(alias BARRACUDA) - USER MANUAL

VOLUME1

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

Date Version

26/03/2010 1.0

Reason

First Version

Editor

J. H. Berti

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:

Web: [email protected]

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 information storage and retrieval system, without written permission of the copyright owner.

ELETTRONICA

Table of Contents

PJ5000U-KLC

3.1 Treatment of electrical shocks

3.2 Treatment of electrical Burns

4.1 Make-up

5. Quick installation and operating reference

5.2 Operation

5.3 Software

6.1 Frontal Panel

8.1 Power Supply Change

9. “Low-Drive Power” Option (/LD)

9.1 “Low-Drive power” Board

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17

19

20

22

8

9

6

6

15

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25

27

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3

2

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3

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User Manual

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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, important for the effi cacy and the maintenance (repairs).

• General Warnings

This equipment should only be operated, installed and maintained by “trained” or “qualifi ed” 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 unqualifi ed 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 unqualifi ed personnel placed under their supervision when working on the equipment.

WARNING: Residual voltage may be present inside the equipment even when 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 qualifi ed 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.

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 specifi cations 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 specifi cations 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 frequencymodulation audio radio broadcasting. Its operating frequencies are not harmonised in designated user countries.

B e f o r e o p e r a t i n g t h i s e q u i p m e n t , u s e r m u s t obtain a licence to use radio spectrum from the competent authority in the designated user country.

Operating frequency, transmitter power and other characteristics of the transmission system are subject to restrictions as specifi ed in the licence.

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 qualifi ed/unqualifi ed persons.

WARNING: The equipment is not water resistant.

Any water entering the enclosure might impair proper operation. To prevent the risk of electrical shock or fi re, do not expose this equipment to rain, dripping or moisture.

Please observe local codes and fi re prevention rules when installing and operating this equipment.

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 closely.

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.

WARNING: This equipment is fi tted with earth connections both in the power cord and for the chassis.

User Manual

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.

For the latest updated terms and conditions, please visit our web site at WWW.RVR.IT. The web site may be modifi ed, 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 fi x 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 installation.

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 specifi ed

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by the R.V.R. Service Manager.

Units returned without a return authorisation may be rejected and sent back to the sender.

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 quantity.

R.V.R. Elettronica S.p.A.

Via del Fonditore, 2/2c

40138 BOLOGNA ITALY

Tel. +39 051 6010506

All personnel engaged in equipment installation, operation and maintenance must be familiar with fi rst aid procedures and routines.

3.1 Electric shock treatment

3.1.1 If the victim is unconscious

Follow the fi rst aid procedures outlined below.

• Lay the victim down on his/her back on a fi rm surface.

• the neck and tilt the head backwards to free the airway system (Figure 1).

• Two rescuers: one rescue breath after each 5 compressions.

• Do not stop chest compressions while giving artifi cial breathing.

• Call for medical help as soon as possible.

3.1.2 If the victim is conscious

•

Cover victim with a blanket.

• Try to reassure the victim.

• Loosen the victim’s clothing and have him/her lie down.

• Call for medical help as soon as possible.

3.2 Treatment of electric burns

3.2.1 Large burns and broken skin

•

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.

• 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.

Figure 1

• If needed, open the victim’s mouth and check for breathing.

• If there is no breathing, start artifi cial respiration without delay (Figure 2) as follows: tilt the head backwards, pinch the nostrils, seal your mouth around the victim’s mouth and give four fast rescue breaths.

Stop at the fi rst sign of retching.

Do not administer alcoholic beverages.

3.2.2 Minor burns

• 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.

• Administer adequate treatment for the type of accident.

• Get the victim to a hospital as quickly as possible.

• Elevate arms and legs if injured.

Figure 2

• 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

• One rescuer: give 2 quick rescue breaths after each 15 compressions.

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The package contains:

1 PJ5000U-KLC (alias BARRACUDA)

1 User Manual

1 Mains power cable

The following accessories are also available from Your R.V.R. Dealer:

• Accessories, spare parts and cables

The PJ5000U-KLC is an RF amplifi er 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 amplifi er is running with a standard load of 50Ohm and operate with less of 70W 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 briefl y describes the machine’s main features.

The PJ5000U-KLC amplifi er 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 amplifi er is controlled by a microprocessor-based system that includes a LCD which carries out the following functions:

• Setting of the output power

• Activating and deactivating power delivery

• Detecting the warning thresholds set by the user (e.g. power delivered below a specifi c threshold), which are made available to the user via the telemetry connector

• Pumps and fan of splitter control

• Reporting the false starts of pumps, so 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 amplifi er work parameters

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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 I 2 C.

The state of equipment is indicated by fi ve 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 amplifi er (RF AMP) and the cooling circuit (COOLANT STATUS).

The amplifi er’s control software is based on a menu system through which the user may navigate using the following four buttons: ESC, , , and ENTER.

A fi fth 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 rectifi er/power supply switching units that normally work in parallel mode and that provide a fair degree of redundancy to the machine. Even if one of the power supply modules breaks down the amplifi er 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.

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A schematic view of the operating theory of amplifi er is shown in the fi gure:

RF

IN

RFL

RF

OUT

A.C.

IN

DISPLAY, KEYS

+50V

R5

RF PWR SETTING

Figure 4-2: theory of operation

TELEMETRY,

RS232, IIC,

INTERLOCK ....

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5. 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 fi rst time, it is advisable to read the entire manual very carefully.

In this description it is assumed that the amplifi er 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.

Unpack the amplifi er and fi rstly 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 single-phase

208 V, +15% -10%

230 V, +10% -15%

•

•

• three-phase three-phase three-phase (with N)

208 V, +15% -10%

230 V, +10% -15%

400 V, +10% -15%

Suggestion: Specify the type of power supply at order placement: the machine will be delivered to you confi gured according to your requirements.

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:

AUX OUT FUSE

(chap. 6.2 – position [9])

SERVICE FUSE

(chap. 6.2 – position [10])

MAINS FUSE

(chap. 6.2 – position [1])

@208/230V single phase

(1x) F6,3T type

5x20

(1x) F6,3T type

5x20

(3x) F32T type

10x38

@208/230V three phase

(1x) F6,3T type

5x20

(1x) F6,3T type

5x20

(3x) F25T type

10x38

@400V three phase

(1x) F6,3T type

5x20

(1x) F6,3T type

5x20

(3x) F16T type

10x38

Install the amplifi er in a standard rack for 19” modules.

Assemble the amplifi er 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 fi tted with N type connectors

(50 Ohm). The exciter should be set to minimum output power and OFF.

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Connect the amplifi er’s 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 amplifi er’s INTERLOCK connector is an output. The operating logic is as follows: the internal conductor fl oats when the amplifi er works correctly, on the contrary power is delivered and the internal conductor is closed to ground to halt the exciter.

Connect the RF output to the antenna cable or to a dummy load capable of dissipating the power generated by the amplifi er.

An ILME model CXF4/2 multipole socket is supplied with the amplifi er 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 fi gure 5-2:

Three-phase power supply:

• G Ground

• 1 Neutral

4 3 11

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Figure 5-2: View of the mains multipole socket - terminals side (internal)

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Single-phase power supply:

• G Ground

• 2 Phase

• 3 Neutral

Danger: avoid the risk of damaging the machine by grounding it correctly. As such, connect the ground conductor of the power supply cable to the specifi c terminal in the multipole socket and check the effi ciency of your own grounding system.

After having plugged in the power supply socket at the back of the machine, power on the amplifi er via the switchboard. The ON LEDs on both modules will turn on and the forced cooling fans will start running. The LCD shows the fi rst introductory screenful and then switches to a screenful that indicates the forward and refl ected 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 amplifi er’s display. Increase the exciter’s power until the amplifi er’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 notifi ed to the user by means of LEDs on the panel and messages on the display.

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.

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This chapter describes the ways in which the microprocessor controls the amplifi er and how the user may interact with the software.

The fi gure in the follow shows the overall software user interface diagram.

Switch On

ESC

ESC

Selection Menu

ENTER

Operation Menu

ENTER

Power Menu

ENTER

ENTER

P.A. Menu

Set Up Menu

ENTER

Alarm Menu

ENTER

Miscellaneous Menu

ENTER

Version Menu

Figure: Flow diagram of the software

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.

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A few seconds later the main screenful is displayed indicating the forward and refl ected power values:

Press the ESC key to view the selection screenful from which to access all the menus:

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 few cases. This occurs when, for physical reasons, the measured vales are not signifi cant for control software internal use.

When the value of a parameter is not available for the aforesaid reason, symbol

“==” appears on the display in lieu of the value.

5.3.1 Operating Menu (Fnc)

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Turn the power amplifi er ON or OFF via this menu.

When the amplifi er 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 amplifi er).

When the amplifi er is turned OFF the software program waits 5 minutes for the machine to cool down and then the fans and pumps turn OFF.

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5.3.2 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 amplifi er’s power section:

• Forward Power (Fwd Pwr)

• Refl ected Power (Rfl Pwr)

• Input Power (Inp Pwr)

• SWR (Standing Wave Ratio)

Depending on the machine’s configuration a few measurements might be disabled.

The fi gure 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):

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 amplifi er of the equipment:

• Voltage (VPA)

• Current (IPA)

• Temperature

• Power Supply Voltage (Mains - percentage variation as compared to the nominal voltage)

• Effi ciency

The fi gure 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):

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5.3.4 Warning threshold setting menu

As mentioned in the introduction the amplifi er 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:

• Forward Power

• Forward Power

5000 W

300 W

Proceed as follows to change the values of the warning thresholds:

• Select the line to be changed (with the UP and DOWN keys)

• Press the ENTER key

• Change the threshold value (UP and DOWN keys)

• Press ENTER to confi rm

The fi gure below shows a confi guration example of this menu.

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In this example the alarm thresholds are as follows:

• PwrGd1 4000 W (80% x 5000 W)

• PwrGd2

• Rfl War

2500 W (50% x 5000 W)

150 W (50% x 300 W)

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5.3.5 Alarm Menu

This menu provides information about the status of the amplifi er’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.

Said 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):

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:

• set the address in the serial bus connection, type I

2

C

• set the main menu display mode

• exchange the operation pump

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The network address I

2

C is very important when the amplifi er 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:

In the analog display mode a small triangle indicates the refl ected power level set in the Alarm Threshold Setting Menu (Rfl War), whereas the bar at the bottom shows the instant refl ected power level.

This type of display might be useful when a device to be tuned is connected to the amplifi er’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 fl ow, 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 condition, 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.

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Note: Please resolve as soon as possible replacing the faulty pump.

5.3.7 Version Menu

This screenful shows the software version and the hardware version of the equipment.

The protection system implemented inside the amplifi er is based on two types of intervention.

The fi rst reaction is called “Foldback” and consists in decreasing the voltage in the power amplifi er when the forward or refl ected power exceeds the proportional limit voltage value. As such, the amplifi er’s gain is reduced and the overall result is an action that opposes the increase of the forward or refl ected power. The yellow

LED on the front panel indicates the tripping of the foldback circuit.

The second type of reaction consists in turning OFF the equipment’s amplifying section when a specifi c variable exceeds a set value.

Depending on the type of event occurred, and after the amplifi er 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 fi rst type of confi guration 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 specifi c parameter: this is indicated by Dis. (Disabled).

While the amplifi er 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 amplifi er turns OFF defi nitely 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:

• If the equipment is off, waiting for the cycle time to be reached, or if it is

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defi nitively off in FAULT state, press the ALARMS RESET button to immediately turn the amplifi er ON and reset the alarm counters.

• If the 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 amplifi er does not trigger any alarms or after the machine the machine has been turned OFF and then back ON.

5.4.1 RF Module Auxiliary Protection

The amplifi er’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 amplifi er. 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 (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 effi ciency.

Note: the RESET button allows you to reset all the auxiliary protection.

5.4.2 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.

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This chapter describes the elements presents on the panels of the PJ5000U-

KLC.

1 2 3 4 5 6 7 8 9 10 11 12 13 14

[1] RF TEST

[2] ALARM RESET

[3] LOC/REM

[4] ESC

[5] DISPLAY

[6] ON

[7] WAIT

[8] FAULT

[9] LOCAL

[10] FOLDBACK

[11] CONTRAST

[12]

[13]

[14] OK

[15] AIR FLOW

[16] COOLANT STATUS

[17] P.S. ALARMS

[18] FAULT

15 16 17 18 19 20 21 22 23 24 25

BNC connector for RF monitor output. The output level is

-60dB referred to the power output in 87.5 - 108 MHz range

Button used to manually reset the protection system

Switch to select the local or remote control modes

Button used to exit from a menu

Green LED indicating the amplifi er is switched on

Yellow LED indicating the amplifi er is waiting for a condition that is blocking the power output to be removed

Red LED indicating that a fault that cannot be automatically reverted

Yellow LED, indicating that the amplifi er is in local control mode

Yellow LED, indicating that the foldback function is active

(automatic reduction of the distributed power)

Trimmer to regulate the contrast of the LCD display

Button used to navigate in the menu system and to modify the changeable parameters

Button used to navigate in the menu system and to modify the changeable parameters

Button used to accept a parameter’s value or to enter into a menu

Grill for the ventilation fl ow passage

Green LEDs, indicating the correct operation of the two pumps (A and B) and the cooling fan of the splitter (C).

Yellow LEDs, indicating the presence of a anomaly on one or more power supply boards

Red LED that indicates a fault that cannot be automatically reverted

User Manual

[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 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 fl ow.

Grill for the ventilation fl ow passage

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1 2 3 4 5 6 7

8 9 10 11 12 13 14

[1] CHECK PUMPS

[2] I 2 C BUS

[3] RS232

[4] TELEMETRY

[5] COM BUS

[6] MAINS CONNECTOR

[7] MAINS FUSE

[8] OUTPUT COOLANT

[9] AIR FLOW

[10] INPUT COOLANT

[11] RF IN

[12] FUSE

[13] INTERLOCK

[14] RF OUT

DB15 connector for interfacement with other equipment

DB9 connector for I 2 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 fl ow 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 fl ange)

User Manual

ELETTRONICA

6.3.1 Telemetry Connector

Type: DB25 Female

Internal Disable

2 Tensione dell’ amplifi catore di potenza RF 3,9V x 50V

4 Refl 4.3V

10 WAIT

12 OFF

13 Interlock

15 RF power amplifi er current 3.9V x 200A

23 LOC

25 ON

6.3.2 RS 232

Type: DB9 female

1 NC

2 TX_D

3 RX_D

4 Internally connected with 6

5 GND

6 Internally connected with 4

7 Internally connected with 8

8 Internally connected with 7

9 NC

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6.3.3 I

2

C Connector

Type: DB9 Female

1 NC

2 SDA

3 SCL

4 NC

5 GND

6 NC

7 NC

8 NC

9 NC

6.3.4 Com Bus

Type: DB15 male

1 GND

2 485+

3 485-

4 GND

5 ON OFF C

GND

8 IRQ

9 GND

11 GND

12 NC

13 NC

14 NC

15 NC

6.3.5 Check Pumps

Type: DB15 male

1 NC

2 ON

3 GND

4 NC

5 ON

6 GND

7 NC

8 NC

9 GND

10 GND

11 FAN

12 H2OWARN

13 H2OMIN

14 FLUX

15 NC

Pump 1 ON/OFF Command

Pump 2 ON/OFF Command

Low level check of coolant

Empty level check of coolant

Flux pression check of coolant

PJ5000U-KLC

User Manual

ELETTRONICA

PPJ5000U-KLC

PParameters

Rated output power

Frequency range

Input power for rated output

Input power for rated output LD version

Primary Power

AC Power Consumption

Overall efficiency

Phisical Dimensions (W x H x D)

Weight

Environmental Working Conditions

Cooling

RF Input

RF Output

RF Monitor

Interlock Output

Interlock Input

SSTANDARD COMPLIANCE

Safety

5000W

FCC -CCIR and other on request

70W typical

< 5 W

230/400 VAC ±15% , 3-phase +neutral,

50/60Hz or 230 VAC ±10%,

1-phase, 50/60Hz; ILME CFX4/2 connector

8250 VA / 8115W / PF: 0,98

> 60 %

483 x 176 x 700 mm

49 kg

-10 ÷ +50 °C / 95% relative Humidity non condensing

Liquid cooling with external unit

N (50 ohm)

7/8" EIA flange type, 50 ohm

BNC (- 60dBr referred to RF output )

BNC

BNC

EMC

/LD-PJM-C

EN 60215:1989

EN60215/A1:1992-07

EN60215/A2:1994-09

EN 301 489-1 V1.4.1 (2002-08)

EN 301 489-11 V1.2.1 (2002-11)

Low drive power (less than 5W)

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The fi gure shows the top and the bottom view of amplifi er. The various cards are described in this chapter.

1 2 3 4 5

1) ProtF Board

PROTPJ-HCLCD

& CPU Board

SL154IN2001

2) Power Supply

PSL5060

3) Low-Drive Power Board

SL154DR2001

4) PFC

PFCPSL5060

5) Surge Protection Board

SL046SR1002

6) PS-RF Interface Board

SLINPSP2K07

User Manual

6

1 2 3 4 5

ELETTRONICA

1) FWD & RFL Power Meter Board

SL042MT1501

2) Splitter Board

SLSPLL5PJ2K

3) Amplifi er Modules

SL154RF2001

4) Fuses Board

SLFUSRFPJ4K1

5) LEDs Board

SL154LD1001

6) Bias Board

SLMTPRTPJ4K1

& CPU Board

CPUPJ2KMC

6

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ELETTRONICA

8.1 Power Supply Change

To use the amplifi er 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

WARNING: the power supply in single-phase can be used only with 208/230V voltage.

For the single-phase, the confi guration of the external power supply plug must have the following characteristics:

• PIN1 of the main connector is connected to Neutral wire.

• PIN2 of the main connector is connected to Phase wire and internally connected to PIN3 by Ø 6mm wire.

• PIN3 of the main connector is internally connected to PIN2 and to PIN4 by Ø

6mm wire.

• PIN4 of the main connector is internally connected to PIN3 by Ø 6mm wire.

• PIN5 is directly wired to ground.

User Manual

8.1.2 Three-Phase Wiring

ELETTRONICA

For the three-phase, the confi guration of the external power supply plug must have the following characteristics:

• 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.

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8.2.1 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.

8.2.2 Power Supply

The three power supply modules are located in the middle part of the amplifi er.

The power supply units are mounted on a cooling fi n to cool the amplifi er by forced ventilation.

The amplifi er houses a transformer the input voltage of which may be selected between 115 and 230 Volts.

The transformer is fi tted with three secondary wires: A) 18-0-18 V, B) 0-17 V, C)

0-11.5 V that supply power to the cards inside the equipment.

8.2.3 PFC Unit

The PFC unit is a rectifi er that modulates the current absorbed so that 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 rectifi ed voltage of 350 V is present on the output.

This card also applies a resistive load when the amplifi er is turned on and excludes said load after a short time to reduce current peaks in the transformer on turning it on (SOFT-START).

8.2.4 PS-RF Interface Board

This interface board is installed at the back of the amplifi er for collecting the main signals of the machine and making them available on the connectors. This interface is connected to the three rectifi ers, 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 specifi c connector for each part.

User Manual

ELETTRONICA

8.2.5 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.

8.2.6 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.

This card carries the signals to the DB25 telemetry connector that is on the machine’s back panel. The connector is fi tted with 7 analog outputs, 8 opencollector digital outputs and 4 digital inputs. It also manages the DB9 signals associated with the RS232 connector, for interfacing with other equipment and for the default programming functions, and the DB9 connector for communications in I

2

C standard.

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 fi n 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=about 2.6-2.7V Idq=200mA (100mA for each MOSFET)

The active device used in the amplifi er modules is a Mosfet (2x) SD2942.

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8.2.8 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 each module to obtain the amplifi er’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 fi tted with the temperature sensor which is monitored by the software.

8.2.9 Bias Board

The task of this card is to check and correct the bias voltage of the Mosfets in the

RF amplifi cation section.

This card also supplies the following measurements: current and voltage of each module, total current and average voltage.

8.2.10 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 amplifi er’s forward power whereas the other one supplies the refl ected power.

8.2.11 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

ELETTRONICA

8.2.12 LEDs Board

This card is fi tted with 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.

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ELETTRONICA

9. “Low-Drive Power” Option (/LD)

The fi gure 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

The “Low-Drive power” board contains an RF amplifi er with only one stage that, with a power of about 1W, can supply an output power of approximately 30W suitable to pilot the amplifi er, with a total gain of approximately 15dB.

The active device utilized in the amplifi er modules is a Mosfet (BLF177) and uses for the feeding the same voltage of 50V

DC

used from the RF amplifi ers modules.

On the output stage of this board is present a directional coupler that measure the refl ected and forward power; the latest comes acquired from the control software that represents it legible like input power.

The board is mounted on the fi n that supplies to its cooling through forced ventilation.

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ISO 9001:2000 certifi ed since 2000

R.V.R Elettronica S.p.A.

Via del Fonditore, 2 / 2c

Zona Industriale Roveri · 40138 Bologna · Italy

Phone: +39 051 6010506 · Fax: +39 051 6011104 e-mail: [email protected] ·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 ® 1998 all rights reserved.

All other trademarks, trade names or logos used are property of their respective owners.