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Technalogix Ltd

.

VIII-2

Heating and Cooling Requirements

The environment’s temperature will contribute greatly to the length of the power amplifier’s life. Refer to the
specifications in Section 3.0 for humidity and temperature specifications. Technalogix recommends that the
building’s filtered air intake must have capacity for all air-flow in the building plus an additional 20%. The TAV-
1000 uses (10) ball bearing fans – (4) for each power amplifier, (1) for the power supply enclosure, and (1) for the
combiner. 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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Summary of Contents for TAV-1000

Page 1: ...TAV 1000 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: ...SECTION IV RF COMPONENTS IV 1 AMPLIFIER PALLETS IV 1 SPLITTER COMBINER IV 4 CIRCULATOR ISOLATOR IV 4 FINAL COMBINER IV 5 DIRECTIONAL COUPLER IV 5 FILTER IV 5 SECTION V POWER SUPPLY SECTION V 1 SECTION VI MONITOR AND CONTROL SYSTEM VI 1 CONTROL BOARD OVERVIEW SERIES IIH VI 1 POWER SUPPLY COMPONENTS VI 1 INTERFACE COMPONENTS VI 2 SIGNAL CONDITIONING COMPONENTS VI 3 DISPLAY COMPONENTS VI 4 MICROCONTR...

Page 4: ...ANTENNA AND TOWER RECOMMENDATIONS VIII 4 SHELTER SECURITY VIII 5 UNPACKING AND INSPECTION VIII 6 LOCATION AND FUNCTION OF CONTROLS AND CONNECTORS TAV 500 POWER AMPLIFIERS VIII 7 LOCATION AND FUNCTION OF CONTROLS AND CONNECTORS COMBINER FILTER ENCLOSURE VIII 9 INITIAL HOOK UP VIII 11 SECTION IX OPERATING PROCEDURES 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: ...ages 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 modif...

Page 9: ...RMA number is provided 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 Techna...

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: ...herever possible thus enhancing the serviceability of the equipment The TAV 1000featuresultra linear amplification and individual channel RF output bandpass filtering The amplifier modules are stable for high reliability and long service life The amplification of the TAV 1000 is comprised of 2 TAV 500 500 watt power amplifiers Firstly the output of the modulator or processor gets split into 2 RF s...

Page 12: ...ER AND ANTENNA 1U ENCLOSURE 5U ENCLOSURE 5U ENCLOSURE 5U ENCLOSURE RF OUT TAV 500 COMBINER FILTER TAV 500 SPLITTER 2 WAY MODULATOR PROCESSOR TAV 1000 Overall Block Diagram Date December 17 2003 Page 1 of 1 Rev ID ...

Page 13: ...nal amplification stage is comprised of 2 P400 VHF L or 2 P400 VHF H final amplifiers for low or high band VHF respectively The outputs of the 2 final amplifier pallets are combined with a 2 way Wilkinson combiner and pass through a dual directional coupler for protection and monitoring purposes as illustrated in the following TAV 500 block diagram ...

Page 14: ...B typ low band VHF A 15dB typ high band VHF A 18dB typ low band VHF A 15dB typ high band VHF RF INPUT RF OUT PA25 VHF DRIVER SPLITTER 2 WAY P400 VHF FINAL P400 VHF FINAL 2 WAY COMBINER V V DIRECTIONAL COUPLER V CIRCULATOR TERMINATION 50 OHM TAV 500 Block Diagram for use with TAV 1000 Power Amplifiers Date December 17 2003 Page 1 of 2 Rev ID ...

Page 15: ...filter enclosure where the signals from each 500 watt amplifier are combined After combining the amplified signals are filtered with a bandpass filter and monitored again with another directional coupler before heading out to an antenna for broadcast as depicted in the following combiner block diagram ...

Page 16: ...1 0dB A 0 05dB A 0 45dB TO WATTMETER AND ANTENNA RF OUT PA2 OUT PA1 OUT 2 WAY COMBINER V V COUPLER DIRECTIONAL U2 Bandpass Filter TAV 1000 Combiner Enclosure Block Diagram Date December 17 2003 Page 1 of 1 Rev ID ...

Page 17: ...60 dB adjacent channel Minimum Input Level 0 dBmV Rated Visual Output Power 1000 Watts Rated Aural Output Power 10 of peak visual power IF Output Level 12 dBm 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...

Page 18: ...e Modulation Noise 50 dB Frequency Modulation Noise 60 dB Intercarrier Stability 250 Hz Physical Characteristics Power Requirements Power Supply 230 VAC 30 AAC Combiner Filter 115 VAC 2 AAC Operating Temperature Range 0 C to 50 C Dimensions TAV 500 Power Amplifier each W 19 flange 17 encl D 25 H 8 3 4 5U Combiner Filter W 19 flange 17 encl D 25 H 8 3 4 5U ...

Page 19: ... measuring the voltage drop across the current sense resistor found directly at the DC power supply lead input to the pallet This resistance is 0 01 ohms providing a 10mV per ampere ratio The final amplifier stages are comprised of 2 P400 VHF L or P400 VHF H amplifier pallets and are each characterized with minimum gains of 18 dB low band or 15 dB high band and maximum drain currents of 28 A low b...

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Page 22: ...r The power amplifier pallets are protected in part by the isolator located in the filter enclosure It is actually made up of a circulator and 50 ohm dump resistor The circulators specifications include an insertion loss of less than 0 2dB with an isolation rating better than 20dB Any reflected power gets dumped into the flanged power resistor Even though the flanged power resistor is rated for on...

Page 23: ...rage for reflected Output power should be set by the following procedure THE POWER OUTPUT SHOULD NEVER BE ADJUSTED EXCEPT UNDER THE TEST CONDITIONS OF NO AURAL CARRIER WITH THE VISUAL CARRIER MODULATED WITH SYNC AND BLANKING The directional coupler has a typical insertion loss of 0 05dB and its Type N connectors can handle 1 500 watts peak The coupler requires 8 to 8 5Vdc to power the internal ele...

Page 24: ...re Mean Well PSP 1500 The power supply found in the filter enclosure is a Mean Well S60 24 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 automa...

Page 25: ...5 230VAC INRUSH CURRENT 100A 230V LEAKAGE CURRENT 3 5mA 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 H...

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Page 27: ... 4Vdc for the LED backlighting on the LCD 3 4Vdc for the contrast voltage required by the LCD 4 8Vdc for the directional coupler supply The 5Vdc is generated from a small switching power supply comprised of C1 C2 D2 L1 and U1 This power supply accepts DC input voltages up to 40Vdc and outputs 5Vdc at 1Adc This voltage is always on as the ON OFF pin on U1 is hard wired to the on configuration The 4...

Page 28: ...in each enclosure so only one needs to be depressed NAVIGATE Turns on backlight to LCD and displays forward and reflected RF power and DC supply voltage parameters When power amplifier is first turned on the LCD comes on automatically and this information is displayed Information is displayed for approximately 2 minutes before the backlight turnsoff and the display is cleared This is set up so as ...

Page 29: ...ly turns off the buzzer The carrier disable circuit simply applies a shutdown voltage to the driver pallet in the system The U14 generates the signal out of pin 21 and controls relay Q2 through R17 When Q2 is turned off the shutdown voltage to the driver is floating and the carrier is on During a fault condition when Q2 is turned on the shutdown voltage is applied to the carrier disable on the dri...

Page 30: ... with U7 and U8 configured as unity gain voltage followers Finally after some further decoupling capacitors and filters the analog signals get digitized by the 8 channel 10 bit ADC U10 and sent to the microcontroller through a serial interface In the power amplifier and filter enclosures there are 3 analog voltages that are conditioned and processed DC power supply sample forward RF power and refl...

Page 31: ...CD is an alphanumeric 20X4 display that uses the industry standard 44780 controller and a parallel interface for data communications The microcontroller sends out the data to be displayed via a serial bus where the signals are latched with U11 and U12 and converted to a parallel data stream The parallel data then transfers directly to the LCD through connector J8 J8 also carriers the power supply ...

Page 32: ...ntroller is monitored closely via supervisor U13 Should the 5Vdc supply drop below 4 5Vdc a microcontroller reset is generated to ensure there are no brown out conditions that may latch up the microcontroller up to an unknown state The front panel Reset momentary switch is also tied to this line after optoisolation The microcontroller s clock source 4 000MHz is generated by ceramic resonator CR1 I...

Page 33: ...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 34: ... signal through the DB9 to one of the optoisolated inputs on the power amplifier s control PCB The power amplifier control PCB in turn then sends its shutdown voltage out to disable the driver and turn off the carrier Remote Port The remote port allows external control of the transmission system via the DB25 connector on each enclosure All functions on the remote port are simply hard wired or para...

Page 35: ...MDC014 2 18 1 J1 CONNECTOR 4 position plug 180 degree wire entry 90 degree screw access 5 08mm Wieland 25 340 3453 Weco 10 808 104 19 1 J1 CONNECTOR 4 position header pluggable vertical closed 5 08mm Through hole 0 2 spacing Wieland 25 350 3453 Weco 20 806 128 20 3 J2 J5 J6 CONNECTOR breakaway header strip 3 and 2 position required Through hole 0 1 spacing Molex 22 28 4300 Samtec TSW 130 05 T S 21...

Page 36: ...REGULATOR switching 5Vdc 1A fosc 150kHz Through hole TO 220 5 National LM2595T 5 0 51 1 U3 REGULATOR linear 8V 1A Through hole TO 220 7808CT 52 1 U4 REGULATOR inverter 100mA SMD SOIC 8 National LM2660M Analog Devices ADM8660 Maxxim MAX660 53 2 U5 U6 OPTOISOLATOR dual Viso 2500V Vce 30V Through hole DIP 8 Fairchild MCT6 54 1 U8 OP AMP quad low voltage SMD SOIC 14 National LMV324M 56 1 U9 REFERENCE ...

Page 37: ...P8 U4 BkLtCtrl GND 8V OUT GND Vin L1 D2 ELECTROLYTIC C1 D1 F1 3 J1 1Vin 2 Vout 4 Feedbk 3 Gnd 5 On Off U1 ELECTROLYTIC C2 5Vdc 4 J1 ELECTROLYTIC C5 ELECTROLYTIC C6 2Vin 1 Vout 4 Feedbk 3 Gnd 5 On Off U2 D3 COMPONENT SIDE L3 Pin15LCD IN COM OUT U3 NEAR POW CONN C7 1206 CHIP 1 J1 J1 2 5Vdc Pin3LCD J2 R3 R2 R1 A Sivacoe SERIES II Control System H Power Supply Section Date May 14 2004 Page 1 of 1 Rev ...

Page 38: ...7 2 Q2 Rly Ctrl 5Vdc RLY1 Rly COM Rly N O Rly N C J7 3 J7 1 Buzzer J5 Q1 5Vdc R16 RES In NC RC6 VW In PWR In J3 1 P1 P2 P3 P4 P5 P6 P7 P8 U6 P1 P2 P3 P4 P5 P6 P7 P8 U5 R5 R6 R7 5Vdc R8 R9 VW uPC PWR uPC R13 R10 R11 R12 5Vdc R14 R15 PIN17uPC RES uPC BZ1 A Sivacoe SERIES II Control System H Interface Section Date March 5 2004 Page 1 of 1 Rev ID ...

Page 39: ... 12 13 4 11 14 U8 4 4 J8 1 Analog 1 J8 2 Analog 2 J8 3 Analog 3 Isoltd 4 Isoltd 3 Isoltd 2 Isoltd 1 BESIDE C18 0805 F8 F7 F6 D9 D10 D11 C13 5V L11 D8 D7 D6 F3 F4 F5 SOLDER SIDE C10 1206 CHIP Isoltd 5 Isoltd 6 Isoltd 7 Isoltd 8 12 13 4 11 14 U7 4 4 J8 8 Analog 8 D5 F2 Analog 7 J8 7 Analog 6 J8 6 Analog 5 J8 5 9 10 4 11 8 U7 3 4 3 2 4 11 1 U7 1 4 5 6 4 11 7 U7 2 4 R26 R32 R31 R30 R29 R28 R27 R19 R18...

Page 40: ... 1 U9 5Vdc C45 C42 C41 C40 C39 C38 C37 C36 C35 C34 C21 C31 C16 C28 NEAR U8 C2 0805 C12 C25 DtoUPC DfromUPC Dclk ConvStrt Isoltd 1 Isoltd 2 Isoltd 3 Isoltd 4 Isoltd 5 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 U10 R33 A Sivacoe Series II Control System H Analog Conversion Section Date May 14 2004 Page 1 of 1 Rev ID ...

Page 41: ... LCD D1 LCD D2 LCD D3 LCD D4 LCD D5 LCD D6 LCD E LCD R W LCD RS J9 13 J9 12 J9 11 J9 10 J9 9 J9 8 J9 7 J9 4 J9 5 J9 6 LCD Vss LCD Vdd LCD Vo J9 1 J9 2 J9 3 LED K LED A J9 15 J9 16 Unbuf D Unbuf C Unbuf B Unbuf A J10 4 J10 3 J10 2 Pin15LCD BkLtCtrl C46 5Vdc Latch1CS Latch2CS 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 out_7 Q...

Page 42: ... C48 5Vdc MCLR Vpp RA0 RA1 RA2 RA3 RA4 RA5 Vss OSC1 CLKin OSC2 CLKout RC0 T1CKI RC1 CCP2 RC2 CCP1 RC3 SCK CLRC4 SDI SDA RC5 SD0 RC6 TX CK RC7 RX CK Vss Vdd RB0 INT RB1 RB2 RB3 RB4 RB5 RB6 RB7 U14 CS SO WP Vss SI SCK HOLD Vcc U15 Vcc GND Reset U13 OSC1 OSC2 GND CR1 R36 A Sivacoe Series II Control System H Microcontroller Section Date March 8 2004 Page 1 of 1 Rev ID ...

Page 43: ...in In addition to the cooling effects of the heat sink within each 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 operated in a push pull configuration to assist with heat dissipation The fans are a 2...

Page 44: ...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 insta...

Page 45: ...000 uses 10 ball bearing fans 4 for each power amplifier 1 for the power supply enclosure and 1 for the combiner 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 conditionin...

Page 46: ...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 47: ...ading 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 hi...

Page 48: ...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 49: ... 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 immediatecarefulinspectionofthe equipment and subsequent immediate filing of the necessary claims against the carrier if necessary If possible inspect the equipment in the...

Page 50: ... Ltd VIII 7 Location and Function of Controls and Connectors TAV 500 Power Amplifier The following illustration depicts the location of the connectors when installing each of the 500 watt power amplifiers TAV 500 ...

Page 51: ...faults Individual control board with reset comes back on with soft start feature RF IN RF input from the output of the RF splitter BNC connector 50 Ω RF OUT 500 watt RF output to be combined with the other 500 watt output Connects to RF IN PA 1 or 2 on combiner unit N connector 50 Ω PA CTRL Control signals communicating with the combiner enclosure Connects with the PA 1 and PA 2 CTRL connector on ...

Page 52: ...Ltd VIII 9 Location and Function of Controls and Connectors Combiner Filter Enclosure The following illustration depicts the location of the connectors when installing each of the 500 watt power amplifiers TAV 500 ...

Page 53: ...al control board with reset comes back on with soft start feature PA1 and PA2 RF IN RF input from the output of each power amplifier N connector 50 Ω RF OUT 1 000 watt RF output to be connected with inline wattmeter and then to antenna N connector 50 Ω PA CTRL Control signals communicating from the combiner enclosure to the power amplifier enclosures Connects with the PA 1 and PA 2 CTRL connector ...

Page 54: ... power supply and bias voltages are present and stable 5 Ensure that modulator or processor RF output level is turned down as far as possible 6 Ensure that the audio modulation is set to 100 with the audio signal supplied as described in the appropriate modulator processor manual will be factory set 7 Ensure that the video modulation level is set to 87 5 with the video signal supplied as described...

Page 55: ...biner enclosure s fan is on 7 Plug the 5U power amplifier enclosures into 220V AC mains 8 On the power amplifier simultaneously switch the AC rocker switches to on position 9 Verify that the power amplifier fans are all on 10 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 11 The internal soft start circ...

Page 56: ... VSWR be detected the system will automatically shut down and cycle as previously described This is also a peak wattage reading 15 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 and power supply enclosures and 24Vdc on the combiner filter enclosure 16 Look at the transmit...

Page 57: ... 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 58: ...rating 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 Fault Correction Horizontal bars in picture may roll either way depending on phase AC grounding AC interfer...

Page 59: ...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...

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