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Table of Contents 

 

S

ECTION

 

I-

 

S

AFEGUARDS

...............................................................................................I-1

 

S

AFETY AND 

F

IRST 

A

ID

.....................................................................................................I-2 

O

PERATING 

S

AFEGUARDS

................................................................................................I-3 

 

S

ECTION 

II

 

-

  

W

ARRANTY

..............................................................................................II-1 

 

S

ECTION

 

III

 

-

 

O

VERVIEW

..............................................................................................III-1 

S

TANDARD 

F

EATURES

....................................................................................................III-1 

P

RINCIPLE OF 

O

PERATION

..............................................................................................III-2 

B

LOCK 

D

IAGRAM

.............................................................................................................III-3 

S

PECIFICATIONS

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

 

S

ECTION 

IV

 

-

 

RF

 

C

OMPONENTS

................................................................................ IV-1 

A

MPLIFIER 

P

ALLETS

....................................................................................................... IV-1 

S

PLITTER

/C

OMBINER

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

D

IRECTIONAL 

C

OUPLER

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

I

SOLATOR

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

F

ILTER

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

 

S

ECTION 

V

 

-

 

P

OWER 

S

UPPLY 

S

ECTION

...................................................................... V-1 

 

S

ECTION 

VI

 

-

 

M

ONITOR AND 

C

ONTROL 

S

YSTEM

....................................................... VI-1 

C

ONTROL 

B

OARD 

O

VERVIEW 

(S

ERIES 

II-I) ................................................................... VI-1 

P

OWER 

S

UPPLY 

C

OMPONENTS

..................................................................................... VI-1 

I

NTERFACE 

C

OMPONENTS

............................................................................................. VI-2 

S

IGNAL 

C

ONDITIONING 

C

OMPONENTS

.......................................................................... VI-3 

D

ISPLAY 

C

OMPONENTS

................................................................................................. VI-4 

M

ICROCONTROLLER 

C

OMPONENTS

............................................................................... VI-5 

F

AULT 

S

HUTDOWN

......................................................................................................... VI-6 

R

EMOTE 

P

ORT

............................................................................................................... VI-7 

B

ILL 

O

F 

M

ATERIALS

....................................................................................................... VI-8 

S

CHEMATICS

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

 

S

ECTION 

VII

 

-

 

M

ECHANICAL 

S

ECTION

...................................................................... VII-1 

 

 

Summary of Contents for TAU-500

Page 1: ...TAU 500 POWER AMPLIFIER NEW ADVENTURES IN BROADCASTING Technalogix ...

Page 2: ...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 4...

Page 3: ...PLIFIER PALLETS IV 1 SPLITTER COMBINER IV 4 DIRECTIONAL COUPLER IV 4 ISOLATOR IV 4 FILTER IV 4 SECTION V POWER SUPPLY SECTION V 1 SECTION VI MONITOR AND CONTROL SYSTEM VI 1 CONTROL BOARD OVERVIEW SERIES II I VI 1 POWER SUPPLY COMPONENTS VI 1 INTERFACE COMPONENTS VI 2 SIGNAL CONDITIONING COMPONENTS VI 3 DISPLAY COMPONENTS VI 4 MICROCONTROLLER COMPONENTS VI 5 FAULT SHUTDOWN VI 6 REMOTE PORT VI 7 BIL...

Page 4: ...TOWER RECOMMENDATIONS VIII 4 SHELTER SECURITY VIII 5 UNPACKING AND INSPECTION VIII 6 LOCATION AND FUNCTION OF CONTROLS AND CONNECTORS TAU 500 POWER AMPLIFIERS VIII 7 LOCATION AND FUNCTION OF CONTROLS AND CONNECTORS POWER SUPPLY VIII 9 INITIAL HOOK UP VIII 11 SECTION IX OPERATING PROCEDURE IX 1 SECTION X MAINTENANCE AND TROUBLESHOOTING X 1 TROUBLESHOOTING X 2 ...

Page 5: ...UMENTATION 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 attemp...

Page 6: ...h 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 electri...

Page 7: ...f 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 operat...

Page 8: ...n 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...

Page 9: ...alogix ca for the RMA form Service and fill it out Either fax it to us or email to us Package equipment carefully for prepaid shipment to Technalogix Include a written description of the problem experienced a copy of the original invoice establishing warranty status and the RMA Technalogix reserves the right to make revisions in current production of the equipment and assumes no obligation to inco...

Page 10: ...er based monitoring and control ensures amplifier will never be overdriven and high VSWR will not damage amplifier AC circuit breaker on back panel to eliminate replacement of fuses All aluminium enclosure maintains power amplifier s light weight Simple design using commonly available parts ensures reliable operation Predominate and third order intermodulation distortion exceeds Industry Canada an...

Page 11: ...is not field tuneable The TAU 500 power amplifier is a modular solid state 500 watt broadcast amplifier utilizing readily available RF components wherever possible thus enhancing the serviceability of the equipment The TAU 500 is comprised of a TECH 30U driver pallet and 2 P300 final pallets that are combined to create 500 watts of peak visual power in addition to the aural carrier power The TAU 5...

Page 12: ... buffer any transients that may come into the power amplifier After attenuation the signal gets preamplified through the driver pallet before the signal gets split into 2 signals for final amplification The output of the 2 final amplifier pallets get combined and passes through an isolator and a bandpass filter Finally the signal passes through a dual directional coupler for monitoring purposes be...

Page 13: ...ypical i A 0 2dB typical A 0 5dB typical A 0 05dB typical RF INPUT RF OUT TECH 30U SPLITTER 2 WAY P300 UHF FINAL P300 UHF FINAL 2 WAY COMBINER V V DIRECTIONAL COUPLER V CIRCULATOR ATTENUATION TERMINATION 50 OHM TAU 500 Block Diagram Date May 24 2005 Page 1 of 1 Rev ID ...

Page 14: ...BmV Rated Visual Output Power 500 Watts Rated Aural Output Power 10 of peak visual power IF Output Level 35 dBmV nominal Input Impedance 75 Ohms Output Impedance 50 Ohms Harmonics 60 dB below rated power Predominant Intermodulation Distortion dBc decibels below visual carrier 920 kHz 53 dBc 920 kHz 53 dBc 2 66 MHz 53 dBc 2 66 MHz 53 dBc 5 42 MHz 53 dBc 7 16 MHz 53 dBc 3 rd Order Intermodulation Di...

Page 15: ...kHz Deviation 1 50 Hz to 15 kHz Amplitude Modulation Noise 50 dB Frequency Modulation Noise 60 dB Intercarrier Stability 250 Hz Physical Characteristics Power Requirements Power Supply 230 VAC 10 AAC Operating Temperature 0 50 C Dimensions TAU 500 Power Amplifier W 19 flange 17 encl D 25 H 8 5U Power Supply W 19 flange 17 encl D 2 H 7 4U ...

Page 16: ...nce separating these connections is 0 01 ohms providing a 10 mV per ampere ratio The P300 UHF pallets used in the final amplification stage use LDMOS Laterally Diffused Metal Oxide Semiconductor technology LDMOS technology offers higher gain efficiency and linearity over standard MOSFET and Bipolar devices and enhances ruggedness and reliability LDMOS transistors have the added advantage of not ha...

Page 17: ......

Page 18: ...P300 UHF 16 Schematic ...

Page 19: ...s a typical insertion loss of 0 5dB and its Type N connectors can handle 1 500 watts peak The coupler requires 8 to 8 5Vdc to power the internal electronics of the coupler and is supplied from the control printed circuit board at the front of each enclosure Isolator The power amplifier pallets are protected in part by the isolator located in the filter enclosure It is actually made up of a circula...

Page 20: ...through a series dropping resistor to lower the supply voltage down as the fans are 24Vdc The power supplies in the power supply enclosure are 2 Mean Well PSP 1000 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 fu...

Page 21: ...H CURRENT 35A 115V 70A 230V LEAKAGE CURRENT 2mA 240VAC OVERLOAD PROTECTION 115 140 TYPE CONSTANT CURRENT LIMITING RESET AUTO RECOVERY OVER VOLTAGE PROTECTION 5 75 6 75 13 8 16 2V 15 5 18 2V 18 21V 27 6 32 4V 31 36 5V 57 6 67 2V OVER TEMP PROTECTION RTH2 95ºC OUTPUT SHUTDOWN REMOTE CONTROL RC RC 0 0 8V POWER ON 4 10V POWER OFF SINK CURRENT 4 10mA TEMP COEFFICIENT 0 03 ºC 0 50ºC SETUP RISE HOLD UP T...

Page 22: ......

Page 23: ...uired by the LCD 4 5Vdc for the directional coupler supply The 5Vdc is generated from a small switching power supply comprised of C101 C102 D102 L101 and U101 This power supply accepts DC input voltages up to 40Vdc unless U101 is an HV option then the maximum input voltage is 60Vdc and outputs 5Vdc at up to 1Adc This voltage is always on as the ON OFF pin on U101 is hard wired to the on configurat...

Page 24: ...amplifiers are still turned off In order to turn the amplifiers on assuming the rocker switch is turned on wait ten seconds after plugging the PA in and push in the POWER tactile button The LCD will read Soft Start Warm Up Please Wait After ten seconds the bias voltages will be turned on and you may then plug in the RF drive Depress for 1 second to turn on and 3 seconds to turn system off In the c...

Page 25: ...es II rev I PCBs is used to buffer potentially noisy or damaging signals from the ADC Power supply samples and forward and reflected power from a directional coupler are then digitized Firstly all analog signals are protected with a resettable fuse and transient voltage suppressor TVS combination These components ensure that voltages above the Vbr breakdown voltage of the TVS get clamped and do no...

Page 26: ...re within their predetermined safe operating levels If a fault is found appropriate action is taken to help protect the system from damage which may include turning the RF carriers off A full description of all faults and their respective actions is found later in this section The power supply for the microcontroller is monitored closely via supervisor U113 Should the 5Vdc supply drop below 4 5Vdc...

Page 27: ...down for 1 minute automatically turn amp on after 1 minute and check again for overdriven amplifier come back to the same power level that it was set If you see this message the system will shut amp down for 5 minutes automatically turn amp on after 5 minutes and check again for high VSWR come back to the same power level that it was set ...

Page 28: ...ctions on the remote port are simply hard wired or paralleled to existing wiring to provide a secondary method of control to the user and are activated as follows pin 1 ground to reset microcontroller float otherwise pin 2 ground for 2 seconds to toggle carrier on off float otherwise pin 3 common ground pin 4 DC power supply sample ...

Page 29: ...square post Through hole 0 1 spacing Molex 22 28 4300 Samtec TSW 130 05 T S 20 1 J105 CONNECTOR breakaway header strip 2 position 0 1 square post Through hole 0 1 spacing Molex 22 28 4300 Samtec TSW 130 05 T S 21 3 J102 J105 J106 CONNECTOR 2 position post shunts 0 1 spacing AMP 382811 6 Samtec SNT 100 BK T 22 1 J103 CONNECTOR 5 position plug 180 degree wire entry 90 degree screw access 5 08mm 0 2 ...

Page 30: ...evices ADM8660 Maxxim MAX660 49 2 U105 U106 OPTOISOLATOR dual Viso 5300Vac SMD DIP8 Fairchild MCT6S 50 1 U108 OP AMP quad low voltage SMD SOIC 14 National LMV324M 51 1 U109 REFERENCE 2 50V for TV PA 250Wpk 0 2 SMD SOT 23 National LM4040BIM3 2 5 52 1 U110 ADC 10 bit 10 channel SMD SOIC 20 Analog Devices AD7812YR 53 2 U111 U112 LOGIC 8 bit shift register with latches SMD SOIC 16 Fairchild MM74HC595M...

Page 31: ...D Vcoupler GND Vin L101 D102 C101 D101 F101 3 J101 1Vin 2 Vout 4 Feedbk 3 Gnd 5 On Off U101 C102 5Vdc 4 J101 C105 C106 2Vin 1 Vout 4 Feedbk 3 Gnd 5 On Off U102 D103 L103 Pin15LCD IN COM OUT U103 C108 1 J101 J101 2 5Vdc Pin3LCD J102 R103 R102 R101 A Sivacoe SERIES II Control System I Power Supply Section Date March 28 2005 Page 1 of 1 Rev ID ...

Page 32: ...102 Rly Ctrl 5Vdc K101 Rly COM Rly N O Rly N C J107 3 J107 1 Buzzer J105 Q101 5Vdc R116 RES In NC RC6 VW In PWR In J103 1 P1 P2 P3 P4 P5 P6 P7 P8 U106 P1 P2 P3 P4 P5 P6 P7 P8 U105 R105 R106 R109 5Vdc R107 R108 VW uPC PWR uPC R115 R110 R111 R112 5Vdc R113 R114 PIN17uPC RES uPC BZ101 A Sivacoe SERIES II Control System I Interface Section Date March 21 2005 Page 1 of 1 Rev ID ...

Page 33: ...Analog 1 J108 2 Analog 2 J108 3 Analog 3 Isoltd 4 Isoltd 3 Isoltd 2 Isoltd 1 C112 F107 F106 F105 D108 D109 C113 5V L105 D107 D106 F103 F104 C111 Isoltd 6 Isoltd 7 Isoltd 8 12 13 4 11 14 U107 4 4 J108 8 Analog 8 D105 F102 Analog 7 J108 7 Analog 6 J108 6 Analog 5 J108 5 9 10 4 11 8 U107 3 4 3 2 4 11 1 U107 1 4 R124 R130 R129 R128 R127 R126 R125 R119 R118 R120 R121 R122 R123 A Sivacoe Series II Contr...

Page 34: ...C140 C142 C141 C139 C138 C137 C136 C135 C134 C132 C131 C127 C126 C124 C122 DtoUPC DfromUPC Dclk ConvStrt Isoltd 1 Isoltd 2 Isoltd 3 Isoltd 4 Isoltd 6 Isoltd 7 Isoltd 8 Vref Cref Vin1 AGND Vin2 Vin3 Vin4 Vin5 Vin6 Vin7 Vin8 A0 DGND TFS RFS Dout Din Dclk ConvStart Vdd U110 R131 A Sivacoe Series II Control System I Analog Conversion Section Date March 21 2005 Page 1 of 1 Rev ID ...

Page 35: ...7 Qh out_7 GND U112 Latch2CS Latch1CS 5Vdc C143 BkLtCtrl Pin15LCD 2 3 4 Unbuf A Unbuf B Unbuf C Unbuf D 16 15 LED A LED K 3 2 J109 1 LCD Vo LCD Vdd LCD Vss 6 5 4 7 8 9 10 11 12 13 LCD RS LCD R W LCD E LCD D6 LCD D5 LCD D4 LCD D3 LCD D2 LCD D1 LCD D0 LCD D7 Dclk DfromUPC 14 J110 5 serial_out reset shift_clk latch_clk output_en serial_in Qa out_1 Vcc Qb out_2 Qc out_3 Qd out_4 Qe out_5 Qf out_6 Qg o...

Page 36: ...145 5Vdc MCLR Vpp RA0 RA1 RA2 RA3 RA4 RA5 Vss OSC1 CLKin OSC2 CLKout RC0 T1CKI RC1 CCP2 RC2 CCP1 RC3 SCK CL RC4 SDI SDA RC5 SD0 RC6 TX CK RC7 RX CK Vss Vdd RB0 INT RB1 RB2 RB3 RB4 RB5 RB6 RB7 U114 CS SO WP Vss SI SCK HOLD Vcc U115 Vcc GND Reset U113 OSC1 OSC2 GND CR101 R134 A Sivacoe Series II Control System I Microcontroller Section Date March 2 2005 Page 1 of 1 Rev ID ...

Page 37: ...isable Reset View Input On Off Input Ground to Switches Fault Input Ground unused J1 2 J1 1 J1 3 J1 4 J6 2 J3 2 J7 7 J7 6 J3 3 J3 1 J3 5 J3 4 Control PCB Series IIG ON OFF VIEW RESET PSU GND OnOff RESET DB25 Remote Port GND FAULT ONOFF CTRL DB9 RFL FWD 8V GND Coupler Directional V V DC Supply DB9 Pallet Driver Series II Control System Wiring I Date June 29 2005 Page 1 of 1 Rev ID ...

Page 38: ...he heat sink within the 500 watt power amplifier enclosure there are four fans that each provide 170 cubic feet per minute CFM of air flow into zero static pressure There are two fans mounted at the front of the heat sink and two 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 as...

Page 39: ...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...

Page 40: ...ional 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 c...

Page 41: ...trical 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 groun...

Page 42: ...d 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 location...

Page 43: ...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 f...

Page 44: ...an 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 t...

Page 45: ...ogix Ltd VIII 7 Location and Function of Controls and Connectors TAU 500 Power Amplifier The following illustration depicts the location of the connectors when installing the 500 watt power amplifiers TAU 500 ...

Page 46: ...nd protection continues during screen saver RESET Tactile button to reset microcontroller in control board Also clears existing faults Individual control board with reset comes back on with soft start feature RF IN RF input from modulator or processor BNC connector 50 ohm RF OUT 500 watt RF output Connects to RF IN on filter enclosure N connector 50 ohm DC IN DC input from power supply enclosure P...

Page 47: ...Technalogix Ltd VIII 9 Location and Function of Controls and Connectors Power Supply ...

Page 48: ...fresh screen after two minute screen saver times out All monitoring and protection continues during screen saver RESET Tactile button to reset microcontroller in control board Also clears existing faults Individual control board with reset comes back on with soft start feature AC IN AC input to switching power supply 31 VDC supply for control system and power supplies Use supplied NEMA to terminal...

Page 49: ... Do not connect the modulated signal from the RF OUT on the modulator or processor to RF IN on the power amplifier at this time Because of the characteristics of LDMOS devices the RF drive should not be connected to the power amplifier until after the power supply and bias voltages are present and stable 6 Ensure that modulator or processor RF output level is turned down as far as possible 7 Ensur...

Page 50: ...or or processor into AC mains 4 With the PA output loaded plug the 5U 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 bi...

Page 51: ...hould read zero However should a high VSWR be detected the system will automatically shut down and cycle as previously described This is also a peak wattage reading 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 monito...

Page 52: ... 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 m...

Page 53: ...rating position Is the input signal present Check LCD readings for presence of forward and reflected power and 30 V DC supply levels The above is an aid in determining the fault if some aspect of the system is not operating The following table deals with quality of operation Symptom Possible Fault Correction Horizontal bars in picture may roll either way depending on phase AC grounding AC interfer...

Page 54: ...ust to meet specification High reflected power Incorrect load Ensure amplifier connected to transmission line Ensure correct antenna impedance 50 ohms Check antenna tuning and VSWR Verify correct cable for transmission line length Check all cables for visible damage kinks nicks or cuts Check all connectors for poor connections water or corrosion Check alignment of antenna Check for physical damage...

Page 55: ...Thank you for choosing Technalogix Ltd ...

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