PJ5000U-KLC - RVR Elettronica SpA Documentation Server
Contents
1. CPU4 LAII I ee D D hh 3AP b mpm DISPLAY KEYS TELEMETRY RS232 Loe INTERLOCK WI ETTIN INI 50V A C IN NS L NI Figure 4 2 theory of operation 5 1 6 32 Quick installation and operating reference The scope of this chapter is to summarize the procedures for installing the machine If any point is not fully comprehensible such as how to operate the machine the first time it is advisable to read the entire manual very carefully In this description it is assumed that the amplifier is not supplied pre installed in a rack inside a transmission system In this case most of the operations outlined herein for instance the wiring ones are obviously not necessary Preparation Unpack the amplifier and firstly check that it has not been damaged in any way during transport Make sure that all the connectors and controls on the front and back panels are in good order Check the default setting of the type of power supply for this machine on the back of the equipment which may be single phase 208 V 15 10 single phase 230 V 10 15 three phase 208 V 15 10 three phase 230 V 10 15 three phase with N 400 V 10 15 Suggestion Specify the type of power supply at order placement the machine will be delivered to you configured according to your require2. Cover affected area with a clean cloth or linen Do not break any blisters that have formed remove any clothing or fabric that is stuck to the skin apply adequate ointment e Administer adequate treatment for the type of accident Get the victim to a hospital as quickly as possible Elevate arms and legs if injured If medical help is not available within an hour the victim is conscious and is not retching administer a solution of table salt and baking soda one teaspoon of table salt to half teaspoon of baking soda every 250 ml of water Have the victim slowly drink half a glass of solution for four times during a period of 15 minutes Stop at the first sign of retching Do not administer alcoholic beverages 3 2 2 Minor burns e Apply cold not ice cold strips of gauze or dress wound with clean cloth Do not break any blisters that have formed remove any clothing or fabric that is stuck to the skin apply adequate ointment If needed have the victim change into clean dry clothing e Administer adequate treatment for the type of accident Get the victim to a hospital as quickly as possible e Elevate arms and legs if injured User Manual ELETTRONICA 4 1 PJ5000U KLC General Description The package contains B 1 PJ5000U KLC alias BARRACUDA B 1 User Manual B 1 Mains power cable The following accessories are also available from Your R V R Dealer A
3. PJ5000U KLC alias BARRACUDA USER MANUAL VOLUME D 9 ON WAIT FAULT L Fi BACK o 4 4 Q A P amp e Uua rur 3 98 Im a 55 we T Eime dA o H 4 LAE Eie c A o MUI AS BROADCAST EQUIPMENT Manufactured by R V R ELETTRONICA S p A Italy File Name BARRACUDA PJ5000U KLC ING 1 0 indd Version 1 0 Date 26 03 2010 Revision History 26 03 2010 J H Beri PJ5000U KLC User Manual Version 1 0 Copyright 2010 R V R Elettronica SpA Via del Fonditore 2 2c 40138 Bologna Italia Telephone 39 051 6010506 Fax 39 051 6011104 Email info rvr it Web www rvr it All rights reserved Printed and bound in Italy No part of this manual may be reproduced memorized or transmitted in any form or by any means electronic or mechanic including photocopying recording or by any informa tion storage and retrieval system without written permission of the copyright owner PJ5000U KLC Table of Contents 1 Preliminary Instructions 1 2 Warranty 1 3 First Aid 2 3 1 Treatment of electrical shocks 2 3 2 Treatment of electrical Burns 2 4 General Description 3 4 1 Make up 3 5 Quick installation and operating reference 6 5 1 Preparation 6 5 2 Operation 8 5 3 Software 9 5 4 Protection System 15 6 External Description 17 6 1 Frontal Panel 17 6 2 Rear Panel 19 6 3 Connector Description 20 7 Technical Specifications 22 8 Operating Theory 23 8 1 Power Supply Change 29 0 2 Card
4. This card 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 DB9Y signals associated with the RS232 connector for interfacing with other equipment and for the default programming functions and the DB9 connector for communications in IC standard RF Power Amplifier The RF power amplifying section consists in 8 power modules coupled by a Wilkinson splitter and combiner and implemented in strip line technology The RF modules the splitter and the combiner are housed inside the top part of the equipment The whole RF section is mounted on the fin that cools the equipment by means of forced ventilation Each RF module supplies 800 watts with 6 to 9 pilot power watts and is powered by the switching PSU The modules operating parameters in standby are as follows VDC 50 5V Vgs about2 6 2 V Idq 200mA 100mA for each MOSFET The active device used in the amplifier modules is a Mosfet 2x SD2942 Rev 1 0 26 03 10 User Manual ELETTRONICA 8 2 8 8 2 9 8 2 10 8 2 11 PJ5000U KLC Wilkinson Splitter and Combiner Both the splitter and the combiner are made in strip line technology The splitter is used for splitting power arriving from the exciter and supplying one part to each of the RF modules The combiner is then used to combine power output from
5. 3 1 2 Three Phase Wiring ELETTRONICA IThreephase Configuration Ground 6mm 3 Phase S Q6mm Phase R Q6mm 3 2 G Phase T 66mm Gp Neutral 6mm For the three phase the configuration of the external power supply plug must have the following characteristics 26 32 PIN1 of the main connector is connected to Neutral wire PIN2 of the main connector is connected to Phase R Wire PIN3 of the main connector is connected to Phase S Wire PIN4 of the main connector is connected to Phase T Wire PIN5 is directly wired to ground Rev 1 0 26 03 10 User Manual ELETTRONICA 8 2 8 2 1 8 2 2 8 2 3 8 2 4 PJ5000U KLC Card Description Surge Protection This card s main function is to avoid any damage to the internal cards by blocking the contact before current reaches the equipment in case overvoltages occur Power Supply The three power supply modules are located in the middle part of the amplifier The power supply units are mounted on a cooling fin to cool the amplifier by forced ventilation The amplifier houses a transformer the input voltage of which may be selected between 115 and 230 Volts The transformer is fitted with three secondary wires A 18 0 18 V B 0 17 V 0 11 5 V that supply power to the cards inside the equipment PFC Unit The PFC unit is a rectifier that modulates the current absorbed so that
6. Description 2 9 Low Drive Power Option LD 23 9 1 Low Drive power Board 31 User Manual Rev 1 0 26 03 10 I This page was intentionally left blank ii Rev 1 0 26 03 10 User Manual ELETTRONICA PJ5000U KLC IMPORTANT The symbol of lightning inside a triangle placed on the product evidences the operations for which is necessary gave it full attention to avoid risk of electric shocks The symbol of exclamation mark inside a triangle placed on the product informs the user about the presence of instructions inside the manual that accompanies the equipment im portant for the efficacy and the maintenance repairs J 1 Preliminary Instructions e General Warnings This equipment should only be operated installed and maintained by trained or qualified personnel who are familiar with risks involved in working on electric and electronic circuits Trained means personnel who have technical knowledge of equipment operation and who are responsible for their own safety and that of other unqualified personnel placed under their Supervision when working on the equipment Qualified means personnel who are trained in and experienced with equipment operation and who are responsible for their own safety and that of other unqualified personnel placed under their supervision when working on the equipment di vacuno Residual voltage may be present inside the equipment even when
7. each module to obtain the amplifier s total power The two cards ensure equal phases among the powers generated by the RF modules One power resistance is used for dissipating the offset power that might be present in case a module breaks down The Splitter card is also fitted with the temperature sensor which is monitored by the software Bias Board The task of this card is to check and correct the bias voltage of the Mosfets in the RF amplification section This card also supplies the following measurements current and voltage of each module total current and average voltage Directional Coupler The task of these two cards that seem identical is to supply the power measurement They are installed on the input RF connector on the inside of the machine One card supplies the amplifier s forward power whereas the other one supplies the reflected power Control Board The control board acts as an auxiliary card for the PROTF card in the PS section should the latter fail to trip due to a malfunction It implements all the functions associated with measurements protection control and communications and is even capable of detecting the individual voltages or currents inside the machine in addition to the overall ones If pre arranged this Board can carry the signals to the DB9 connector located on the machine s back panel in RS485 standard User Manual Rev 1 0 26 03 10 29132 3 2 12 LEDs Board This card is fitted w
8. few cases This occurs when for physical reasons the measured vales are not significant for control software internal use When the value of a parameter is not available for the aforesaid reason symbol zz appears on the display in lieu of the value 5 3 1 Operating Menu Fnc Uri IFF Turn the power amplifier ON or OFF via this menu When the amplifier is turned OFF the internal conductor of the INTERLOCK connector is set to ground so as to force the connected exciter to a stand by condition this takes place only if the exciter features the interlock option like those produced by RVR and if the associated connector is connected to the amplifier When the amplifier is turned OFF the software program waits 5 minutes for the machine to cool down and then the fans and pumps turn OFF 10 32 Rev 1 0 26 03 10 User Manual ELETTRONICA 5 3 2 Du PJ5000U KLC Power Menu Pwr This screen made up of several lines that may be scrolled through using the UP and DOWN keys displays all the measurements associated with the behaviour of the amplifier s power section e Forward Power Fwd Pwr e Reflected Power Rfl Pwr e Input Power Inp Pwr e SWR Standing Wave Ratio Depending on the machine s configuration a few measurements might be disabled The figure below shows the complete aspect of this screen only two lines can be seen at a time use the UP and DOWN keys to scroll through it Fwd Pur 4 94
9. kl Efl Fur 1 4 WM Ine Pur 71 7 W Silk Lit f Power Amplifier Menu P A This screen consisting of several lines that may be scrolled through by using the UP and DOWN keys displays all the measurements associated with the RF amplifier of the equipment e Voltage VPA e Current IPA e Temperature e Power Supply Voltage Mains percentage variation as compared to the nominal voltage e Efficiency The figure below shows the complete aspect of this screenful only two lines can be seen at a time use the UP and DOWN keys to scroll through it User Manual Rev 1 0 26 03 10 11 32 Wa B ELETTRONICA 9 3 4 Warning threshold setting menu As mentioned in the introduction the amplifier offers three settable warning thresholds Each one is compared with the level of one of the machine s operating parameters The results of the comparison are available on the telemetry connector on the contacts of the optional external telemetry card and may be read on the display as O open i e false result or C closed i e real result The three settable thresholds Power Good refer to the emitted power level The limit voltages of the quantities monitored by the warning thresholds for are the follows e Forward Power 5000 W e Forward Power 300 W Proceed as follows to change the values of the warning thresholds e Select the line to be changed with the UP and DOWN keys Press the ENTER key Cha
10. level check of coolant Flux pression check of coolant Rev 1 0 26 Technical Specification Rated output power 5000W Frequency range Input power for rated output Input power for rated output LD version 230 400 VAC 15 3 phase neutral Primary Power 50 60Hz or 230 VAC 10 1 phase 50 60Hz ILME CFX4 2 connector AC Power Consumption Overall efficiency Phisical Dimensions W x H x D Weight 10 50 C 95 relative Humidity non condensing Cooling Liquid cooling with external unit RF Input N 50 ohm RF Output 7 8 EIA flange type 50 ohm RF Monitor BNC 60dBr referred to RF output Interlock Output BNC EN 60215 1989 Safety EN60215 A1 1992 07 EN60215 A2 1994 09 EN 301 489 11 V1 2 1 2002 11 LD PJM C Environmental Working Conditions 22 32 Rev 1 0 26 03 10 User Manual ELETTRONICA PJ5000U KLC 8 Operating theory The figure shows the top and the bottom view of amplifier The various cards are described in this chapter op View 1 ProtF Board PROTPJ HCLCD amp CPU Board SL1541N2001 2 Power Supply PSL5060 3 Low Drive Power Board SL154DR2001 4 PFC PFCPSL5060 5 Surge Protection Board SL0O46SR1002 6 PS RF Interface Board SLINPSP2K07 User Manual Rev 1 0 26 03 10 Bottom View i oie ilis inal 1 FWD amp RFL Power Meter Board SL042MT1501 2 Splitter Board SLSPLL5PJ2K 3 Amplifie
11. obviously without the contribution of the module even if it is advisable to single out and clear the cause for the malfunction and replace the fuse as soon as possible to fully restore the machine s working efficiency Note the RESET button allows you to reset all the auxiliary protection Power Supply Units Three power supply units which work in parallel mode power the machine Should one of the power supply units malfunction the machine automatically compensates the delivered power down to a value compatible with the current deliverable from the surviving power supply This situation is indicated by the P S ALARMS LEDs on the front panel of the PS module Rev 1 0 26 03 10 User Manual LAD PJ5000U KLC 6 External Description This chapter describes the elements presents on the panels of the PJ5000U KLC 6 1 Frontal Panel 234 5 6 7 8 9 10111213 14 18 1920 21222324 25 1 RF TEST BNC connector for RF monitor output The output level is 60dB referred to the power output in 87 5 108 MHz range 2 ALARM RESET Button used to manually reset the protection system 3 LOC REM Switch to select the local or remote control modes 4 ESC Button used to exit from a menu 5 DISPLAY LCD display 6 ON Green LED indicating the amplifier is switched on 7 WAIT Yellow LED indicating the amplifier is waiting for a condition that is blocking the power output to be removed 8 FAULT Red LED indicating that a faul
12. ona Industriale Roveri 40138 Bologna Italy wl E Zh wl ed Phone 39 051 6010506 Fax 39 051 6011104 ELETTRONICA 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 9 1998 all rights reserved All other trademarks trade names or logos used are property of their respective owners
13. the ON OFF switch is set to Off Before servicing the equipment disconnect the power cord or switch off the main power panel and make sure the safety earth connection is connected Some service situations may require inspecting the equipment with live circuits Only trained and qualified personnel may work on the equipment live and shall be assisted by a trained person who shall keep ready to disconnect power supply at need R V R Elettronica S p A shall not be liable for injury to persons or damage to property resulting from improper use or operation by trained untrained and qualified unqualified persons A WARNING The equipment is not water resistant Any water entering the enclosure might impair proper operation To prevent the risk of electrical shock or fire do not expose this equipment to rain dripping or moisture Please observe local codes and fire prevention rules when installing and operating this equipment A WARNING This equipment contains exposed live parts involving an electrical shock hazard Always disconnect power supply before removing any covers or other parts of the equipment Ventilation slits and holes are provided to ensure reliable operation and prevent overheating do not obstruct or cover these slits Do not obstruct the ventilation slits under any circumstances The product must not be incorporated in a rack unless adequate ventilation is provided or the manufacturer s instructions are followed closel
14. 0 13 32 The network address I C is very important when the amplifier is connected in an RVR transmission system that envisages the use of this protocol Do not change it for any reason whatsoever The main menu may be displayed either in Digital mode this is the standard mode or Analog mode kfl Fur 1 43 In the analog display mode a small triangle indicates the reflected power level set in the Alarm Threshold Setting Menu RflWar whereas the bar at the bottom shows the instant reflected power level This type of display might be useful when a device to be tuned is connected to the amplifier s output such as a cavity The pump is exchanged automatically every time you switch off and subsequently re switch on the equipment In case you never switch off the equipment the pump is exchanged automatically every 10 days of normal operation The operation of pumps exchange is necessary for the regular functioning of the same In case of a fault on pump pressure and then an interruption of the cooling flow after 10 seconds is recorded by the machine which starts the operations of exchange pumps Note the delay of 10 seconds is necessary to prevent the record of false positives as a momentary pressure drop due to air bubbles in the cooling system The machine will continue to exchange the pumps every two minutes until the situation that caused the alarm is resolved After six minutes the equipment goes in a WAIT con
15. ately turn the amplifier ON and reset the alarm counters e Ifthe system is transmitting but alarms were triggered earlier causing certain counters not to be at 0 pressing the key will have no effect unless it is pressed while inside the alarm menu As such the system will be sure that the user takes note of the alarms that were triggered before resetting them The system resets the alarm counters automatically after thirty minutes of operation i e the user need not do anything if the amplifier does not trigger any alarms or after the machine the machine has been turned OFF and then back ON RF Module Auxiliary Protection The amplifier s RF module contains a second microcontroller that manages local measurements and carries out auxiliary protection functions of the machine together with the main protection system This microcontroller card indicates its interventions via the LEDs of the RF module 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 LED FUSE BLOWN indicates that one of the fuses that protects the power supply of the MOSFET modules has blown In this case the machine keeps running as usual
16. ating frequency transmitter power and other characteristics of the transmission system are subject to restrictions as specified in the licence 2 Warranty La R V R Elettronica S p A warrants this product to be free from defects in workmanship and its proper operation subject to the limitations set forth in the supplied Terms and Conditions Please read the Terms and Conditions carefully as purchase of the product or acceptance of the order acknowledgement imply acceptance of the Terms and Conditions Forthe latest updated terms and conditions please visit our web site at WWW RVR IT The web site may be modified removed or updated for any reason whatsoever without prior notice The warranty will become null and void in the event the product enclosure is opened the product is physically damaged is repaired by unauthorised persons or is used for purposes other than its intended use as well as in the event of improper use unauthorised changes or neglect In the event a defect is found follow this procedure 1 Contact the seller or distributor who sold the equipment provide a description of the problem or malfunction for the event a quick fix is available Sellers and Distributors can provide the necessary information to troubleshoot the most frequently encountered problems Normally Sellers and Distributors can offer a faster repair service than the Manufacturer would Please note that Sellers can pinpoint problems due to wrong in
17. ccessories spare parts and cables The PJ5000U KLC is an RF amplifier for frequency modulation sound broadcasting with a max rated output of 5000W cooled via a non toxic and non corrosive liquid that can withstand temperatures under 30 C The amplifier is running with a standard load of 50Ohm and operate with less of 7OW of piloting power The cooling system features a double pump with switching and automatics diagnostics Pump reversal is programmable to avoid malfunctions due to long intervals of pump inactivity It is a fully solid state apparatus of modern design that use MOSFET as active components in the FM amplifying modules This chapter briefly describes the machine s main features Make Up The PJ5000U KLC amplifier is designed in only 4 units for assembly in a 19 rack The pumps used for the cooling system are B CT 61 for powers up to 5kW and the liquid cooling is TEMPER30 The PJ5000U KLC houses eight identical modules based on the MOSFET SD2942 2x each supplies 800 watts The amplifier is controlled by a microprocessor based system that includes a LCD which carries out the following functions e Setting of the output power e Activating and deactivating power delivery e Detecting the warning thresholds set by the user e g power delivered below a specific threshold which are made available to the user via the telemetry connector e Pumps and fan of splitter control e Reporting the false starts of pumps so
18. dition and will be reported through the red LED on the front in the meanwhile the machine will continue to exchange pumps every 2 minutes in order to resolve the alarm condition Note Please resolve as soon as possible the condition that brought the equipment to the alarm this to restore the correct operation Check the LEDs indicators on the front panel or check the ALARM menu to see which alarm condition has brought to the halt of the machine In the event that only one of two pumps work correctly and then exchange pumps can not be done will be reported into display PUMP FAILED after 3 minutes of the failed attempt 14 32 Rev 1 0 26 03 10 User Manual ELETTRONICA PJ5000U KLC Note Please resolve as soon as possible replacing the faulty pump 5 3 Version Menu This screenful shows the software version and the hardware version of the equipment oftware ler L CFFH iig 1 Hz Hd 5 11 H39 Hardware aer H3 1t 5 4 Protection System The protection system implemented inside the amplifier is based on two types of intervention The first reaction is called Foldback and consists in decreasing the voltage in the power amplifier 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 trip
19. emetry Connector Type DB25 Female oO Internal SWR Tensione dell amplificatore di potenza RF GND Reflected Power Interlock Check Pumps GND On Command Set 1 10 WAIT 11 Reset alarm 12 OFF 13 Interlock 14 Temperature 15 RF power amplifier current 16 Forward Power 17 FAULT 18 Set 3 19 Input power 20 OFF Command OOnN OAR WDNDM gt o 21 GND 22 Set2 23 LOC 24 Vcc 25 ON 6 3 2 RS 232 Type DB9 female NC TX D RX D Internally connected with 6 GND Internally connected with 4 Internally connected with 8 Internally connected with 7 NC O oo 4o0o0id cohnH5 20 32 Rev 1 0 26 03 10 Wa P ELETTRONICA Disable 3 9V x 50V GND 4 3V x 300W GND 3 9V x 100 C 3 9V x 200A 4 3V x F S 3 9V x 150W GND User Manual RaWa Ra ELETTRONICA PJ5000U KLC 6 3 3 IC Connector Type DB9 Female OCOnNDOFRWDNDN 6 3 4 Com Bus NC SDA Type DB15 male o 3 m o 3 X 4 A 5 6 _ O 8 9 10 11 12 13 14 15 6 3 5 Check Pumps Type DB15 male Oo 3 f E 3 2 4 ae 5 po 6 Ce 7 8 9 10 11 12 13 14 User Manual NC ON GND NC ON GND NC NC GND GND FAN H2OWARN H2OMIN FLUX NC Serial Data Serial Clock GND Pump 1 ON OFF Command Pump 2 ON OFF Command Radiator fan check Low level check of coolant Empty
20. er interface diagram Switch On PJS688U ELC Fwd Pur 4 94 KM SM 2 61 HW 1 81 Efl Fur 31 4 WM ESC Fie Pur P H Set Alm Mix Ure Selection Menu ENTER On gt off Operation Menu Fud Pur 4 94 El kfl Pur 1 4 W Power Menu UPH 49 86 Uu IFA Io Ae PA Menu PurGdl gt 560 PurGd gt 58 Oe Set Up Menu Fwd Pur mH c22 Efl Fur H 223 Alarm Menu IZC Addr 1 DisPlay Did Miscellaneous Menu H U 1 8 S l 2 81 Version Menu Figure Flow diagram of the software NB Note the user may issue commands to the equipment only when in LOCAL mode by means of the selector Otherwise the user may only read the parameters and not change them When turned on the LCD shows the introductory screenful with the equipment s software and hardware versions PJ SHRBU KLE 2 2 591 Hi 1 H1 User Manual Rev 1 0 26 03 10 9 32 RW ELETTRONICA A few seconds later the main screenful is displayed indicating the forward and reflected power values Fwd Pur d 94 El ktl Fur 31 4 W Ine Fur 71 7 ll hF Lit Press the ESC key to view the selection screenful from which to access all the menus Fre Fur P H Set Alm Mix Ure To access one of the submenus select its name which is underlined by a blinking cursor using the RIGHT or LEFT keys and then press the ENTER key Take note that certain parameters which are measured and shown to the user might not be available in a
21. he exciter Connect the RF output to the antenna cable or to a dummy load capable of dissipating the power generated by the amplifier An ILME model CXF4 2 multipole socket is supplied with the amplifier to power the machine The socket must be connected to the multipole cable that will be wired to the mains switchboard Danger to avoid any risk of shock make ABSOLUTELY sure that the power supply cable is NOT powered when the multipole socket is connected to the cable itself Connect the multipole socket to the power supply cable as described below and refer to figure 5 2 Three phase power supply e G Ground e 1 Neutral e 2 R Phase e 3 S Phase e 4 T Phase e 11 12 Not connected Figure 5 2 View of the mains multipole socket terminals side internal Rev 1 0 26 03 10 Wa Ra ELETTRONICA Single phase power supply e G Ground 1 Not connected 2 Phase e 3 Neutral 4 Not connected 1 1 12 Not connected Danger avoid the risk of damaging the machine by grounding it correctly As A such connect the ground conductor of the power supply cable to the specific terminal in the multipole socket and check the efficiency of your own grounding system 5 2 Operation After having plugged in the power supply socket at the back of the machine power on the amplifier via the switchboard The ON LEDs on both modules will turn on and the forced cooling fans will start running The LCD shows the first introduc
22. ith 12 warning LEDs that indicate the machine s general operating status It also has a trimmer for adjusting power AGC control Use a small screwdriver to change the delivered power 30 32 Rev 1 0 26 03 10 User Manual Wa Ra ELETTRONICA 9 Low Drive Power Option LD PJ5000U KLC The figure shown the top view of RF section of the equipment with LD option The board comes described in the continuation of this chapter Figure 9 1 Low Drive power Board 9 1 Low Drive power Board The Low 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 30W suitable to pilot the amplifier with a total gain of approximately 15dB The active device utilized in the amplifier modules is a Mosfet BLF 177 and uses for the feeding the same voltage of 50V used from the RF amplifiers modules On the output stage of this board is present a directional coupler that measure the reflected and forward power the latest comes acquired from the control software that represents it legible like input power The board is mounted on the fin that supplies to its cooling through forced ventilation User Manual Rev 1 0 26 03 10 31 32 This page was intentionally left blank 32 32 Rev 1 0 26 03 10 User Manual ISO 9001 2000 certified since 2000 V R Elettronica S p A ni D ia del Fonditore 2 2c j l
23. ments Check if need be that the fuses are installed in good working order and accessible on the back panel of the PS module The required fuse values are as follows 208 230V 208 230V 400V single phase three phase three phase AUX OUT FUSE 1x F6 3T type 1x F6 3T type 1x F6 3T type chap 6 2 position 9 20 5x20 5x20 f 5x SERVICE FUSE 1x F6 3T type 1x F6 3T type 1x F6 3T type chap 6 2 position 10 5x20 5x20 5x20 MAINS FUSE 3x F32T type 3x F25T type 3x F16T type chap 6 2 position 1 10x38 10x38 10x38 Install the amplifier in a standard rack for 19 modules Assemble the amplifier with the pumps through two tubes Connect the output of a suitable type of FM exciter e g the PTX100LCD of R V R Elettronica to the RF input RF module using a cable fitted with N type connectors 50 Ohm The exciter should be set to minimum output power and OFF Rev 1 0 26 03 10 User Manual Wa Ra ELETTRONICA User Manual PJ5000U KLC Connect the amplifiers INTERLOCK connector on the back of the PS module to the exciter s Interlock input if available it is available in all RVR Elettronica exciters using a twin wire with BNC connectors Note the amplifier s INTERLOCK connector is an output The operating logic is as follows the internal conductor floats when the amplifier works correctly on the contrary power is delivered and the internal conductor is closed to ground to halt t
24. nge the threshold value UP and DOWN keys Press ENTER to confirm The figure below shows a configuration example of this menu et mt Furldi Purlds 3 Purlds 3 In this example the alarm thresholds are as follows e PwrGd1 4000 W 80 x 5000 W e PwrGd2 2500 W 50 x 5000 W e HflWar 150 W 50 x 300 W 12 32 Rev 1 0 26 03 10 User Manual ELETTRONICA 5 3 5 Alarm Menu PJ5000U KLC This menu provides information about the status of the amplifier s built in protection system It consists of a certain number of lines each of which contains the name of the variable controlled by the protection system and the type of intervention carried out by the system oaid intervention may be as follows X Y Wait or Dis Disabled The aspect of this menu is as follows only two lines can be seen at a time use the UP and DOWN keys to scroll through it Fwd Fur Efl Fur Inr Pur LH P H I F H Mains SWF Eft Inhibit H 32 H a H 32 bis M t eo Wait Dis Dis Lit f E F Hlarm UfT H20 Press Uff The task of this menu is essentially to help the technician in identifying the possible causes of any malfunction 5 3 6 Miscellaneous Menu In this menu the user may e set the address in the serial bus connection type I C e set the main menu display mode exchange the operation pump Item IIC Addr DisrPl sy Fume User Manual Rev 1 0 26 03 1
25. ntenance must be familiar with first aid procedures and routines 3 1 Electric shock treatment 3 1 1 If the victim is unconscious Follow the first aid procedures outlined below e Lay the victim down on his her back on a firm surface the neck and tilt the head backwards to free the airway system Figure 1 Figure 1 e If needed open the victim s mouth and check for breathing If there is no breathing start artificial respiration without delay Figure 2 as follows tiltthe head backwards pinch the nostrils seal your mouth around the victim s mouth and give four fast rescue breaths Figure 2 e Check for heartbeat Figure 3 if there is no heartbeat begin chest compressions immediately Figure 4 placing your hands in the centre of the victim s chest Figure 5 Figure 3 Figure 4 Figure 5 e One rescuer give 2 quick rescue breaths after each 15 compressions Rev 1 0 26 03 10 Wa Ra ELETTRONICA e Two rescuers one rescue breath after each 5 compressions Do not stop chest compressions while giving artificial breathing Call for medical help as soon as possible 3 1 2 If the victim is conscious e Cover victim with a blanket e Try to reassure the victim Loosen the victim s clothing and have him her lie down e Call for medical help as soon as possible 3 2 Treatment of electric burns 3 2 1 Large burns and broken skin
26. ping of the foldback circuit The second type of reaction consists in turning OFF the equipment s amplifying section when a specific variable exceeds a set value Depending on the type of event occurred and after the amplifier has been turned OFF it will be reactivated after a set length of time or only after the sharing which caused the locking has been cleared In the alarm menu the first type of configuration is indicated by X Y whereas the second one is indicated by Wait The third possibility is that the system does not trigger the protection conforming to a specific parameter this is indicated by Dis Disabled While the amplifier is OFF temporarily owing to an alarm the yellow WAIT LED lights up and the reason the protection was triggered is shown on the display When the protection system trips due to a cyclic type parameter a counter begins counting up the X value in the alarm menu If the counter reaches the max admissible cycle value Y the amplifier turns OFF definitely and the red FAULT LED lights up on the front panel The user may press the ALARMS RESET key to interact with the protection system The effect differs depending on the machine s status when the key is pressed e f the equipment is off waiting for the cycle time to be reached or if it is User Manual Rev 1 0 26 03 10 15 32 9 4 1 9 4 2 16 32 definitively off in FAULT state press the ALARMS RESET button to immedi
27. r Modules SL154RF2001 4 Fuses Board SLFUSRFPJAK1 5 LEDs Board SL154LD1001 6 Bias Board SLMTPRTPJAK1 amp CPU Board CPUPJ2KMC 24 32 Rev 1 0 26 03 10 User Manual ELETTRONICA 8 1 Power Supply Change PJ5000U KLC To use the amplifier with different types of power supply you should connect the mains power supply socket as outlined in chapter 5 Also modify the connections inside the varistors board box as explained below In order to access the varistors board box remove the screws from the side and back of the PS module which keep it in place and take out the box 8 1 1 Single Phase Wiring Monophase Configuration Ground 6mm Neutral 6mm To Unk through cables Phase 6mm Of GOO6mm D WARNING the power supply in single phase can be used only with 208 230V voltage For the single phase the configuration of the external power supply plug must have the following characteristics e PIN1 of the main connector is connected to Neutral wire e PIN2ofthe main connector is connected to Phase wire and internally connected to PIN3 by 6mm wire e PIN3 of the main connector is internally connected to PIN2 and to PIN4 by 6mm wire e PIN4 of the main connector is internally connected to PIN3 by 6mm wire e PINS is directly wired to ground User Manual Rev 1 0 26 03 10 25132
28. stallation 2 If your Seller cannot help you contact R V R Elettronica S p A and describe the problem if our staff deems it appropriate you will receive an authorisation to return the equipment along with suitable instructions 3 When you have received the authorisation you may return the unit Pack the unit carefully before shipment use the original packaging whenever possible and seal the package perfectly The customer bears all risks of loss i e R V R shall not be liable for loss or damage until the package reaches the R V R factory For this reason we recommend insuring the goods for their full value Returns must be sent on a C I F basis PREPAID to the address stated on the authorisation as specified User Manual Rev 1 0 26 03 10 1 32 __ LS be rejected and sent back to the sender 2132 e R V R Service Manager Units returned without a return authorisation may 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 replacement parts orders to the address provided below Make sure to specify equipment model and serial number as well as part description and Jantity R V R Elettronica S p A Via del Fonditore 2 2c 40138 BOLOGNA ITALY Tel 39 051 6010506 3 First Aid All personnel engaged in equipment installation operation and mai
29. t provide a fair degree of redundancy to the machine Even if one of the power supply modules breaks down the amplifier will keep working at reduced power On rear panel are housed network input connectors that allows its use with common power supply voltages input and output RF connectors telemetry connector protection fuse input and output interlock connectors I2C connector RS232 connector for programming common bus connector for interfacing with other PJ5000U KLC in cascade the I O pump connector to control the external pump and the input output connectors of the coolant Rev 1 0 26 03 10 User Manual A V R ELETTRONICA A schematic view of the operating theory of amplifier is shown in the figure m 5 z E E 3 9 e T m 4 o oO m o S 3 5 E B Ees lz wo e M E S m J 9 N oOo AB N RF N IN D RF OUT 3 3 WI 2 2 2 bis ee E uem CH ou z 2 8 2 8 8 gd 2 a os SIE a z wo wo wo 8B 8 18 amp 3 2 5 8 m m m m m m m m m m d a a 4 a n n n n n ud oO is ud e MN N nD N N oO oO oO oO oO A A A A A N N N N N FWI z o ED et
30. t that cannot be automatically reverted 9 LOCAL Yellow LED indicating that the amplifier is in local control mode 10 FOLDBACK Yellow LED indicating that the foldback function is active automatic reduction of the distributed power 11 CONTRAST Trimmer to regulate the contrast of the LCD display 12 Button used to navigate in the menu system and to modify the changeable parameters 13 Button used to navigate in the menu system and to modify the changeable parameters 14 OK Button used to accept a parameter s value or to enter into a menu 15 AIR FLOW Grill for the ventilation flow passage 16 COOLANT STATUS Green LEDs indicating the correct operation of the two pumps A and B and the cooling fan of the splitter C 17 P S ALARMS Yellow LEDs indicating the presence of a anomaly on one or more power supply boards 18 FAULT Red LED that indicates a fault that cannot be automatically reverted User Manual Rev 1 0 26 03 10 17132 19 FUSES 20 FOLDBACK 21 RF PWR ADJ 22 WARNING 23 LOW 24 FLOW 25 AIR FLOW ELETTRONICA Yellow LED that indicates the presence of one or more broken fuses Yellow LED indicating that the foldback function is active automatic reduction of the distributed power Power regulation trimmer A G C control Yellow LED indicating the presence of a low level of coolant Red LED indicating the malfunction due to the absence of liquid cooling Red LED indicating
31. the malfunction due to the absence of pressure of the liquid coolant from the pump This signal is acquired by the CPU 10 seconds after the successful termination of the flow Grill for the ventilation flow passage Rev 1 0 26 03 10 User Manual RaMa Ra ELETTRONICA 6 2 Rear Panel 1 2 3 4 5 6 7 8 9 1 PJ5000U KLC f C 6 CHECK PUMPS CHECK PUMPS lC BUS RS232 TELEMETRY COM BUS MAINS CONNECTOR MAINS FUSE OUTPUT COOLANT AIR FLOW 10 INPUT COOLANT 11 RF IN 12 FUSE 13 INTERLOCK 14 RF OUT mao oma DB15 connector for interfacement with other equipment DB9 connector for I C bus networking DB9 connector to interface with external devices or factory programming DB25 telemetry connector DB15 connector for interfacement with other equipment Plug for mains power supply Protection fuses of the power supplies 1 2 and 3 Hydraulic connector for the output of liquid cooling 1 2 Grill for the ventilation flow passage Hydraulic connector for the input of liquid cooling 1 2 RF input connector N type Protection fuse for the service section BNC connectors to inhibit an external device as an exciter In case of fault the inner connector is shorted to ground RF output connector 7 8 EIA flange User Manual Rev 1 0 26 03 10 19 32 6 3 Connector Description 6 3 1 Tel
32. the wave shape is the most possible sinusoidal obtaining a factor of power of 99 The PFC can work with input supply voltages from 170 V to 250 V A rectified voltage of 350 V is present on the output This card also applies a resistive load when the amplifier is turned on and excludes said load after a short time to reduce current peaks in the transformer on turning it on SOFT START PS RF Interface Board This interface board is installed at the back of the amplifier for collecting the main signals of the machine and making them available on the connectors This interface is connected to the three rectifiers the CPU the fans the transformer from which it receives the signals and to which it issues commands This interface card is designed to make the PS part communicate with the RF part and making available the dedicated signals at the specific connector for each part User Manual Rev 1 0 26 03 10 27132 8 2 5 8 2 6 8 2 28 32 RW B ELETTRONICA LEDs Board Three LEDs are present on this board for indicating the operating status of the three power supply modules The lighting up of a LED indicates a malfunction in the associated module CPU This subsystem is made up of three cards the CPU card the display card and the analog card The CPU subsystem implements all the software functions measurements protection control data display communications outlined in the previous chapters
33. to allow the operator to preventively diagnose possible failures in normally function and the construction of tanks in case of liquid reserve indicator Measuring and displaying amplifier work parameters User Manual Rev 1 0 26 03 10 3132 4 32 RW P ELETTRONICA Protecting the amplifier as far as potentially harmful situations are concerned such as excess supplied power SWR excessive pilot power or temperature Communicating with external devices such as programming or telemetry systems via RS232 serial interface or l C The state of equipment is indicated by five LEDs on the front panel ON WAIT FAULT LOCAL FOLDBACK besides two yellow LEDs indicate possible malfunction of the alimentation More informations are provided through additional synoptic panel with LEDs indicating the power status POWER SUPPLY modules amplifier RF AMP and the cooling circuit COOLANT STATUS The amplifier s control software is based on a menu system through which the user may navigate using the following four buttons ESC and ENTER A fifth button is provided for resetting any triggered alarms Furthermore on the front panel is present the ALARM RESET button the switch for selecting between local and remote function LOC REM and the BNC connector for RF drawing on 60dB refers to the output power level The PJ5000U KLC houses three rectifier power supply switching units that normally work in parallel mode and tha
34. tory screenful and then switches to a screenful that indicates the forward and reflected power values Turn on the exciter at lowest power and wait until it locks to the work frequency Once locked increase power gradually and check the amplifier s display Increase the exciter s power until the amplifier s output attains the desired value keep in mind that due to the measurement digitalization effect it might not be possible to obtain a reading of exactly maximum power but a lightly higher or lower value which is perfectly normal Now all of the machine s operating parameters may be checked via the software control system As a rule the machine does not need to be manned to work If any alarm conditions occur they will be managed automatically by the protection system or notified to the user by means of LEDs on the panel and messages on the display NB Note the pump is exchanged automatically every time you switch off and subsequently re switch on the equipment In case you never switch off the equipment the pump is exchanged automatically every 15 days of normal operation The operation of pumps exchange is necessary for the regular functioning of the same 8 32 Rev 1 0 26 03 10 User Manual B V n PJ5000U KLC 5 3 Software This chapter describes the ways in which the microprocessor controls the amplifier and how the user may interact with the software The figure in the follow shows the overall software us
35. y A WARNING This equipment can radiate radiofrequency energy and if not installed in compliance with manual instructions and applicable regulations may cause interference with radio communications A WARNING This equipment is fitted with earth connections both in the power cord and for the chassis Make sure both are properly connected Operation of this equipment in a residential area may cause radio interference in which case the user may be required to take adequate measures The specifications and data contained herein are provided for information only and are subject to changes without prior notice R V R Elettronica S p A disclaims all warranties express or implied While R V R Elettronica S p A attempts to provide accurate information it cannot accept responsibility or liability 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 radio broadcasting Its operating frequencies are not harmonised in designated user countries Before operating this equipment user must obtain a licence to use radio spectrum from the competent authority in the designated user country Oper
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