MB-1 Circuit Description - Version 1.01 - MB-1
Contents
1. SW RELAY 10 1 8 11 SPI OUT R SPI IN R2 RS232 Connector IRSI1 DIFRT 24 ET S Figure 10 Schematic Controller Board Miscellaneous External Hi Vis Displays 7 7 4 CLK Hv2 5 7 F HCTS4 2 7 3 7 i Vi Hi Vis Hi Vis Conector 1 Conector 2 u7f 74HCT 4 r3 12 1 1578 91 Numbers In are Carresponding Pin Numbers on SURE Elact Hi Vis Display Devices H1 VCB PWR2 EXT7SEGL EXT BEG2 5V AUX 5 AUX 1 L L2v RLY OUT 3 1l2v RLY OUT Connect 5 or 12V to HI Vis Display lLaads based an Device Type seo User Manual Sounder 45 Y AUX Saunder valuma Fiezzoi Unused Not Upad HCF4B49UBEY 6b x PR use HOF 4069 UBEY HCF4 69UBEY GND 4 n u amp f HCF4P69UBEY GND 13 12 Notes2. v211 ENNAWMS 5 NYTT v3T1 DTI o2 SH MENU DOHN SW MENU UP SW DISPLAY 3468 vac NYZI E E Word 2 N p E O N 2 YT dn B S p 2 yb Y2311 rano z 9 lt NVT 9 Wo z x 9 x amp NYTT 9358448 WOO m uoa x ON 3 4 NYZz1 WORT SW MINMAX SW RELAY LED SW CHG ND a EED AUTRNG 4 LED ovRNG LED DEMO ON 7 LED v IRT couPS alLED srARTUP SET 1 LED SNOOZE Figure 4 Schematic Controller Board Power 1 of 2 L3 CONDC Fuse 12V WART 1 2 12v FUSED 8 V FILT AMP Pw TID GND dii D 2 D3 5V FILT GND D4 12v DIODE OUT IR 41 2 HCF4065UBEY 12v RLY OUT GND
3. To Internal Analog Meter and Front Panel Pot O A Coverters 35 1 Alarm Relay BPl CLK R 4 48V AUX BPI DUI R 1Nt551 C amp D 2 8 BPI CLK R Panel Meter Jacks IPM RLY AL NO1 184 R2 IRL Y AL COH1 RLY AL NOL 15 RLY AL NOZ RLY AL COM2 17A RLY AL NC 16 _ p 1 55 21 19 3 7 zL X on 3 PHS OUT 19 OND BNO PN4 QUT 22 PM 9 23 45y aux A gt 2 5 22 5 2 G 5 25 5 E Figure 8 Schematic 7 Seament LEDs To Front SPI OUT E1 R 32 BEPI DOLIT EL 2 SPI OFF BOARD2 GPI OUT Bz R 82 SPI OUT R SPI OUT R SFI CLK B1 R SPIL CLH B1 SP1I CLK E2 FR SPI CLK B2 SP CLK R Hi Z ADH PHON 658 M LHX JN T7HOdd33793 ZAH NXUT2 Z H 85 14 2 AH LYO H 83 d u21 a im 37932 27182 0381 885 181 1 3 01 TW 7MB EWS ZW Ma 18 85 d s8a z v 0 s2 1 4 82 tt 5357 155 t 52 952 22 4 301 62 31794 55 52 SE 2N Hesderi SP 1_OF F_BOARD2 SBP C_DFF_BOARDL ET PIC Stamp Module Header2 T HoHd33 82 5960 9 1313710478 1190 41134 808 4002
4. 0 41 7 031 H 73NH AO 031 08 010 0317 d NO O0W30 031 4 84002 141 437 3 138 4014 15 431 71 037 d 32100N Q031 3 37 1 4 773 4334 037 H 7H BNHZE D31 1 4 488 1 131 3 6H3 HM8 31 CALIB POT Froen wiper of Front Panel 3 Vin Z2 out Pot To Front Switch LEDs LED AUTRNG R LED OVRNG R 1K LED AUTO BG R LED DEMO ON R 1K LED VIRT COUPS R LED STARTUP SET R 1K LED AL ON R j LED SNOOZE R 1K R35 To Front Switch LEDs and 7 Segment LEDs ON OFF ON OFF SW2 5 R32 LED DUR RI 1K LED M1 R 1K LED REF CAL R 1K LED SCRNSVR R LK Pe SSBB YE LED M4 R 1K LED TRIP R LED HI SWR R 1K LED SWR CHG C 8 78EG R SPI OUT B1 R LED SWR CHG R SPI IN R1 SPI QUT B2 R SPI CLK B2 R ON UI LCD OUT Figure 9 Schematic Controller Board Ext EEPROM 411 25 128 25 256 CS EEPROM 152 5 1 8 1 81280 HoLpLZ S FILT 68 1 1 8 GND 4 vss To Front Panel Switches ISW SW MENU DOWN I O Expander ug SW MENU DOWN SW MENU UP 2 SW DISPLAY ne
5. MeterBuilder MB 1 PROGRAMMABLE RF POWER METER CIRCUIT DESCRIPTION Version 1 01 June 2011 gt 209 Patent and Copyright Notices Patent Applied For Copyright Material in this document copyrighted 2011 FullWave LLC All firmware and software used in the MB 1 copyrighted 2011 FullWave LLC 1 CIRCUIT DESCRIPTION 1 1 DISPLAY SWITCH BOARD 1 2 CONTROLLER BOARD 2 SCHEMATICS Figure 1 7 Segment LED Pin Out Figure 2 Schematic Display Board 1 of 2 Figure 3 Schematic Display Board 2 of 2 Figure 4 Schematic Controller Board Power 1 of 2 Figure 5 Schematic Controller Board Power 2 of 2 Figure 6 Schematic Controller Board Coupler Processing Circuitry Figure 7 Schematic Controller Board Panel Meter and Alarm Relay Circuitry Figure 8 Schematic Controller Board Processor Module Figure 9 Schematic Controller Board I O Figure 10 Schematic Controller Board Miscellaneous TABLES Table 1 Connections Between Display Board and Controller Board 1 Circuit Description 1 1 Display Switch Board 7 Segment LEDS The internal 7 Segment LEDs are driven from Maxim 7219 7221 ICs These chips provide a serial interface that is driven by the PIC processor thereby reducing the number of interconnect leads between the Display Board and the Controller Board Each 7219 7221 device drives eight 7 segment LEDs This chip also controls the brightne
6. after it is further filtered with a two pole low pass RC filter The gain factor of MCP6S28 of 32 together with the 10 bit A to D resolution of the PIC processor provides an effective low range resolution of 15 bits The software controls the gain of the MCP6S28 multiplexer amplifier device based on the instantaneous value of the voltage being processed on the coupler FWD and REFL coupler port leads The gain is adjusted to maximize the signal that is applied to PIC processor s A to D input without overdriving it This provides maximum achievable resolution under all signal conditions Panel Meter Drive Circuitry The internal analog crossneedle Panel Meter and any user provided external analog meters are driven from dual port 12 bit D to A converters MCP4922 IC External Panel Meters are supported only if the Expansion Kit option is installed Using the menu system each Panel Meter is first calibrated by the user with the calibration values being stored in EEProm Two resistors are connected in series between each D to A output and its corresponding Panel Meter output connection which terminates on a rear panel RCA jack A 100k ohm potentiometer is used for full scale adjustment of the meter movement and a 2 7k ohm resistor is used for meter movement protection by limiting the maximum meter movement current to less than 2 mA regardless of the setting of the panel meter trim pot By setting the Panel Meter trim pot for minimum full sca
7. at the output of the coupler FWD port matches the DC voltage benchmark value printed on the coupler label An RCA Y connector will facilitate this measurement by allowing the voltage to be measured simultaneously by a multimeter The coupler trim pot is then simply adjusted until MB 1 FWD power reading matches the corresponding power level printed on the coupler s benchmark label A similar process can be used to adjust the trim pot for the REFL coupler port 2 Schematics The schematics below have adequate resolution so they can be expanded for easier viewing LI 9 gt S za gt S m 2 un LJ 8 E 2 LI 50 E Uza MAX7219CNG cS0 7 SEG DP SEG DISPLAYZ DISFLAY4 uzb 7213 DISPLAYS DISPLAY1 1 a tot 72994700 NANNAN 05 10 20 0 v uia HMAX7218C0NG SPI CLK MAX Z19CNG 5 LI 9 gt S za gt S m 2 un LJ 8 E 2 1 e e 50 LL E 0 0 84 1 20 2 h LED REF CAL LED SCRNBYR OUT c8a 7SEG LED SW CHG o2 2 ON 2 9 NY CI D watt z 7 5 9 NYTT F NSHAB
8. d and the duration of the press Most front panel switches have multiple functions depending upon the duration that a switch was pressed MB 1 provides a push duration indicator that allows a user to easily determine when the short medium and long push durations of a multi purpose switch have been reached The push duration indicator can be programmed to either flash an LED or to emit a beep at the transition of each duration The green LED on front panel switch SW MENU DOWN top left most switch 1s used for this indicator when an LED indication is selected The 80 character LCD is also driven from the processor SPI serial port interface The critical serial port signals SPI OUT and SPI CLK are buffered through 74HCT08 buffers to reduce the coupling of noise on to the processor pins The J45 connector on the processor board is used for factory programming only and is not used for field operation The white push button switch on the PIC processor board must be in the UP position for normal operation and the white jumper pins on the PIC processor board must be connected as shown in the Assembly Manual The processor board also contains a MAX232 Driver Receiver which converts the CMOS levels from the PIC processor to signals that are compatible with driving the RS 232 interface of a PC serial port The RS 232 interface is used to communicate with a PC when loading new firmware into MB 1 when backing up or restoring MB 1 s EEPROM data or w
9. hen updating the preloaded OEM coupler tables in EEProm with new updates issued by MeterBuilder The RS 232 transmit and receive signals are routed from the processor board to the DB9 connector on leads XMT and RCV via the two jumper leads that connect between the PIC Processor board and two spare connections on one of the 40 pin headers Note that the PIC18F8722 has a Write to Program Memory instruction that is used by the bootloader when loading new firmware Therefore no special programmer or special voltage connections are required to update the MB 1 firmware Front Panel High Precision Potentiometer The front panel pot is a 10 turn pot connected across the 5 volt bus 4 5 V The center wiper is connected to lead CALIB POT which is connected to a voltage divider The tap of this voltage divider feeds one of the processor s A to D inputs on lead CALIB POT FILT The voltage divider drops the maximum voltage from the potentiometer s center wiper to a voltage slightly higher than the 4 096 volt reference used by the PIC s A to D converter This prevents a dead spot at the top 20 travel of the high precision pot that would have otherwise resulted This high precision pot is used for a number of functions including Panel Meter Calibration and Trim calibration of the coupler settings When used for these types of operations the front panel pot is used solely during the calibration functions to aid the software in determining calibratio
10. le overshoot during calibration the maximum obtainable resolution will be achieved during operation This will provide excellent resolution with any analog meter If you decide to use the Soft Overrange feature to drive the meter somewhat beyond full scale this will have a negligible impact on resolution Alarm Relay The Alarm Relay RLY2 is tripped when the ALARM feature is enabled and user defined thresholds are exceeded In addition to the normal RF power meter trip functions such as SWR low power trip and high power trip the alarm functions can also be used for RF ammeter and Generic Meter Applications when MB 1 is used with user provided analog sensors When the software determines that a trip condition has occurred it applies a logic signal to lead RLY ON which turns on transistor Q2 thereby operating relay RLY2 This relay has two sets of NO NC contacts which are located on the Panel Meter RCA jacks on the rear of the meter Piezo Sounder The sounder can be used to provide an audible alert when an alarm trip condition occurs The sounder can also be configured to provide an enunciator for the push durations of the front panel switches short medium and long presses The piezo device is controlled from logic signal SOUND from the PIC processor board which turns on transistor Q3 thereby activating the sounder You can reduce the volume of the sounder by increasing the value of 47 ohm resistor that is in series with the so
11. ly for powering the external 7 segement and external Bar Graph display devices that are provided with the Expansion Kit The 5V AUX bus also powers the alarm relay and sound transducer and is also connected to the 5v RCA jacks on the rear panel that are provided for prototyping 1 can drive larger external 7 segment displays up to 7 inches high The 7 segment displays larger than 1 5 inches are powered from 12 volts instead of 5 volts Two headers on the main control board EXT 7SEG1 and EXT 7SEG2 and associated jumper pins are used to select the correct voltages for the external display devices 5 volts or 12 volts based on the types of external display devices connected to the two Hi Visibility output connectors on the rear panel of the meter Combinations of 5 volt and 12 volt external 7 segment display devices can be used at the same time as long as the jumper settings are set properly The User s Manual provides complete details on selecting the proper voltages for the various types of external display devices The larger 7 segment displays greater that 1 5 inches high are supported only if the Expansion kit and Large 7 Segment Display option are installed in MB 1 Note that for reference purposes the SURE Electronics pin numbering scheme for the 10 pin IDC connectors on connectors JHV 1 and JHV2 are given in parentheses on both the schematic and silkscreen on the PCB This numbering is different than the standard numbering used f
12. n constants that are stored in EEPROM The front panel pot is also used to quickly dial in settings when adjusting meter functions such as the Peak Hold Time For example the Peak Hold Time can be easily adjusted from 1 seconds to 9 9 seconds in 1 second increments by dialing in the desired value with the front panel pot The high resolution of the 10 turn pot makes it easy to quickly dial in one of these 98 values which is then saved in EEPROM for later recall This approach is also used for several option selections used in the menu and setup screens Coupler Trim Pots Because MB 1 supports a wide variety of coupler types and also supports interfacing to user provided analog sensors each coupler input port will have its own full scale level The coupler trim pots are used to scale the signal level reaching the inputs of the MCP6S28 Amplifier Multiplexer so that maximum resolution can be obtained without overdriving the input circuitry Calibration of the MB 1 Coupler using the Trim Pots All that is required for final calibration of the included MB HF1 Coupler is a DC voltmeter and 50 ohm resistive dummy load The MB 1 coupler that is supplied with the MB 1 meter has been benchmarked at the factory and the coupler calibration table has also been preloaded at the factory To adjust the coupler trim pot power is applied from a transmitter though the MB HF1 coupler into a dummy load The transmit power is then adjusted until the DC voltage
13. oard 12 Controller Board Power 12 volt DC power is constantly applied from the Power Adaptor to the 4069 IC and the common terminal of Power Relay RLY regardless of the relay s state The meter is protected with a quick blow 1 6 amp fuse Each press of the power switch on the Display Board toggles the state of the 4069 flip flop When the flip flop is toggled on this turns on transistor Q1 which in turn operates the Power Relay RLY1 The 1000 pf capacitor which is connected to the 4069 flip flop is used to force the state of the flip flop to a predictable off condition after a power interruption if the meter was powered off at the time of the interruption If the meter is powered on and a short duration power interruption occurs a few seconds the meter will turn back on with the Startup Set settings when power is restored Power relay RLY1 switches the DC 12 volt nominal input voltage to the two 7805 5 volt regulators Power is applied through four power diodes 1N540x These diodes are used as voltage drop diodes to reduce the heat dissipation of the 7805 regulators They also provide polarity protection on the 12 volt input Because of the current demands of the external display devices two regulators are used with each regulator feeding its own power bus The 5 bus is used for all of the internal MB 1 circuitry including the PIC processor the LCD and the internal 7 Segment LEDs The 5V AUX bus is used primari
14. or these IDC connectors in the MB 1 documentation The parenthetical entries will be useful if you need to cross reference the MB 1 documentation with the SURE Electronics documentation for any reason RF chokes L2 and L3 and associated bypass capacitors provide additional filtering of the 5V bus L1 provides filtering for the 12 volt powers that feeds the 4069 flip flop Coupler Input Circuitry Up to four couplers each with a FWD and REFL signal may be connected to the RCA Coupler Port jacks MB 1 also supports applications other than RF Power measurement Such applications referred to as Generic Meter Applications in the 1 documentation allow MB 1 to be interfaced to a wide range of analog sensors These applications make use of only the FWD port on the associated coupler input The signal from each coupler input port is fed through an RC low pass filter to remove excess RF or other high frequency noise signals The signal is then fed into a 15 turn trim pot which controls the input level fed into 6528 multiplexer amplifier The MCP6S28 serves both as a Programmable Amplifier with a maximum gain of 32 and as a multiplexer After one of the eight input signals is selected by the multiplexer function one of six gain settings is applied and the amplified signal is routed to the output pin of the MCP6S28 The output signal is connected to the 10 bit internal A to D converter of the PIC Processor on signal COUP BUS FILT
15. ss of the 7 Segment LEDS The MB 1 software allows you to adjust the brightness of the 7 Segment LEDs to one of nine different levels The 7 Segment LEDS are plugged in to 40 pin sockets making it easy to swap the LEDs for a different color Any 52 inch common cathode 7 Segment LED that has the electrical footprint below and the pin out footprint compatible with the 40 pin socket spacing can be used as long as the current requirement is 20 mA or less per segment If you obtain your own 7 Segment devices cut the leads to a length of 3 8 mm if they are longer so that they will fit properly into the 40 pin sockets Figure 1 7 Segment LED Pin Out Front Panel switches With the exception of the Power switch and the four menu switches SWMENUI SWMENU4 each of the normally opened contacts of the front panel switches when pushed applies a ground to an input of the I O expander chip MCP23S17 on the Controller Board The I O expander chip in turn generates a signal that is read by the processor which then determines the switch that was pushed and the duration of the push The software then takes the appropriate action such as bringing up a menu on the LCD The On Off Power switch simply applies a closure to the flip flop HCF 4069 IC on the Controller Board to toggle the on off state of the power relay Menu Switches SWMENU1 SWMENU4 are wired directly to the four external interrupt pins of the PIC processor board When any of these fo
16. tI HCF4069UBEY 905145 o 1 Vin Vout eV AUK GND 144001 on GND GND Figure 5 Schematic Controller Board Power 2 of 2 GND L2v FUSED l2v FILT HCF4069UBEY u9e 74HCTO8 GND g 74HCTQ4 Figure 6 Schematic Controller Board Coupler Processing Circuitry 100K e Rie 5V AUX COUP BUS IN ass COUP BUS FILT R47 5V AUX to ET PIC t 1 9 20730 COUP1 FWD Coupler Jacks JCOUP COUP1 REF 13 C1 FWD R SNB C1 FWD IN 14 C3 FWD R 8 u1 Prog Amp Mux E su 6528 3 5V FILT AMP GND 15SPI CLK R C1 REF IN C2 EWD IN 4 NS 83 16 C1 REF R 17 C3 REF R 18 200ua GND 12CS PGAMP T _ 2 19 C2 FWD R 20 C4 FWD R 21 CH7 9 C4 REF IN COUP2 REF 5 1 C2 REF IN C3 FWO IN 5 1K w COUP3 FWD CALIB POT RCA GND C3 REF IN COUP4 FWD COUP4 REF C4 FWD IN GND CA REF IN Figure 7 Schematic Controller Board Panel Meter and Alarm Relay Circuitry
17. under Processor Daughter Board The main processor functions are provide by the ET PIC Stamp daughter board which contains a high performance PIC18F8722 PIC processor with 128 KB on on board program memory This processor also contains 3 KB or RAM and 1 KB of EEPROM Because of the sizeable EEPROM requirements for the MB 1 calibration tables and other configuration settings one of two external serial EEPROM memory devices a 25AA128 or 25 256 is provided depending upon whether the Expansion Kit is installed IC 25AA128 provides an additional 16 KB of EEPROM memory IC 25 256 provides additional 32 KB of EEPROM memory The pre programmed 25 256 that comes with the Expansion Kit must be installed to support the External Display modules and external analog Panel Meters A high precision 4 096 volt voltage reference is generated by an MCP1541 which is connected to voltage reference input VREF on the processor board The 23516 16 Bit I O Expander chip is connected to the processor board through the SPI serial interface signals SPI CLK B SPI OUT B and SPI IN Nine of the 16 ports on the I O Expander are used to detect the state of nine of the front panel switches When any of these switches is pushed the generated signal is processed by the I O Expander chip which asserts a logic 0 to the processor board on lead IO EXT INT The software then interrogates the I O Expander chip to determine the front panel switch that was presse
18. ur menu buttons is pressed an interrupt is generated and is immediately processed by the software This allows most menu selections to be made without disrupting normal meter operation Both the Processor interrupt leads and External I O chip inputs have internal pull up resistors in the PIC which eliminates the need for external pull up resistors Each front panel switch contains one or two LEDS that provide status information to the user for example the on off state of the Panel Meter s AutoRange feature or the presence of an alarm trip condition All of the switch LEDs with the exception of the LED on the Power switch are driven from output ports from the PIC processor board The LED on the Power switch is illuminated directly from the 5 volt bus through a resistor when the Power Relay is operated Interconnection to Controller Board Three ribbon cable assemblies connect signals between the Display Board and the Main Controller Board These cables route the following signals Table 1 Connections Between Display Board and Controller Board Connector Signals JPWR 5 volts from Controller Board to Display Board and Signals to Drive the LEDs on some of the Front Panel Switches Signals to Drive the LEDs on some of the Front Panel Switches and Switch Closure to 4069 Flip Flop Ckt when Power button is pressed Signals from the Front Panel Switch Contacts to the I O Expander chip and to the 4 interrupt leads on the Processor B
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