will illuminate. Also, all the elements of the displays behind the
display readout window will illuminate momentarily as a display test.

4. Observe the numbers displayed behind the display readout window after
the test. They will indicate:

• Microprocessor software version;

• Internal option dipswitch settings;

• RS-232 unit ID (if so equipped); and

• Last tuned channel.

5. After a moment, the Lock Detect LED will illuminate.

Setup and Operation

A. Output level and channel selection; connecting monitor.

1. Connect a spectrum analyzer, or a field strength meter tuned to the
frequency of the video RF carrier of the desired channel, to the RF
OUTPUT jack on the rear panel of the unit. Alternatively, connect a
spectrum analyzer or a field strength meter to the –20dB TEST POINT on
the front panel of the unit.

2. Select the desired output channel using the CHANNEL SELECT paddle
switch on the front panel.

• Hold the CHANNEL SELECT switch in the up- or down-position
for approximately 3 seconds to activate the channel -select
circuit;

• Toggle the CHANNEL SELECT switch up to select a higher
channel or toggle it down to select a lower channel. The switch
may be held in the up- or down-position for rapid channel
switching.

Technalogix Ltd. TM-100 Modulator