TAV-25 POWER AMPLIFIER NEW ADVENTURES IN BROADCASTING
You’ve already unpacked it, haven’t you? You’ve unpacked it and plugged it in and turned it on and fiddled with the knobs. No? Okay, good. Please take a few minutes to read the manual and familiarize yourself with your new Technalogix power amplifier. We believe that this manual, and of course our equipment, should be everything you need to get on the air with superb broadcast quality video.
Table of Contents SECTION I- SAFEGUARDS ...............................................................................................I-1 SAFETY AND FIRST AID .....................................................................................................I-2 OPERATING SAFEGUARDS ................................................................................................I-3 SECTION II - WARRANTY..............................................................................................
SECTION VIII - INSTALLATION ..................................................................................VIII-1 BUILDING RECOMMENDATIONS ....................................................................................VIII-1 HEATING AND COOLING REQUIREMENTS ....................................................................VIII-2 ELECTRICAL SERVICE RECOMMENDATIONS ................................................................VIII-3 ANTENNA AND TOWER RECOMMENDATIONS ...............................
Section I - Safeguards General Safeguards This section is written as a general guide to keep all 5 fingers on your hand and is intended for those having previous knowledge and experience with these kinds of equipment. It is not intended to contain a complete statement of all safety precautions, which should be observed by personnel using this or other electronic equipment. DOCUMENTATION - Read, retain and follow instructions before operating the equipment.
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.
Operating Safeguards It is a known fact that our broadcast transmitters and translators enjoy 50-ohm load impedances. So much so, that it is imperative you maintain 50-ohm impedances throughout your system. In return, your equipment will provide you with maximum power transfer to the antenna and decreased reflected power heading back towards the amplifier pallets, reducing the amount of magic smoke that gets let out of the power amplifier.
Section II - Warranty Our legalese is straightforward. It is simply designed to give you peace of mind and helps you resist the temptation to have your electronics friend try to repair your Technalogix product. Technalogix Ltd. products have been completely tested and found to meet specifications and be in proper operating condition. They are warranted to be free from defects in materials and workmanship for a period of one year from the date of shipment.
To claim your rights under this warranty: • Contact Technalogix and describe the problem in as much detail as possible. See troubleshooting section in this manual. If a solution cannot be found at this time, it may be determined that the unit will have to be returned to Technalogix for repair, once a Return Materials Authorization (RMA) number is provided. Please look under our web site (www.technalogix.ca) for the RMA form (Service) and fill it out. Either fax it to us or email to us.
Section III - Overview Standard Features • Narrow output bandpass filter allows adjacent channel operation • Front panel Liquid Crystal Display (LCD) to monitor forward and reflected RF power, and DC voltage • Microcontroller-based monitoring and control ensures amplifier will never be overdriven and high VSWR will not damage amplifier • AC circuit breaker on back panel to eliminate replacement of fuses • RF/EMI filtering on AC entry plug • All aluminium enclosure maintains power amplifier’s ligh
Principle of Operation The TAV-25 power amplifier supplies a 25-watt peak video signal with an aural carrier level 10 to 13 dB below visual carrier (dBc) on any of the VHF television channels 2 through 13. Please note that channel selection must be made at time of order, as the transmitter or translator is calibrated and tested to the channel requested and is not field tuneable.
Block Diagram The RF signal enters through the RF Input connector on the power amplifier enclosure from the modulator or processor. It then passes through an RF attenuator to limit the output power level of the power amplifier and to help buffer any transients that may come into the power amplifier. After attenuation, the signal is amplified through the VHFTV-25 driver before the signal passes through a bandpass filter.
FILTER UHFTV-25 DIRECTIONAL COUPLER CIRCULATOR ATTENUATOR RF INPUT RF OUT V V A=-0.5dB typ. A=+40dB typ. low band VHF A=+34dB typ. high band VHF V A=-0.05dB typ. TO WATTMETER AND ANTENNA A=-0.6dB typ.
Specifications The following specifications were taken with a Technalogix modulator/processor. Should a different modulator or processor be used, specifications could vary. For this reason, we recommend that any different modulator/processor be shipped to Technalogix so the system can be matched and set up optimally. In addition, the audio/video ratio the input to the power amplifier needs to be –10 dB in order for the software and LCD readout to be accurate.
Aural Characteristics Input Level for 25 kHz Deviation Frequency Response (Standard Pre-emphasis) Harmonic Distortion (25 kHz Deviation) Amplitude Modulation Noise Frequency Modulation Noise Intercarrier Stability 0.3 VPP ±1 dB < 1% 50 Hz to 15 kHz > 50 dB > 60 dB ±250 Hz Physical Characteristics Power Requirements TAV-25 Power Amplifier 115 VAC , 4 AAC or230 VAC , 2 AAC 0 - 50°C TAV-25 Power Amplifier W-19" flange (17” encl.) , D-21.25", H-5.
Section IV – RF Components Amplifier Pallets The VHFTV-25 pallet is a two stage ultra linear class-A linear pallet. The VHFTV-25-L has a typical gain of 40dB and the VHF TV-25-H has a typical gain of 34dB. These pallets draw no more than 3.0Adc total drain current (the exact bias and drain currents of your system are found in the spec sheet supplied with each manual).
TECHNALOGIX LTD. 25 W UHF HI BAND DRIVER P25-UHF R.S.
23 TECHNALOGIX LTD. 25 W UHF LO BAND DRIVER A P25-UHF-L R.S.
Filter The passive bandpass filter rejects spurious and harmonic output products and passes the VHF channel RF output. The cavity resonator uses aperture coupling and is a linear resonator design. Typical insertion loss is 0.6 dB to 1.0 dB depending on channel frequency. Average roll off is –33 dBc at a point 4.5 MHz below the peak visual carrier frequency and –30 dBc 9.0 MHz above the peak visual carrier frequency. The filter is DC grounded on both the input and output for additional lightning protection.
Section V – Power Supply Switching AC-DC power supplies are used to power the amplifier pallets, the control circuits, and all of the fans. There is (1) power supply used to generate the necessary current for the amplifier pallets, set to 31.0 Vdc nominally. The power supply is a Mean Well S-240-30. This switching power supply is fully protected against short circuit and output overload. Short circuit protection is a cycling type power limit.
S-240 240W Single Output Switching Power Supply series Features : Auto switched 88 ~ 264VAC input Built-in passive PFC choke Protections:Short circuit/Over load/Over voltage/Over temperature Forced air cooling by built-in DC fan Built-in cooling Fan ON-OFF control LED indicator for power on Fixed switching frequency at 75KHz 2 years warranty SPECIFICATION MODEL OUTPUT S-240-5 S-240-7.5 S-240-12 S-240-15 S-240-24 S-240-30 S-240-48 DC VOLTAGE 5V 7.
S-240 240W Single Output Switching Power Supply Mechanical Specification Case No. 911 series Unit:mm 159.5 139.5 133 49.5 20 7 6 4-SO M3 L=6 2 44 43.5 41.5 3 62.5 4 8 93 84.5 9.5 5 1 Air flow direction 190 171.25 26 7.5 37.5 50 65 3-M4 L=6 Terminal Pin. No Assignment Pin No. 1 2 3 Pin No.
Section VI – Monitor and Control System Control System Overview (Insight) The Insight control system is used for a variety of functions, the most important of which is ensuring that the transmitter continues to operate in a safe manner. The control system also allows the user to monitor and control the transmitter from both the front panel and the remote access port. Five modules comprise the Insight control system. These modules work together to provide all the functions of the control system.
monitored by U101 to U105, buffered by U106 to U108, and sent to the analog to digital converter integrated into the microcontroller. There are five circuits for which the current is monitored by this system. As the DC supply passes through the user interface module, it undergoes filtering to ensure that the supply to the pallets is as clean as possible. Each of the five circuits passes through a network of transient voltage suppressors, capacitors, and inductors.
RF Conditioning Module The RF conditioning board is located at the RF input of the amplifier. Its main function is to act as a variable attenuator, so that the control system can add attenuation to the input of the amplifier in order to limit the output power of the transmitter. The RF signal comes in to the RF conditioning module through J302 before it passes through a manually variable attenuator made up of R305, VR303, and R307.
Remote Port The remote port allows external control of the transmission system via the DB25.
Fault Shutdowns On the LCD (Liquid Crystal Display) the following messages may appear: If you see this message, the system has been driven to a power level higher than it is rated for. This message will likely only appear momentarily, before the amplifier will add attenuation at its input to bring the output power to a safe level. This message indicates that excessive reflected power has been detected at the output of the transmitter.
Monitor and Control System (Insight) Bills of Materials Circuit: Revision: User Interface Module 1.03 Designations Qty Description Package U112 1 IC MICROCONTROLLER 256 BYTE RAM 64QFP C106, C107, C117, C118, C128, C129, C141, C142, C148, C149, C163 11 CAPACITOR 0.01 uF 50V 10% C108-116, C119127, C130-140, C143-145, C161 33 Manufacturer Mfg. Part Number Texas Instruments MSP430F135IPM 0805 Yageo 08052R103K9B20D CAPACITOR 0.
L106, L107, L108, L109, L110 5 INDUCTOR 0.01uH 1210 TDK NLV32T-010J-PF Y101 1 6.00 MHz CRYSTAL SMT Citizen HCM49-6.00 U111 1 IC SUPERVISOR 2.70V LOW SOT23 Microchip Technology MCP130T-270I/TT U114 1 IC TXRX 3.3V CAN 8-SOIC Texas Instruments SN65HVD232D U113 1 IC CAN CONTROLLER W/SPI 18-SOIC Microchip Technology MCP2510-I/SO U115 1 IC REG SIMPLE SWITCHER T O-263-5 National Semiconductor LM2576HVS-5.
Circuit: Revision: Coupler Conditioning 1.04 Designations Qty C201, C203, C204, C205, C208, C209, C212, C213, C214, C215, C216, C217, C218, C219, C220, C221, C222, C223, C224, C225, C226, C227, C228, C229 24 C202 1 C206, C207 2 C210, C211 2 D201, D202 2 Capacitor, ceramic, 0.01uF, 50Vdc, +/-20% Capacitor, ceramic, 0.1uF, 50Vdc, +/-20% Capacitor, ceramic, 33pF, 50Vdc, 5% Capacitor, electrolytic, 100uF, 10V, +/-20% Diode, TVS, 5.0Vdc, 600W, unidirectional D203, D204 2 Diode, LED, red, 2.
U202 1 IC, microcontroller, 16-bit, 16k X 8 program, 48 I/O, flash 64-QFP Texas Instruments MSP430F135IPM U203 1 IC, CAN transceiver, 3.
R301 1 Resistor, thick film, 5%, 620ohm, 1W DNS SMD 2512 Panasonic ERJ-1TYJ621U SMD 0805 Yageo America 9C08052A1001JLHFT SMD 0805 Yageo America 9C08052A1300FKHFT R302, R303 2 R304, R312, R313, R318, R319, R322 6 R305, R307 2 Resistor, thick film, 5%, 1.0kohm, 1/8W Resistor, thick film, 1%, 130ohm, 1/8W R308, R309, R314, R315, R320 5 Resistor, thick film, 5%, 1.
J601, J603, J604, J605, J606, J607, J608, J609, J610, J611 10 Connector, modular, jack, 8position, vertical, PCB mount Tyco 5556416-1 J602 1 Connector, D-sub, 25 position, female, vertical, PCB mount Kycon K85-BD-25S-R VI-11
Insight System Schematics The following pages contain the schematics for the Insight system.
User Interface Module DC Supply Conditioning Vin J101A L101 ETQ-P6F1R3LFA F101 V1 Input V1 Cond + TAC 58V see table SMBJ30A TV SMBJ48A FM J101B D101 C101 100uF 63V R102 20 R101 2.7k TV 4.87k FM R103 20 D102 Green SML-LX1206GW L102 ETQ-P6F1R3LFA F102 V2 Input V2 Cond + TAC 58V see table SMBJ30A TV SMBJ48A FM J101C D103 C102 100uF 63V R105 20 R104 2.7k TV 4.
User Interface Module Current Monitoring L106 0.01uH +3.3 Vdc C107 0.01uF C106 0.01uF R117 0.012 V1 Cond J102A V1 Out 4 3 R118 0.012 + U101 INA168 I1 Buff 1 R119 100k 2 5 U106A OPA2340UA C109 0.1uF C108 0.1uF C110 0.1uF C111 0.1uF C112 0.1uF R120 0.012 V2 Cond J102B V2 Out 4 3 R121 0.012 + U102 INA168 I2 Buff 1 R122 100k 2 5 U106B OPA2340UA C114 0.1uF C113 0.1uF C115 0.1uF C116 0.1uF L107 0.01uH +3.3 Vdc C118 0.01uF C117 0.01uF R123 0.
User Interface Module Voltage/Current Monitoring L108 0.01uH +3.3 Vdc R129 0.012 R130 0.012 V5 Out + U105 INA168 I5 Buff 1 R131 100k 2 5 U108A OPA2340UA C131 0.1uF C130 0.1uF + C132 0.1uF C133 0.1uF C134 0.1uF R134 R132 V1 ADC Vin 37.4k - TV 68.1k - FM J102E 4 3 V5 Cond C128 0.01uF C129 0.01uF 249k R133 3.3k U108B OPA2340UA C135 0.1uF R135 249k I1 Buff I1 ADC C136 0.1uF R136 249k I2 Buff I2 ADC C137 0.1uF R137 249k I3 Buff I3 ADC C138 0.
User Interface Module Microcontroller U111 MCP130 L109 0.01uH +3.3 Vdc C141 0.01uF RESET Reset GND Vcc C142 0.01uF TCK TMS TDI TDO C143 0.1uF CAN CLK I1 ADC LED1 I2 ADC Buzzer I3 ADC BkLtCtrl I4 ADC I5 ADC Pin15LCD J104 V1 ADC P64 AVcc P63 DVss P62 AVss P61 A2 P60 A1 P59 A0 P58 RST P57 TCK P56 TMS P55 TDI P54 TDO P53 P52 P51 P50 P49 LED A C144 0.
User Interface Module J105D +5Vdc +5V-1 J106D CAN and Programmer Interface +5V-2 J105F +3.3Vdc +3.3V-1 J106F +3.3V-2 J105E GND-1 J106E GND-2 L110 0.01uH J106A RESET RESET-2 +3.3Vdc C148 0.01uF J105H C149 0.
User Interface Module Power Supplies U115 LM2576S-5.0 F107 +5 Vdc + Gnd Vin C150 100uF L111 100uH Littlefuse 1812L R154 tbd Vout + VgenCond On/Off Feedbk D114 30BQ060 U116 ULN2003 P1 P2 P3 P4 P5 P6 P7 P8 LED1 Buzzer BkLtCtrl R156 10k C151 1000uF D113 Green SML-LX1206GW P16 P15 P14 P13 P12 P11 P10 P9 D116 S1D-13 D115 +5V LED R155 1k RL101 G6L-1F 5Vdc BZ101 R157 4.7 Pin15LCD +5 Vdc U117 LM1117MP-3.3 IN C152 10uF 10V tantalum F108 +3.
Coupler Conditioning Module Microcontroller U201 MCP130 +3.3 Vdc RESET Reset GND Vcc TCK TMS TDI TDO C201 0.01uF C202 0.1uF L201 0.01uH C203 0.01uF L202 0.01uH FWD-POW C204 0.01uF C205 0.01uF P64 AVcc P63 DVss P62 AVss P61 A2 P60 A1 P59 A0 P58 RST P57 TCK P56 TMS P55 TDI P54 TDO P53 P52 P51 P50 P49 RFL-POW DVcc P1 A3 P2 A4 P3 A5 P4 A6 P5 A7 P6 P7 Xin P8 Xout P9 P10 P11 P1 0 P12 P1 1 P13 P14 P15 P16 DRVR DIS LED1 LED2 C206 33pF C207 33pF Y201 6.
Coupler Conditioning Module CAN and Programmer Interface +5Vdc C210 100uF J201c4 D201 +5V-1 J201d4 +5V-2 J201c6 +3.3Vdc +3.3V-1 C211 100uF J201d6 D202 +3.3V-2 J201c2 GND-1 J201d2 GND-2 L204 0.01uH J201c1 +3.3Vdc RESET C212 0.01uF RESET-1 C213 0.01uF J201c8 CANH-1 J201d8 CANH-2 U203 SN65HV232 D P1 GND P2 Vcc P3 R P4 J201c7 CANL-1 J201d7 P8 P7 CANH P6 CANL P5 U204 CANL-2 CANterm1 R201 100 CANterm2 CAN CLK MCP2510 RESET SCK SIMO SOMI CAN CS TDO J202 JTAG header TDI +3.
Coupler Conditioning Module +3.
Coupler Conditioning Module RF Power Output C216 0.01uF L206 0.01uH C217 0.01uF +5 Vdc U211A OPA2340UA + R214 1k SIMO FWD-OUT DAC CS P1 P2 P3 P4 1 3 U212 TLV5625 P8 P7 P6 P5 D206A + RFL-OUT U211B OPA2340UA U213 LM4040-2.5 R215 10k 1 2 SCK D206B R216 10k Coupler Input L207 L208 0.01uH 0.01uH +5Vdc +3.3 Vdc C218 0.01uF C219 0.01uF C220 0.01uF C221 0.01uF R217 1k J206A FWD-GND J206B FWD-5V J206C FWD-IN + L209 U214A OPA2340UA 0.01uH C222 0.01uF C223 0.01uF L210 0.
J301 F301 U301 R301 PSU In IN L301 +5 Vdc OUT 1 COM R302 R304 D301 Ground C301 R303 J301 C302 C303 2 D302 CTL 1dB U302 Alpha 110-85 RF 2 P1 P2 P3 P4 P5 P6 P7 P8 P9 P10 CTL 2dB P20 P19 P18 P17 P16 P15 P14 P13 P12 P11 CTL 4dB CTL 8dB CTL 16dB C304 C305 J303 +5 Vdc RF OUT C306 Ext 5Vdc J304 4 +5 Vdc S301 1 2dB in 1dB in S301 2 J304 2 U303 P1 P2 P3 P4 J304 1 P8 P7 P6 P5 R308 R309 S301 3 8dB in 4dB in S301 4 CTL 2dB CTL 1dB R310 R311 R312 R313 D303 D304 U304 J304 5
U306 DBTC-20-4 RF 1 RF 2 V V DIR. COUPLER R324 U307 AD8362 P1 P2 P3 P4 P5 P6 P7 P8 C307 R323 C310 P16 P15 P14 P13 P12 P11 P10 P9 C308 DIP16 Shutdown C320 RF IN R305 VR303 VR301 C309 U308 SAGE WIRE -HCT2 J302 +5 Vdc C311 C312 RF 1 R307 HYBRID COUPLE C314 C313 R325 R326 D309 D310 R327 U309 78L20 PSU In IN C316 C315 R329 R328 OUT VR302 COM C317 C318 C319 A. Sivacoe, N. Hendrickson RF Conditioning Module Rev ID 1.04 Insight Control System Date: Sept.
Temperature Sensor DRV DIS TMP SO TMP SCK TMP GND TMP VCC TMP CS J1G U1 LM70 J1C P1 P2 P3 P4 J1D J1A J1B J1H P8 P7 P6 P5 C1 1uF J2 TMP VCC 1 N. Hendrickson, A. Sivacoe Temperature Sensor Board Rev ID 1.
PSUflag J601 1 RFL samp 2 TEMPflag 3 FWD samp 4 VSWRflag 5 ODRVflag 7 ground 8 CAR on J603 F602 J602 13 12 11 10 9 8 7 6 5 4 3 2 1 1 CAR off 2 CAR up 3 +5 Vdc 4 CAR down 5 +3.
Section VII – Mechanical Section The heat sink allows the amplifiers to operate at a cooler temperature and prevents overheating, which helps the longevity of the entire system. The heat sink has hollow fins, which help dissipate the heat from the amplifiers faster than a conventional serrated or corrugated fin. In addition to the cooling effects of the heat sink, there is a fan that provides 110 cubic feet per minute (CFM) of air flow (into zero static pressure).
Section VIII - Installation This section contains installation recommendations, unpacking, inspection, and installation instructions for the power amplifier. We are sure that you are chomping at the bit to install your new system, so we recommend that you read the following sections very carefully. Building Recommendations The quality of the building is of great importance if you are to expect long life and continued performance from the power amplifier.
Heating and Cooling Requirements The environment’s temperature will contribute greatly to the length of the power amplifier’s life. Technalogix recommends that the building’s filtered air intake must have capacity for all air-flow in the building plus an additional 20%. Keep the intake below the roofline to avoid intake of solar heated air. Please ensure that the intake and exhaust areas are on the same side of the building to avoid pressure differentials during windy conditions.
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.
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.
Shelter Security The FCC requires that the transmitter or translator be secure from entry or control by unauthorized persons, and that any hazardous voltages or other dangers (including most tower bases) be protected by locks or fences as necessary to protect personnel and prevent unauthorized tampering or operation. Security of the building further implies that it be secure from wildlife. Use sturdy construction materials, including sheet metal if necessary.
Unpacking and Inspection Check the outside of the container. Carefully open the container and remove the power amplifier. Retain all packing material that can be reassembled in the event that the equipment must be returned to the factory. Exercise care in handling equipment during inspection to prevent damage due to rough or careless handling. Visually inspect the enclosure of the power amplifier for damage that may have occurred during shipment.
Location and Function of Controls and Connectors (TAV-25 Power Amplifier) The following illustration depicts the location of the connectors when installing the 25-watt power amplifier (TAV-25). Technalogix Ltd.
POWER - Tactile button to turn carriers on and off. NAVIGATE - Tactile button to move between menu items, or to refresh the screen after it has timed out. SELECT- Tactile button to select menu item, or to refresh the screen after it has timed out. RESET - Tactile button to reset microcontroller in control board. Also clears existing faults. The amplifier will come back on with the soft start feature. RF IN – RF input from modulator or processor. BNC connector, 50 ohm. RF OUT – 100-watt RF output.
Initial Hook Up 1. Ensure that the antenna has been swept and has a return loss of greater than 20dB (VSWR = 1.2:1). This should be done before connecting the antenna cable to the transmitter output. 2. Check that your video source is present. 3. Place the transmitter/translator in its permanent location near a receptacle supplying required AC voltage. DO NOT APPLY AC POWER AND TURN ON POWER TO THE TRANSMITTER / TRANSLATOR AT THIS TIME SINCE THE RF OUTPUT MUST BE PROPERLY LOADED BEFORE OPERATION. 4.
Section IX - Operating Procedure Assuming the previous installation instructions have been completed and cautions noted, and the TAV25 power amplifier is ready to receive a properly modulated video and audio signal, proceed with the following steps to place the system in operation. The TAV-25 power amplifier has been factory aligned for channel frequency (per system specification), signal levels and optimum performance.
10. The TAV-25 LCD shows the user the present status of the amplifiers. Adjust RF output power to desired level (see Important RF Power Notice in previous section). Verify that the FWD Power reads 80% to 100% on the filter enclosure - depending on signal content. The system is set up for 25 watts peak visual power using the sync and blanking signal and should read 100 % FWD Power on the LCD under this condition only.
Section X – Maintenance and Troubleshooting Periodic Maintenance If your unit employs a filter on the air inlet for the fans, the filter should be cleaned every 30 days. If the equipment is operated in a severe dust environment, the filters on the inlet fan may need to be cleaned more regularly. Turn the system off and unplug all of the AC inlet cords. The filter can be lifted off the fan and cleaned using an air compressor at low pressure.
Troubleshooting The first and most important aspect of troubleshooting anything is to be systematic. Note where you have looked and what you found. Look first for the obvious. • Make a physical inspection of the entire facility.
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