NA1001 MANUAL - 3
Contents
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3. SRFBIKOAL2 RF CONTROLS amp MEASURES BOARD COMPONENT LAYOUT NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc Ty teat 1814 Kol d rez 619 29 ma 402 e Sar 2025 ollo PSY ie he abe ET tali GO x gt E 39911 blu E Lyr S 2 a NR 1193 o A 26 ee le E gia Spy F Puce ss l1 30 20 060 3 l ezai 2 1 E 5 1628 kc D Seu 220 QM a D Ti 1 6b 5 mas A pul al u 2 1198 2 8 Sei T 2 4 5 Id esx a o gt 1 OSU STI pp LESA EE bo NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc 48 70 SMPS REGULATOR ELECTRICAL DIAGRAM POWER SECTION SRFBIKSALM y A a TIE sa oc es 31 NA10
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7. 19 Slowly increase the power and measure the balance of the current drained by each module at half level and at full power Verify the limits written in paragraph 5 20 Turn off the equipment reassemble the screening covers and the bottom panel of the apparatus and reposition it in its working location with full connections 21 Perform a limited testing period at full power i e 1050 1100 W and then reduce power at maximum nominal working level i e no more than 1000 W NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc NA1001 AMPLIFIER FRONT amp TOP INTERNAL VIEW O e T WR ADJUST POWER O 5 Lj 2 A O U 424 8 o Sy e
8. 1 zo aan aN S5 Quz 5 ZOLN El AIA 5 19 EN 4 Quz B y 1 Bl bra 8 N 1 WANN iga su LOIN m VL Alddns xnv vr p 27 NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc ELECTRICAL DIAGRAM 115 230Vac NA1001 AMPLIFIER Ln vsz 9 er 3 91 4 nane zr N indui ur Lo vez 20 A kolb 19 XE Nya use mojok 18 AMSA K K oy eum x COOLOGEAYS eN ebunio N zia 12019 e saze Ozu 1 2 EA 1 5 w SH LL HOS 8803 ET AL Y 219 ems us y n g 9 i 5 voyuow ds n 6r
9. NEED BY BRAND NEW ONES AND POSSIBLY RETURNED BACK TO FACTORY TO VERIFY IF THEY CAN BE REPAIRED ANY ISPECTION ON THE MODULES DESCRIBED ABOVE MUST BE EXECUTED WITH THE TOP COVER REMOVED AND OFTEN WITH THE OPERATING APPARATUS CONNECTED TO THE POWER ALTHOUGH MOST OF THE PARTS UNDER VOLTAGE ARE INSULATED AND ARE NOT EASILY ACCESSIBLE THIS EXPOSES TO THE RISK OF ACCIDENTAL CONTACT WITH THE AC VOLTAGE TO AVOID IT ALWAYS USE INSULATED TOOLS AND NEVER TOUCH THE SUPPLY TRANSFORMER THE POWER SWITCH OR THE POWER SOCKET WITH AC CONNECTORS NEVER OPERATE THE EQUIPMENT WITH THE COVERS REMOVED REMOVAL OF THE BOTTOM RF COVER MAY LEAD TO IMPROPER FUNCTIONING OF ANY ELECTRONIC MEASURING METER DUE TO HIGH RF FIELD AC VOLTAGE MAY KII L 6 3 Thepowersupply components NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc The power supply components other than the boards below described are very few mainly the power transformer with a power relay a bridge rectifier and a power capacitor which delivers the raw rectified DC power to the SMPS regulator module The unregulated DC voltage nominally 140 VDC may range 120 170 V The primary tap on the power transformer is factory set on the 230V input allowing a power range approximately 200 250 VAC Should the mains voltage be 240VAC nominally we suggest changing the transformer tap to that voltage If the power voltage is a stable 215 225 Vac the transformer tap may be left as factory set
10. wrong installation orexternal causes such as AC overvoltage This warranty covers work done exclusively in our laboratories and in those of our agreed representatives The goods shall be delivered carriage prepaid to the laboratory and shall be returned freight forward This guarantee does not cover any consequential damage due to non operation or faulty operation 14 NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc 6 SERVICEMANUAL 6 1 SYSTEM DESCRIPTION 3 basic sections compose the NA1001 the RF amplifier box the power supply and the control and metering section The RF section comprises 2 500W amplifiermodules connected through strip line combiners All the RF transistors are Mos Fet type A low pass filter with directional coupler completes the section whichis completely screened by a metal box to comply with EMIrequirements A fully planar design permits an immediate access and inspection to the 4 internal modules The power supply comprises a mains transformer whose output is rectified and filtered and a highly efficient Switch Mode Power Supply regulator The RF control section is built on one small board It performs RF AGC and protection control providing metering and an interface to the external I O port Both direct and reflected power are displayed and provided as proportional analog signals at the Remote I O port Through this port is possible as well to command the RF output power overcoming the i
11. 001010108 14 6 SERVICEMANUAL ansiada 15 6 1 SYSTEM DESCRIPTION 15 6 2 INTERNALDESCRIPTION 16 7 REPAIR AND REPLACEMENT OF DAMAGED MODULES 21 DRAWINGS NA1001 amplifier front amp top internal view D1067 1001 amplifier rear and bottom internal view D1068B 2 NA1001 general electric diagram ver 220 240Vac E0893 NA1001 general electric diagram ver 115 230Vac E0895 SRFB1KOAL2 controller and measure board diagram and layout E0894 SRFBIKSALM 48V 70A SMPS regulator module diagram and layout 1001 1000W amplifier assembly electric diagram E0857 SRFBIKOIN 2 port RF input splitter diagram and layout E0858 SRFBIKOPB 2 port RF output combiner amp LPF diagram and layout E0859 SRFB500W 500W amplifier module diagram and layout E0764 p 2 NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc RFB 1001SM 1 0kW FM POWER AMPLIFIER 1 GENERAL DESCRIPTION The NA 1001 isahighly integrated broadband solid state Mos Fet FM amplifier of 1000W rated power fitted ina4 unit 19 rack which dontrequire any specific calibration to
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13. Only if there are frequent drops of power input below 195V and consequent system stops we suggest lowering the input tap to 220V To do that the power cord must be disconnected from the AC the top cover must be removed and the transformer voltage terminals may be accessed An USA version is provided with a somewhat different transformer and general wiring see the appropriate electrical diagram and internal layout In this version some jumpers must be preset on the equipment s internal terminal board TB1 to provide 115 or 230Vac operation if not factory wired In detail these settings are Jumper wire 115Vac 230Vac JP1 TB1 A3 to A6 TB1 A3 to A4 JP2 TB1 B4 to B1 TB1 B3 to B4 Brown wire from SW1 TB1 A7 1 8 A slightly higher secondary tap nominally 114Vac is provided in these equipment to wired to the rectifier bridge instead of the regular 105V tap if the local mains is so low than the internal unregulated voltage is costantly under 130Vdc 6 4 TheSwitch Mode Power Supply regulator DO 9 VF2 D O A7 AUX 6 085 las PA o DO A4 JAO A2 1 oo NA1001 Positioning of the power supply internal terminal board NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc This module performs an efficient regulation of the raw DC input nominally 140
14. be at least 3KVA and the p 8 NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc nominal voltage is 230Vac In some countries where 1 15Vacis the norm this voltage must be internally setin the factory or by skilled people before installation While the power supply regulator accepts a wide input voltage 190 250 Vac operation near thelowerinput voltage on high impedance lines must be avoided ifthe line drops more than 10 volt at full load the low line sense circuitry may trigger an oscillating turn on turn off cycle which is very dangerous In this case adopt an external line stabilizer The nominal power input range 190 250 Vac is achieved when the primary side of the main transformer is wired to the 230 V tap Two other taps the first one slightly lower 220 V the second higher 240 V are available to adjust the input voltage range of 10 V In countries were a stable 240V is the norm itis important to set this tap on the transformer In this case the allowed voltage range window must be shifted higher to avoid a nuisance trip at occasional higher power voltage See proper section in the service section of this manual To ensure proper operation and comply with the safety regulations efficient grounding is required Use yellow green lead in the power cable The cable s neutral lead is blue Never connect the earth tothe mains neutral lead The cable connecting the NA 1001 mains input terminal block to the
15. by dust Because of the high quality materials used in their manufacture if itis installed as set forth under INSTALLATION AND USE it will not require special maintenance for quite some time A regular service routine mainly to remove internal dust is suggested over a 6 month to a year period Keep in mind that 90 of the air circulation 15 restricted to main internal ventilation channel and does not affect the components Regularly change the ventilation fan especially in higher temperature environments Change the fan every 2 years always use the same high quality ball bearing fan type After a few years of continuous service it is recommended that the apparatus be overhauled in the factory or ina specialized laboratory where the characteristics can be checked against the initial ones and recalibration can be made when needed It is also especially important that the power supply be over hauled when the apparatus has been working at high temperatures over 86 F 30 C Never change or cause the original settings to be changed when the necessary complex testing equipment and standard calibration procedures are not available 5 WARRANTY Like all NICOM s solid state equipment the NA1001 carries a two year warranty on all its components with the exclusion of the final RF power module which may be damaged by faulty output connections This warranty is void if the unit is tampered with or if failure is due to improper use
16. combiner A group of C R and L RF decoupler and dampening components are mounted on the positive supply line of each amplifier plus a small value resistor R12 and R13 for possible separate current detection of each supply leg p 19 NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc The gate bias is separately adjusted through R15 and R16 on each section Do not tamper with the factory bias preset values The full power output of the whole module exceeds 600W to provide some room for coupling losses on the combining stages of higher power amplifiers like the same NA1001 6 8 TheoutputRF power combiner LPF and coupler This module is symmetric to the input power splitter and is another printed Wilkinson coupler whose power management capability is obviously much higher than the input board In this case the power balancing resistors are high power devices whose centre connection is referred to ground through an inductor which discharges any static electricity on the anten na up to a relevant amount of power The power combiner is followed by a printed low pass filter which attenuates the harmonic products generated by the amplifiers 3 directional sample lines derive two rectified voltages proportional to the direct and reflected output power and a RF signal for external monitoring purposes 7 REPAIR AND REPLACEMENT OF DAMAGED MODULES NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc The NA1001 is a highly rel
17. operate inthe 87 5 lt 108 MHz frequency range Its compact size high efficiency wide AC range acceptance low maintenance requirements and broadbandconstruction make this amplifieridealin medium power repeaters in unattended posts in N 1 systems and as a reserve Its sturdy modular mechanical and electrical construction guarantees a high MTBF and an easy maintenance The modules are easily identifiable and inspectable with few interconnections with eachother through multi pole connectors The nominal RF output power is obtained over the full FM range with a mere 12W drive and is particularly stable against time temperature and frequency variations being ALC regulated with a front panel adjustment The output power may be varied from a minimum level to the nominal level and the frequency varied over the full FM range without retouching the drive power or any other adjustment than the ALC control The output stage has a reverse intermodulation figure which is lower than standard bipolar construction due to the all Mos Fet design and approaches that of tube equipment A simple metering and alarm section completes the amplifier permitting an easy check of the functions with few unambiguous readings Powerreadings and control are externally available on aremote port for an external controller The whole assembly is designed in accordance with the CCIR FCC and tighter international norms and conforms to the recent strict requ
18. 01 USER AND MAINTENANCE MANUAL NicomUsa nc SRFBIKSALM 48V 70A SMPS REGULATOR ELECTRICAL DIAGRAM CONTROL SECTION p 32 NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc SRFBIKSALM 48V 70A SMPS REGULATOR COMPONENT LAYOUT POWER SECTION NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc p 34 HR OBE HR HP 48V 70A SMPS REGULATOR COMPONENT LAYOUT CONTROL SECTION SRFBIKSALM NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc ELECTRICAL DIAGRAM NA1001 RF AMPLIFIER ASSEMBLY INE Ox uOu ja er 4 91 4 3nd no 3 2 35 JOLINDOK 100 dei voa OUT LA dus Az voa OUT M E 139 a 1243 HOS 6S803 HOS v9403 HOS 8S803 3SN3S Md 1438 Bs A 78 svia 3SN3S Md 3SN3S Md 13438 3SN3S NI sa NI fat ino da T0ALNDD 32 MOOS A 00883Ns JO31NOO HOS v9403 A svig Jano N NI 8100 NI 228 ino NI dB Ir ASNIGWOD 20 lt 182 25 3314I ldWv MOOS 650058325 3LIlI dS INANI NIOPSIS JAS 2 PORT RF INPUT SPLITTER ELECTRICAL DIAGRAM NA1001 USER AND MAINT
19. A1001 USER AND MAINTENANCE MANUAL NicomUsa nc Remove the amplifier cabinet from the rack after having disconnected from its rear connectors the RF input and output cables the power supply and the control cables Disconnect also the ground cable from its screw To investigate the damaged parts or to test the repair one must externally connect the removed cables and the RF output load to the amplifier assembly in a manner to allow inner inspection of the top and bottom of the unit If the latter is placed on a small stand next to the main rack the internal cables are usually long enough to allow the connections avoiding extension cables Open the bottom cover of the cabinet and remove the screen from the damaged module s if any If the damage is not immediately visible it may be helpful to measure the currents sunk by each 300W sub module amplifier To this aim a low ohmic value shunt resistor is inserted in series to the 48V power supply of the module s subsections R12 and R13 10mQ To measure the current sunk the amplifier assembly must be completely connected and powered with and without RF A sensitive RF proof digital voltmeter must be used to measure the voltage across the shunt resistors which vary from nearly 1 mV at no load to 100 mV at full power Take care most of low quality digital or analog meters are not able to do this reading because they are affected by the high RF field and their reading is completely meaningl
20. ENANCE MANUAL NicomUsa nc SRFB1KOIN va d p8328148H 007 oor SX SU Ma 13438 O oa ca md 328010 doo 102 ag ont ela O T Za fe E es 82 dio E 1 92 a Aa INANI 2 ont L3 0 2 T svia m v1 Md 31d S EEE ER 9 EE zm 2 E 8 out E out AST 607 elo 19 T Td sq _ 01 a u 1 9001 dee 15 door aa 20 I ei ru a 4 8021 A Ta 2005 EM woot 21001 128 G dog i i 1 NI sds AI AI 129 3001 vas 223 2 ino O p 36 NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc SRFBIKO0PB 2 PORT RF OUTPUT COMBINER amp LPF ELECTRICAL DIAGRAM v i n u c 5 te 0 C V Le 9 vo ut os na cc va 0 5 gt Qu 5 7716 J3 BNC 100p RS 47R 75R R2 100k 75R RA 47R cs 47p I 7 k 100 ji 1005 R9 R6 R3 c3 eep 81 47R De SD101C Y je c a 38 ue oH Hi Ja 20 ON ao u A 14 2 ND YN u d o A o o
21. GE THIS FAILUREIS NOT COVERED BY THE GUARANTEE AVOID THE USE OF TOO POWERFUL EXCITER AN INPUT POWER HIGHER THAN 20W MAY PERMANENTLY DAMAGE THE RF TRANSISTOR CAUSING COSTLY DAMAGE WHICH IS NOT COVERED BY THE WARRANTY A STABLE AND PROPERLY REGULATED 20 25W EXCITER LIKE NICOM S NT30 IS THE BEST CHOICE NA1001 driven by atypical NICOM exciter generates a very clean RF output Nevertheless if any strong RF signal coming fromnerby transmittersis coupled to the antenna it may cause intermodulation in the output transistors and generate spurs In this case a tuned output filter may be required to remove the problem It is mandatory to provide adequate ventilation to the apparatus to maintain its internal temperature as low as possible in the recommended range 41 F 77 F 5 25 C Even if the apparatus may sustain 113 F 45 C and occasionally slightly higher temperatures his life expectancy will be impaired by high temperature As general rule the life expectancy may be halved by each 50 F 10 increase in ambient temperature over 86 F 30 NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc 3 7 OPERATION Check that the antenna the subsequent power amplifier or a suitable dummy load 1s connected to the amplifier RF output Ifthe NA 1001 drives a tuned tube amplifier check that the input of the power amplifier is already tuned on the desired frequency Control that the power cords are correctly connected to the amplifier a
22. NA1001 1 0kW POWER AMPLIFIER USER AND MAINTENANCE MANUAL NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc CONTENTS 1 GENERAL DESCRIPTION 00108 3 2 TECHNICAL FEATURES u 00 4 2 1 FRONT PANEL COMMANDS AND SIGNALLING 4 2 2 THE REAR PANEL AND THE CONNECTION S 5 2 3 TECHNICALSPECIFICATIONS 6 2 4 WVOREMOTE CONTROL SPECIFICATIONS 6 3 INSTALLATION AND USKE 7 31 FOREWORD TO INSTALLATION 7 3 4 PLACINGTHEAPPARATUS 8 33 WIRING INTO THE MAINS 9 34 ANTENNA CONNECTION 9 3 57 LECONNECTION ccs L L LR 10 3 6 OTHER RECOMMENDATIONS 10 3 7 OPERATION add eS 12 3 8 POSSIBLEMALFUNCTION S 13 4 SERVICE AND MAINTENANCE 14
23. TO PREVENT ELECTRICALHAZARDS IN OPERATION AND FULLY COMPLY WITH CE EMI AND SAFETY REQUIREMENTS NEVER TOUCH THE INSIDE OF THE APPARATUS WITHOUT FIRST DISCONNECT ING IT FROM THE POWER DANGEROUS AC DC AND RADIO FREQUENCY VOLTAGES ARE PRESENT INSIDE AND BECOME ACCESSIBLE WHEN THE COVERS AREREMOVED ACVOLTAGE MA Y KILL p 7 NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc 3 2 INSTALLATION Install apparatus in a dry sheltered but well ventilated room away from dust moisture insects and vermin mice Place apparatus as close as possible to the antenna to prevent excessive power loss in the cables If this is not feasible use antenna cables of suitable cross section Room size shall be such that the apparatus can be placed in an upright position and that technical personnel can easily carry outroutine orextraordinary maintenance The minimumrecommended size 152 5m x 2m and 2 2m high when there is no other broadcasting or support equipment nearby The room must be ventilated to ensure that the inside temperature never exceeds 35 C Even if 45 Cisthe max allowed temperature itis anyway suggested not to approach to this limit This condition cannot generally be met when the exhaust cooling airis not pushed outside andis fed back into the room This 15 even truerif more than one apparatus is installed in the same location An efficient ventilation system is thus required in the room Air exchange in the room shall have a min
24. V 15 to a lower 48V 11 Being its efficiency very high very little heat is produced in the regulation process The nominal current capability of the regulator is much higher than requested and approaches 70A 48V A control I O connector on an upper daughter board permits a remote control of the regulator by the apparatus controller i e output on stand by current and voltage monitoring status prompting and alert A fast 80A semiconductor grade protection fuse is screwed on the board it may be fused by the crowbar protection in case of switching transistor damage If this happens verify the integrity of the power transistor before attempting to replace the fuse Usually something is broken causing the fuse to blow up Fixing this module in the field is very difficult if any component other than the fuse and or a power transistor failed We suggest substituting the module with a new one and sending back the damaged unit to the factory for inspection and possible repair 6 5 RF control and measure board This small board carries all the circuitry to control and protect the RF amplifier stage Let us consider its various loops Two identical buffers IC4a and IC3a insulate and amplify the direct and reflected signal detected on the RF output coupler with different gain The main direct power regulator loop is built around the subsequent IC4d op amp which compares the sensed signal with the preset power level on RT5 Adjusting
25. an the general fuses 16A are inserted on this line Limit the power absorption from this outlet to low levels i e 100W max w WARNING Setting the AC voltage for 115 or 230V operation requires to gain access to the inner of the equipment removing the top cover Be sure to remove the power cord from power to avoid direct exposure to hazardous mains voltage which are always present on the fuses and the input board even with power on switch in the off position p 5 NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc 2 3 TECHNICAL SPECIFICATIONS 1kW RF output if not otherwise specified Frequency range 87 5 108 MHz RF input power 12 W nom 15 W max RFoutput power 1000 W 0 5 dB RF input output impedance 50 Q RFinput connector N RFoutputconnector 7 8 RF monitor connector BNC Harmonic and spurious emissions 70 dBc RF monitor attenuation 54 dB typ Max total current handling capability on the auxiliary socket IA 230 Vac 100W max not fused Mains supply requirements 190 250 Vac 50 60 Hz 1900W 2500 VA Operating temperature range 0 35 C recommended 10 45 C max Dimensions notincluding the handles 19 x 7 x 21 483 177 x 535 mm See drawings Weight approx 66 Lbs 30 kg 2 4 1 0 REMOTE CONTROL SPECIFICATIONS A remote I O DB25 female connector located on the rear panel makes available 3 analog lines to permit remote control an
26. d surveillance of the equipment as detailed Pin Line Range use 1 3 21 ground common 9 Reflected Power 0 5V vs 021300Wout Zo 10kQ 4 typ 1000W 10 Forward Power 0 5V vs 0 1300Wout Zo 10kQ 4 typ E 1000W 13 Power control External RF output control 0 5V to full scale low impedance The remote I O signal and control el Tb sep e o 08 O DB25 female connector on the rear E C bulis did 99 panel NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc 3 INSTALLATION AND USE 3 1 FOREWORD TO INSTALLATION Although in most cases no special instruments are required have skilled personnel install the apparatus To make best use of the apparatus s capabilities and prevent damage to the unit comply with the recommendations throughout this manual When in doubt or if any technical problems should arise during the installation procedure NICOM strongly recommend the apparatus not be tampered with in any way by unskilled personnel and will be gladto supply qualified after sale service As arule the user should not have access to the inside of the apparatus for normal installation and use Tampering with the factory settings makes the guarantee null and void and might also affect apparatus performance causing costly damage Ww WARNING NO ADJUSTMENT OR INTERNAL PRESETTING IS REQUIRED FOR NORMAL OPERATIONS THE APPARATUS SHALL BE PROPERLY GROUNDED AND BE OPERATED WITH ALLTHE COVERS CLOSED
27. ectrum analysis is now advisable to assure no spurious products due to internal or external causes i e reverse intermodulation stage are generated NICOM wishes you successin your work and reminds you that they are always available for further information orto tackle any specific problem NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc 3 8 POSSIBLE MALFUNCIONS No LED alarm should be on during regular operation following is a listof possible malfunction causes VSWR LED on This LED turnson when the reflected output power exceeds the 70 80 W threshold In this case do notoperate the system and check antenna relevant wiring and connectors When the amplifieris connected to a successive amplifier re tune the latter s input to obtain the smallest reflected power This light should never turn on it might however flash briefly at low power when firstly tuning the input of an NA 1001 driven tube amplifier or a cavity band pass filter Temperature LED on This LED turns on when the internal temperature is excessive Reduce environment temperature and increase room ventilation In this case itis important that the hot air released by the unit be exhausted Check the regular operation of the internal ventilation fans and clean any externally applied dust filter ifany NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc 4 SERVICE AND MAINTENANCE Since NA1001 is cooled by air itis subject to clogging
28. ess WARNING great care must be paid not to accidentally short circuit the resistor leads to the ground with the voltmeter probe tips during the measurements When properly functioning at full power each module 300W subsection will sink 8 10 Amperes i e 80 100 mV across the shunt resistor The absorption must be balanced 10 around the mean value on each amplifier A lower or higher value may mean a module failure Remove the power supply cable screwed on a centre terminal in the board and the small bias cable Unscrew the input and output RF connections at the module opposite sides Carefully unscrew the RF transistor flanges from the heatsink base plate This operation if not properly done may mechanically over stress the transistor cracking the internal delicate beryllium oxide ceramic which supports the active silicon dies and determine unrecoverable damage of the device CAUTION beryllium oxide is toxic and must not be thrown with domestic refuse but in specialised toxic material disposals No special handling precaution must be paid when the transistors or power resistors are not mechanically broken apart those deriving from the handling of mechanically fragile and very costly devices If the transistor or resistor flange is broken p 22 NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc avoid touching it or the brittle white exposed internal ceramic or inhaling the dust from it Dispose of the transistor or the e
29. external board should consist of leads of adequate cross section Recommended values are 1 5 to 2 5 mm squared Do never switch the apparatus on without antenna connection even when no RF drive is on 3 4 ANTENNA CONNECTION 7 8 output connector is fitted at the back ofthe amplifier module Itis very important to check thattheantenna the connecting cables and the connectors are suitable for 1 0 KW The antenna coupler too should be capable of adequate power its input connector shall be 7 16 or 7 8 orlarger The cable connecting the amplifier and antenna will generally be of the corrugated spongy dielectric type such as a 1 2 or 7 8 celflex or flexwell Smaller cables as RG214 cannot be used The antenna shall be earthen via a copper braid of adequate cross section to prevent lightning reaching the amplifier via the antenna cable 3 5 LF CONNECTION To maximally avoid earth loops wire the modulation signal line directly on the exciter with high quality shielded and preferably balanced cable Earth the shield only on the exciter LF input p 9 NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc If balanced lines are not feasible use the highest available level the suggested NT30 exciters may easily accommodate signals at 6 or 10 dBm 3 6 OTHER RECOMMENDATIONS The ambient temperature shall range between 23 F 5 C and 86 F 30 C Itis advisable to hang a min max thermometer on the wall to display any varia
30. iable unit due to the excellent design and development done to assure the maximum reasonable working margin for each part Nevertheless with all units which work 24 hours a day for years some failures are possible especially in those environments which over stress the apparatus like hot or dusty or moist places or those subjected to wide power fluctuations or static discharges etc In the event of any failure an appropriate analysis must be done to avoid subsequent failures due to faulty ambient conditions An often underestimates cause of failure is simply a too high ambient temperature or insufficient ventilation Improving the ambient and system ventilation as suggested in the installation paragraph of this manual usually fixes the problem Other obvious causes may be dust clogging and ventilator fan failure A regular service and maintenance routine will avoid these sources of problems and we suggest changing the ventilator every two years even if no damage is visible especially at high ambient temperature If a pipe is added to extract air then an additional fan is required to help air flow In any case if the amplifier fails some work can be done on the unit to fix the problem With the appropriate spare parts most of repair may be done on site without need of special tools and often without need of any solder joint In general very little need be said about changing board components virtually all of them may be changed in few mi
31. imum flow rate of 500 metres cubed per hour or more If the apparatus is fitted in a rack system the back door of the rack cannot usually be fixed in place If a completely closed assembly is needed a suitable ventilation extraction unit must equip the system To aid air ducting an optional flange may be retrofitted on the ventilation outlet to which a ductcan be attached to convey hot air outside In this case remember that the NA 1001 internal fans are low pressure units some sort of external air extraction bloweris than imperative on the exhaust air duct Ventsinthe walls and any other openings shall be fitted with a metal grating to keep rodents out and with a dust filter Make absolutely certain that no water can seep through the vents or the air exhaust duct or antenna cable grommet and that the floor cannot be flooded during heavy rainfall If notimpedited by properairfiltering insects in some location may be conveyed in the internal heatsink accumulating on it and finally obstructing it causing theovertemperature alarm to be triggered Even moisture and or dust when contained in the airorin the room in excessive quantity may cause condensation build up in the amplifier When the system is periodically switched on and off this can trigger destructive electric arcs and short circuits and thus cause damage that is not covered by the warranty 3 3 WIRING INTO THE MAINS The NA1001 is powered by a single phase line Power capacity must
32. irements for EMI susceptance and emission This equipment complies in particular to ETSI EN300 384 and EN 300 447 Broadcast and EMI EMC standards EN60065 and EN60215 safety standards and FCC parts 73 amp 74 p 3 NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc 2 TECHNICAL FEATURES 2 1 FRONT PANEL COMMANDS AND SIGNALLING G OVER TEMP VSWR PWR ADJUST POWER Forword Pw Cy O Reflected Pw l O AR 2 O J RF MONITOR O NA1001 The frontcontrol panel carries the power on switch the control meter some alarm warning LED s anda RF monitor connector On the bottom a panel grid allows for ventilation At the RF monitor output BNC type a sample of the output power is available which is attenuated 54 dB typically i e 6 dBm 1 0 kW output Even if this output is fairly flat vs frequency one should notuse this for accurate harmonic analysis The switchable meter permits the reading of the most important operating parameters i e the forward and reflected power 1250W f s and the regulated and unregulated power supply voltage 300Vdc f s The 2 LED s light only incase of failure The meaning of these LED is summarised on the following table 2 2 THE REAR PANEL AND THE CONNECTIONS LED MEANING VSWR High RF output reflected power g
33. ll gt RF IN Notes NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc Notes NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc Notes NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc
34. nd its driver and both the units are off Before connecting to the amplifier make sure that the exciter poweris setat zero ora very low level 1W andthe frequency is correctly set Check that the exciter output signalis fed to amplifierinput then S Switch on the power on switch on the NA1001 the switch will glow red Internal blowers will start NoLED should light on No RF output power should be present 2 Properly position the meter switch to observe the RF output increasing on the amplifier 3 Switch on the power on switch on the exciter 4 raise the drive power to required level i e 10 12 W The RF output power should rise from zero to the nominal 1000 Watt if the output power adjustment is set is to maximum on the amplifier front panel NoLED should light on Asa general rule the input power must be 20 higher than the minimum level required to the full output power e g 12W if 10W are enough to obtain 1000W on the output 5 Control and note for future reference the correct reading of the operating parameters through the internal instrumentation which must indicate the following values FORWARD POWER up to 1000W REFLECTED POWER gt 50 W typ 0 20W REGULATED VOLTAGE 48V 300V meter range UNREGULATED VOLTAGE 140V 115 Someamplifiers do not permit the reading ofthe regulated and unregulated voltage on the internal meter The installation of the amplifier is thereby completed A sp
35. nternal front panel regulation 6 2 INTERNAL DESCRIPTION 500W Amp 1 Pat gt x gt 500W Amp 2 1000W AMPLIFIER MODULE power supply control bus POWER SUPPLY amp CONTROL NA1001 Block diagram NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc The NA1001 amplifier is composed by 6 internal different modules boards plus some spare components as can be seen in the drawing of the inner contents and in the General wiring diagram both comprised in this manual The power supply transformer rectifier and capacitor The Switch Mode Power Supply regulator The RF control and measure board The input RF power splitter The 500W RF power amplifier modules The output RF combiner Low Pass Filter and coupler For the detailed description of each module on the following pages always refer to the corresponding electrical diagram in the relevant section of the manual w WARNING THIS SECTION IS ONLY AIMED AT GENERAL KNOWLEDGE OF THE UNIT AND FOR THE PURPOSE OF SERVICING THE UNIT BY SKILLED PERSONNEL AS EXPLAINED IN THE PREVIOUS SECTIONS INTERNAL ADJUSTMENTS ARE NOT REQUIRED DURING NORMAL OPERATION TAMPERING WITH INTERNAL SETTINGS VOIDS THE WARRANTY MAY HARM THE APPARATUS AND JEOPARDIZE THE GUARANTEED PERFORMANCE IN ADDITION MANY MODULES ARE TOO SPECIALIZED AND DIFFICULT TO REPAIR EVEN BY SKILLED TECHNICIANS AND MUST BE REPLACED IN CASE OF
36. ntire broken module as previously described 9 Make a note of the position and the length and remove the threaded screen spacers and the board fixing screws 10 Remove the broken module and clean the supporting heatsink base plate before mounting the new one 11 Smear thin heat conductive silicon grease below the flanges of the power transistors and resistors of the new module before mounting it 12 Position the new module placing the threaded spacers and screws over the p c board avoid tightening them When all the screws are placed correctly align the transistors and resistors fixing holes and tighten the screws and spacers 13 Insert the proper screws and washers if any across the transistors and resistors and carefully tighten them in several alternate steps 14 Reconnect the power supply and bias cables to the module 15 Turn on the amplifier fully connected but without RF power with RF load connected and driver exciter off Enable the equipment with the exciter still off 16 Measure the bias current of the two transistors on the module as explained on previous paragraphs 4 and 5 They were factory adjusted to 100 mA 1mV 17 1f the currents are off the range 50 200 mA 0 5 2 mV carefully retouch the bias trimmers on the board A small clockwise rotation increases the bias current 18 Reduce the output power setting to a low value acting on the front panel power set trimmer and turn on the exciter power
37. nutes without retouching the adjustments Most of them are immediately accessible or need a minimum of dislocation of other components and plates Only the RF boards require more work RF boards are delicate modules which contain some parts as flanged power transistors and resistors which must separately be screwed on the supporting heatsink and may be easily damaged by improper handling These boards are the 500 W power amplifier modules and the RF output combiner Repairs of these modules are usually made in the factory or in a specialized laboratory if possible at all If the p c board is damaged perhaps only the costly RF active devices may be recovered Nevertheless very often this is worthless because in the case of major damage these parts are internally electrically damaged or degraded Repair of the RF modules requires too at the end of the reparation a full check of the module s working parameters in a dummy fixture or in a test assembly which are not available even in most specialized laboratories Because of this repair of the modules especially the higher power amplifiers is mostly discouraged and the broken one must be replaced by new parts with the same identical characteristics fully tested at the factory To replace the modules avoiding as much as possible to damage the new part or the old transistors if not already broken carefully follow the subsequent steps p 21 1 2 3 4 5 6 7 8 N
38. rectifier and a regulator TR5 provides the negative bias to completely disable the RF power if needed The positive regulator TR4 derives the positive 11 3V board supply from the 48V regulated line 6 6 RF power splitter The purpose of this simple board is mainly to divide the input RF drive power in two identical signals one for each power amplifier module providing a good insulation between each output port 220 dB typ 23 dB minimum on the whole FM band This is done by a Wilkinson type printed coupler followed by the balancing resistor array R21 R24 A directional coupler senses the input RF level and RTI is regulated to provide the overdrive protection circuit trip at the right maximum input level The board also supports the forward and reflected detector sensitivity trimmers whose input comes from the output board Two additional lines support the RF module bias or AGC line and the temperature sensing PTC thermistor 6 7 TheRE power amplifier modules These modules are built around a couple of Gemini type Mos fet transistors each one forming a 300W push pull amplifier Discrete Wilkinson type couplers equip both the input and the output module section doing the job of dividing and recombining the input and output signals providing a suitable insulation between the transistors A small balancing resistor is mounted on the input splitter while a much bigger resistor R14 is mounted in the output
39. t 80 100 W TEMPERATURE High internal temperature probably due to high environment temperature or failure of the ventilation system Table 1 warning LED meaning p 4 NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc The rear panel allocates the RF power and the I O ports in addition to the mains power cord and G9 2 CD mo O AUX A max RF IN fuse the grounding screw and an auxiliary AC socket on some models The power cord is not removable If itis required a longer cable than that provided in the factory roughly 2 meters long a suitable 1 5 mm sg power cord may easily replace the original one The fuse has a different rating for 115 or230Vac operation be sure to adopt the right type for your power network The Antenna output is brought out on a 7 8 connector while the inputconnectorisa N type A remote I O port is available on a SUBD 25 poles female connector Theexhaustair output opening must not be obstructed during operation wide spacing must be provided during installation to permit asustained ventilation air flow Inserting theequipmentin aclosed rack withouta suitable external air extraction system will damage the equipment and void the warranty An auxiliary IEC 320 female type power outlet is provided which is powered only when the amplifier is on to supply the exciter No fuses other th
40. this trimmer the RF output power may be varied to values different from that factory preset Never exceed a safe 1000W on RF output even if the amplifier is usually able to easily go over this limit to have some safety margin The output of ICAd constitutes AGC line which is buffered by 5 to drive the RF transistor gates Both the two sections of IC5 are in parallel to increase the current capability of the external AGC line The reflected power protection is managed by IC3c which compares the reflected sensed signal to a fixed threshold which is set to 70 80W as determined by R35 and R36 The output of IC3 adds on the internal AGC line though D14 The action of this circuit is proportional i e the output power is continuously decreased till the fraction which is reflected back no more exceeds the safe maximum level There is no RF complete switch off even with severe load mismatch Both direct and reflected signal lines are conveyed to the remote connector through insulating IOkohm resistors NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc The temperature protection on the output stage is performed by IC4b which trips when the temperature sense line crosses its preset threshold completely disabling the RF output The temperature sensor is mounted on the heatsink near the RF transistors and is constitued by a precise PTC resistors which varies its resistance accordingly to the temperature On this board a small negative
41. tion Air conditioning at 20 25 would obviously be the best solution but installation and operating costs are generally excessive Thermal isolation and efficient ventilation with a thermostat controlled blower are generally the most advantageous solution Powerfluctuation and electric discharges due to the weather or nearby industrial machinery may cause significanttrouble especially in mountain areas and in places close to industrial areas In such cases itis advisable if not indispensable to install a protector and insulating transformer or possibly anelectromechanical power voltage regulator NICOM can provide all these accessories on request Since the total cost of the plant inclusive of broadcasting equipment antenna system and installation is rather high a certain percentage of the budget should be estimated for buying and installing suitable protection and conditioning facilities as described above Depending on location the share of total cost should be around 20 30 with this expenditure however the machinery will operate under optimum conditions its useful lifespan will increase and above all the incidence of accidental breakdowns due to ambient or powertrouble will be reduced NA1001 USER AND MAINTENANCE MANUAL NicomUsa nc WARNING OPERATION WITHOUT THE ANTENNA OR WITH FAULTY ANTENNA CONNECTION MAY CAUSE DEGRADATION AND POSSIBLE DESTRUCTION OF THEFINALSTA
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