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User Manual

Rev. 3.0 - 21/03/18

PJ5000U-K

• Remove the amplifier module and replace it with a new spare part.

• Redo all previously steps, performed in reverse, in order to reassemble and fix

the module in place.

9.4.5 How to replace the Service power supply

• Open the top cover of

PJ5000U-K

by unscrewing all the screws.

• Unscrew all the points

with the help of an Quadrex screwdriver.

•  Slip off the block of cards, by rotating it at the same time about 90°-180°.
•  Identify the module to be replaced.
•  Disconnect all the connectors at positions

Summary of Contents for PJ5000U-K

Page 1: ...PJ5000U K USER MANUAL VOLUME1 Manufactured by R V R ELETTRONICA S p A Italy ...

Page 2: ... any means electronic or mechanic including photocopying recording or by any informa tion storage and retrieval system without written permission of the copyright owner File Name PJ5000U K_ING_3 0 indb Version 3 0 Date 21 03 2018 Revision History Date Version Reason Editor Approval 21 03 2018 3 0 Third Version J H Berti A Franceschi Declaration of Conformity Hereby R V R Elettronica declares that ...

Page 3: ...down arrow to visualize the measure Note The input power value read from the amplifier may differ from the one read from the modulator 7 Press ESC key until the display shows the main screen FWD and RFL readings 8 Adjust output power using RF PWR ADJ trimmer 9 After ten minutes readjust the output power of the amplifier s it will be lowered due to heating 10 Repeat the procedure if the carrier fre...

Page 4: ...n compliance with the essential requirements and other relevant provisions of Directive 99 5 CE R TTE and therefore carries the CE mark The conformity assessment procedure referred inArticle 10 and detailed inAnnex III of Directive 99 5 EC has been followed The following harmonized standard have been applied EMC 3 1b EN 301 489 1 V1 4 1 2002 08 EN 301 489 11 V1 2 1 2002 11 Safety 3 1a EN 60215 198...

Page 5: ...g about 45 Cooling type Forced with internal fans Acoustic Noise dBA 78 Connector N type Impedance Ohm 50 Driver power for rated output W 50 70 Max Max input power before protection W 100 Connector 7 8 EIA Impedance Ohm 50 Connector BNC Impedance Ohm 50 Output Level dB approx 60 Interlock Output Connector BNC Com Bus Connector DB15M I2 Cbus Connector DB9F Telemetry Interface Connector DB25F AUX po...

Page 6: ...ion 6 4 5 Connector Description 7 5 Installation and use 9 5 1 Installation 10 5 2 Operation 18 5 3 Management Firmware 14 5 4 Protection System 26 6 Identification and Access to the Modules 28 6 1 Upper View 28 6 2 Lower View 29 7 Working Principles 30 7 1 PS Section 31 7 2 RF Section 33 7 3 Logic Section 35 8 Low Drive Power Option LD 37 8 1 Low Drive power Board 37 9 Working Principles 30 9 1 I...

Page 7: ... for any errors or inaccuracies in this manual including the products and the software described herein R V R Elettronica S p A reserves the right to make changes to equipment design and or specifications and to this manual at any time without prior notice Notice concerning product intended purpose and use limitations This product is a radio transmitter suitable for frequency modulation audio radi...

Page 8: ...or the type of accident Get the victim to a hospital as quickly as possible Elevate arms and legs if injured Units returned without a return authorisation may be rejected and sent back to the sender 4 Be sure to include a detailed report mentioning all problems you have found and copy of your original invoice to show when the warranty period began with the shipment Please send spare and warranty r...

Page 9: ...r of the equipment for example from 2500W to 5250W in case of PJ5000U K outside these limits the equipment is able to work properly but can not guarantee an efficiency of 70 The operating logic during the output power regulation which is necessary in order to not deteriorate the efficiency even of 5 6 expects to set the pilot power to the optimum power dependent on the amplifier for example the PJ...

Page 10: ...us indications ON LOCAL FOLDBACK and RF MUTE On left side four LEDs provide indications relatively the status of RF signal amplified FAULT FUSE BLOWN FOLDBACK and ON At last on right side four LEDs provide indications relatively the fault status of power supplies PS1 PS2 PS3 and PS SERVICE The amplifier management firmware is based on a menu system User has four navigation buttons available to bro...

Page 11: ...Y Liquid Crystal Display 8 ESC Press this button to exit a menu 9 ON Green LED turns on when amplifier is powered on 10 LEFT UP Navigation button used to browse menu system and edit parameters 11 LOCAL Yellow LED indicating that the amplifier is in local control mode 12 RIGHT DOWN Navigation button used to browse menu system and edit parameters 13 FOLDBACK Yellow LED indicating that the foldback f...

Page 12: ...put connector N type 4 SERVICE DB9 connector for factory parameters programming only for factory programming 5 MAINS Plug for mains power supply 6 PS1 Protection fuse of the power line 1 7 PS2 Protection fuse of the power line 2 8 PS3 Protection fuse of the power line 3 9 COMMON BUS DB15 connector for interfacing with other devices 10 INTERLOCK OUT Interlock output BNC connector to inhibit an exte...

Page 13: ...5 Interlock 6 Set 4 7 GND 8 On Command 9 Set 1 10 WAIT 11 Alarm Reset 12 OFF 13 Interlock 14 Temperature 3 9V x 100 15 RF power amplifier voltageCurrent 4 3V x F S 16 Forward Power 4 3V x F S 17 FAULT 18 Set 3 19 Potenza in ingresso 4 3V x F S 20 OFF Command 21 GND 22 Set 2 23 LOC 24 Vcc 25 ON 4 5 2 I2 C Connector Type Female DB9 1 NC 2 SDA Serial Data 3 SCL Serial Clock 4 NC 5 GND 6 NC 7 NC 8 NC ...

Page 14: ... 485 3 ON OFF C 4 IRQ C 5 PWR REG 6 NC 7 NC 8 NC 9 RS 485 10 GND 11 ST BY C 12 GND 13 GND 14 INHIBIT PJ C 15 RESET PJ C 4 5 4 Service for programming of factory parameters Type Female DB9 1 NC 2 TX_D 3 RX_D 4 NC 5 GND 6 NC 7 Internally connected with 8 8 Internally connected with 7 9 NC ...

Page 15: ...icable law on workplace safety matter These companies must provide appropriate training to their staff on electrical devices and make sure that they familiarize themselves with the contents of this manual The respect of the safety instructions set forth in this manual or in the specified legislation does not exempt you from compliance with other specific regulations regarding installation place Co...

Page 16: ...tant to remember that strong changes in temperature can lead to generation of condensation in particular environmental conditions In case of the station where this device is located should be subjected to these physical events it is good to monitor these devices once you put it into service in addition to trying to protect the device itself as much as possible IMPORTANT never supply voltage to the...

Page 17: ... to possible noise pollution or on fragile supports The operation of the equipment can cause a noise due to forced ventilation The mounting surface must be able to withstand the weight of the device and must be sturdy Note below we will refer to a complete station where the device can be a part of it The same procedures also apply in case of the device is used individually The device is usually co...

Page 18: ...tion of the room COLD HOT 50cm In alternative is cooled by forced ventilation and the air outlet is located on the roof of machine Is recommended a length of tube approximetively of 1 5 meter COLD HOT 50cm Is highly recommended to install the rack at least 50 cm from the rear and side wall so as to allow an optimum air flow and to facilitate workers ...

Page 19: ...neral disconnecting switch terminals Note The connection of machine to power supply is done by fixing a multi pole cable with exposed terminals to a terminal board Make sure with no possibility of error that the cable is not under tension when you connect it to the machine WARNING Is highly recommended to don t turn on the machine without first having connected the RF output to antenna or dummy lo...

Page 20: ...dequate earth connection properly connected to the equipment This is a pre requisite for ensuring operator safety and correct operation The following table shows the recommended cable cross sections CONNECTOR THREE PHASE CABLE SECTION SINGLE PHASE CABLE SECTION L Ø 6mm R Ø 4mm S Ø 4mm T Ø 4mm N Ø 4mm Ø 6mm PE Ø 4mm Ø 6mm Tipically the distribution board contains the thermal magnetic circuit breake...

Page 21: ...a PTX60LCD S For operating tests only dummy load with 50 Ohm impedance and adequate capacity 5000W as a minimum Nota to ensure the safety of the operators carry out the wiring according to the laws and regulations in force in the country where this equipment is installed Check that the POWER switch on the front of PJ5000U K is in the OFF position An ILME model KKCNTCQF04 2 CQF04 2 multipole socket...

Page 22: ...lifier and its exciter and the connection with the load are represented in figure 5 2 Note to ensure both the safety of the operators and the correct functioning of the apparatus it is essential that the network system is grounded and that it is properly connected to the equipment Useful tips for a correct connection Provide an adequate grounding of the electrical system This has both a direct pro...

Page 23: ... connectors for interlock signal connection between exciter and amplifier RF cable for output to load antenna 50 Ohm coaxial cable with standard N connector Audio cables between transmitter and audio signals sources WARNING risk of burns due to RF Make sure that the device can not emit RF at the output before connecting the antenna cable WARNING For electromagnetic compatibility reasons only doubl...

Page 24: ...bles of own sources to the input connectors 5 2 Operation 1 After having plugged in the power supply socket at the back of the machine power on the amplifier via the switchboard The ON LEDs will turn on and the forced cooling blowers will start running The LCD shows the first introductory screenful and then switches to a screenful that indicates the forward and reflected power values Menu 1 2 Rota...

Page 25: ...Normally the machine can run unattended Any alarm condition is handled automatically by the safety system or is signalled by the LED indicators on the panel or by display messages NOTE Standard factory settings are output power set to upper limit unless otherwise specified by customer and OFF 5 3 Management Firmware The machine features an LCD with two lines by 16 characters that displays a set of...

Page 26: ...en the display is on pressing the ESC button from the default menu menu 1 calls up the selection screen menu 3 which gives access to all other menus Menu 3 To gain access to a submenu select menu name name is highlighted by cursor using button or and press the ENTER button Press ESC again to return to the default menu menu 1 5 3 1 Operation Menu Fnc In this menu you can set power output On Off tog...

Page 27: ...om other connected telemetry systems Pg1 Modifies Power Good forward power threshold The Power Good rate is a percent of machine rated power 5000W for PJ5000U K not of forward output power This means that this threshold set at 50 will give 2500 W regardless of set power level The Power Good feature enables output power control and reporting When output power drops below set Power Good threshold th...

Page 28: ... Rfl Reflected power reading Inp Input power reading 5 3 3 Menù Power Amplifier P A This screen is made up of four lines that can be scrolled using the buttons and shows the readings relating to final power stage Menu 6 Note that these are readings rather than settings and cannot be edited note the empty arrow VPA Voltage supplied to amplifier module IPA Current absorbed to amplifier module Eff Ef...

Page 29: ...shows the cause for the stop After 15 seconds the machine attempts to re start if a new alarm condition is detected cycle is repeated over and over again up to 10 times maximum If machine re starts successfully all alarm counters are reset after 30 minutes regular operation After 10 alarm conditions triggered by the same cause the machine goes into fault lock out mode a lock out mode warning appea...

Page 30: ...ld exceeded Alarm 3 Monitoring cycle is as follows An alarm condition occurs Alarm is displayed and device is locked out for 15 sec Operating conditions are restored Verification Upon reaching the 10 cycle limit a FAULT LOCK indication is triggered and the device goes into lock out mode the appropriate LED turns on figure 6 1 and this screen is displayed I Over Forward Power Forward power alarm di...

Page 31: ...rm menu menu 7 or power off and back on again using the POWER switch Machine set to REMOTE control mode power off and back on again sending the appropriate command via the DB25 connector pin 8 and 20 There is a fourth alarm that does not trigger a FAULT condition but allows some time until correct operating conditions are restored When the temperature alarm threshold is exceed about 85 C the follo...

Page 32: ...fier when the forward or reflected power exceeds the proportional limit voltage value As such the amplifier s gain is reduced and the overall result is an action that opposes the increase of the forward or reflected power The yellow LED on the front panel indicates the tripping of the foldback circuit The second type of reaction consists in turning OFF the equipment s amplifying section when a spe...

Page 33: ...EDs i interventi tramite i LED A delivered power automatic back off mechanism is envisaged for excess temperature SWR or current absorbed by a MOSFET module The yellow FOLDBACK LED indicates this case A FAULT signal is triggered red LED when a fault occurs that stops the power amplifier This situation is signaled to the machine s main microcontroller as well and triggers a lock situation FAULT The...

Page 34: ...ntenance and any required module replacement easier 6 1 Upper view The figure below shows the upper view of the machine with the various components pointed out figure 6 1 1 Telemetry 2 PFC 3 Services Power Supplies 4 Blower Control Board 5 Power Supplies 6 PWR Input Measure Card 7 Bias e Measure Card 8 CPU Card 9 Signal Interface Card 10 Status Led Card 11 Panel Card 12 PS Fault LED Card ...

Page 35: ... 03 18 6 2 Lower view The figure below shows the lower view of the machine with the various components pointed out figure 6 2 1 Low Pass Filter and Combiner 2 Amplifier Modules 3 Bias Distributor and Splitter Card 4 Pass through Filter Card ...

Page 36: ...elow provide an overview of PJ5000U K figure 7 1 modules and connections BPF 3 H Load FWD RFL Output LPF FWD Bias Board Interface Card Service PS Blower Panel Card PFC PSL PFC PSL PFC PSL Service PS Service PS Service PS PA True RMS Detector LD PJ Low Power Option Input figure 7 1 ...

Page 37: ...sinusoidal obtaining a power factor with a cos φ of 0 998 and can work with input supply voltages from 186 to 250 V The PFC units are mounted on a plate fixed to the central heat sink in order to allow an easy replacement in case of failures 7 1 2 Power Supplies The three power supplies are located in the high part of the amplifier connected in series to PFC units and deliver at the output an adju...

Page 38: ...ies and has a control line which allows to reduce the necessary output power in the event of a fault in one of services power supplies or in case of lack of one of supply phases furthermore it measures the temperature through the sensor mounted on the main heatsink this allows the automatic adjustment of the blowers present on the machine 7 1 5 Interface card This card principally performs the int...

Page 39: ...oad Load Load Load BPF 3 H Load Input figure 7 3 7 2 1 PWR Input Measure Card This card measures the input power and send it subsequently to the bias card which provides to send to protection in the event of excess power 7 2 2 RF Power Amplifier The RF modules the splitter and the combiner are housed inside the lower part of the equipment The RF amplifier section consists of 8 power modules couple...

Page 40: ...vice used in the amplifier modules is a single LD Mosfet The task of the low pass filter is to reduce the harmonic emissions of the amplifier to below the levels allowed by standards 7 2 3 Bias Board The task of this card is to measure the current drawn by the RF modules and the several input and output power providing for fault reporting and the management of their guards This card also carries t...

Page 41: ...r Use a small screwdriver to change the delivered power 7 3 2 PS status LEDs Card Three LEDs are present on this board for indicating the operating status of the three power supply modules and a fourth LED indicating the status of the service supplies The lighting up of a LED indicates a malfunction in the associated module 7 3 3 Scheda Pannello The panel board accommodates the microcontroller tha...

Page 42: ...carries the signals to the DB25 telemetry connector that is on the machine s back panel The connector is fitted with 7 analog outputs 8 open collector digital outputs and 4 digital inputs It also manages the DB9 connector for communications in I2 Cstandard ...

Page 43: ...w Drive power board contains an RF amplifier with only one stage that with a power of about 1W can supply an output power of approximately 50W suitable to pilot the amplifier The active device utilized in the amplifier modules is a Mosfet and uses for the feeding the same voltage of 50VDC used from the eight RF amplifiers modules On the output stage of this board is present a directional coupler t...

Page 44: ...turning the equipment off and making sure that you have closed them all before restarting the equipment Be sure to disconnect the amplifier s mains supply before proceeding to any maintenance operation on the system 9 3 Ordinary maintenance The only regular maintenance required on the PJ5000U K is the periodic blower replacement and dust cleaning of the air filter and of any trace of it inside the...

Page 45: ... the four fixing screws C Reconnect the connector in the position B and secure it with two screws Replace the front cover and screw all the screws into the position A 9 4 Module substitutions Only authorized and qualified technical personnel must be proceed with the replacement of the component parts in the relevant device 9 4 1 How to replace the RF module Open the bottom cover of PJ5000U K by un...

Page 46: ... l e 7 m o d u l e 8 Disconnect connector A and unsolder points B B A Unscrew all the Allen screws located in positions C C At this point replace the module placing on the back of the new RF module some Compound paste with high thermal conductivity and without silicones We recommend the Compound paste of the HTC Electrolube or equivalen ...

Page 47: ... the trimmer E until to the reading of the indicated value However if the amperometer does not provide any indication it is very probabely that the fuse is broken Proceed with its replacement by following the next chapter D E At this point screw the screws into the position C Reconnect the connector in its housing A Put the cover back on and tighten all the screws necessary to close it 9 4 2 How t...

Page 48: ...ace the broken fuse with one of equal value as in point B B Redo all previously steps performed in reverse in order to reassemble everything 9 4 3 How to replace the power supply Open the top cover of PJ5000U K by unscrewing all the screws Identify the power supply module to be replaced based on the signaling LED on the front panel ...

Page 49: ... 3 0 21 03 18 M M M Unscrew all the points A with the help of an Allen screwdriver A Remove the two plates near points A Disconnect all the connectors at positions B and unscrew all the points C with the help of an Allen screwdriver ...

Page 50: ...a new spare part Redo all previously steps performed in reverse in order to reassemble and fix the module in place 9 4 4 How to replace the PFC Open the top cover of PJ5000U K by unscrewing all the screws Identify the module to be replaced Unscrew all the points A with the help of an Allen screwdriver ...

Page 51: ... 21 03 18 A Remove the two plates near points A Disconnect all the connectors at positions B and unscrew all the points C with the help of an slotted screwdriver C B Lift up the protective film and disconnect the connector in position D ...

Page 52: ... to reassemble and fix the module in place 9 4 5 How to replace the Service power supply Open the top cover of PJ5000U K by unscrewing all the screws Unscrew all the points A with the help of an Quadrex screwdriver A Slip off the block of cards by rotating it at the same time about 90 180 Identify the module to be replaced Disconnect all the connectors at positions B ...

Page 53: ...1 03 18 B Unscrew all the points C with the help of an Quadrex screwdriver C Remove the amplifier module and replace it with a new spare part Redo all previously steps performed in reverse in order to reassemble and fix the module in place ...

Page 54: ...48 48 User Manual Rev 3 0 21 03 18 PJ5000U K Pagina lasciata intenzionalmente in bianco ...

Page 55: ..._____________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________________________________________________________________ ______________________...

Page 56: ...1104 e mail info rvr it web http www rvr it The RVR Logo and others referenced RVR products and services are trademarks of RVR Elettronica S p A in Italy other countries or both RVR 1998 all rights reserved All other trademarks trade names or logos used are property of their respective owners ISO 9001 2000 certified since 2000 ...

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