INSTALLATION AND SERVICE MANUAL TRC-1P
Contents
1. 13 oax switch manual 7 pages oax switch manual 10 pages www tunwallradio com 330 995 9642 TRC 1P CONTROLLER The TRC 1P is a controller for one coax switch two transmitters one antenna and a dummy load It is compatible with Dielectric Delta Andrew ERI and MCI coax switches or any other switch with 12VDC 24VDC or 120VAC position command inputs The controller can also be used with AM RF contactors directly if the contactor is 120VAC or with pilot relays for 240VAC An alternate program is usually loaded into the PLC for use with AM contactors which can speed up transmitter changes although this is not required This controller is the same as the standard TRC 1 with the addition of plate on and off closures for both transmitters It is a PLC based coaxial switch and transmitter interlock controller Switch timing and transmitter interlocks are controlled by a NAIS FP0 C14RS programmable logic controller The PLC uses EEP ROM for program memory No backup battery is required so program loss should not be a concern even if the controller is unplugged for months or years The 24 volt power supply illuminates front panel indicators energizes DC coax switch relays and provides operating and input common voltage for the PLC The controller s AC and DC fuses are located on the rear of the unit The DC fuse is 1 2 A The AC fuse i2. when the transfer can be attempted again If the coax switch does not start to move within 2 seconds after a position change command and the switch is still in a valid position the interlock for the correct transmitter will be restored This is unlikely but might happen if the switch motor AC power connection fails FRONT PANEL SWITCH POSITION STATUS INDICATORS The coax switch position status indicator pairs and flow chart graphic indicate the transmitters signal path to antenna or load The switch position number that corresponds to main transmitter on air depends on which ports the transmitters and antenna or dummy load have been connected to A logic reverse jumper is described in the switch position tally paragraph in the connections section of the manual LOAD INTERLOCK With fan cooled or water loads the tally contacts in the load will allow the off air transmitter to run through the controller s load interlock circuit When the load is on the front panel dummy load indicator is on for testing transmitters With convection loads an external switch should be connected to the load interlock terminals If a transmitter change command is given during a load test the coax switch is protected because both transmitters will be muted FUSES The rear panel DC fuse 1 2 A is on the output of the 24V power supply The AC fuse is in series with the hot lead for the entire controller and the AC power for the coax switch Thi
3. 27 TRC 1P TRC 1 WITH PLATE ON AND OFF ADDED OCT 2010 SHEET 2 OF 2 DRAWN BY S TUNWALL TUNWALLRADIO LLC SWITCH AND REMOTE CONTROL SUCH AS BURK CONNECTIONS 50000 AND 60000 SERIES 50000 SERIES 60000 SERIES 50000 SERIES 60000 SERIES DC COMMANDS DC COMMANDS AC COMMANDS AC COMMANDS R R S S TX 1 REMOTE COMMANDS TX 2 COMMAND STATUS 0 REMOTE STATUS TX 1 O STATUS OUTPUTS STATUS TX 2 O ol DUMMY LOAD D INTERLOCK TALLY SWITCH POS 2 NORMAL TX 1 ON RELAY COIL 5 VDC TX 1 ON CLOSURE TRANSMITTER 1 MAIN TX 1 INTERLOCK TX2 INTERLOCK TRANSMITTER 2 AUX TX 2 PLATE ON TX1 PLATE OFF TX 1 PLATE ON TX 2 PLATE OFF TX 2 PLATE ON COAX SWITCH CONNECTIONS FOR FM CONTROLLERS DIELECTRIC DIELECTRIC DIELECTRIC DIELECTRIC 50000 60000 50000 60000 DELTA ANDREW MCI DC COMMANDS DC COMMANDS AC COMMANDS AC COMMANDS CONTROLLER Px weet Suh Ha SW1 POS 1 TALLY R gt R 2 o a SW1 POS 1 TALLY 6 5 16 4 SW 1 POS 2 TALLY N u 14 SW 1 POS 2 TALLY L 2 L 12 2 15 M SW1 POS 1 COMMAND 22 of eina COMMAND COM N 3
4. blower or water is This allows the transmitter not on air to be energized for load testing When the load interlock function is not being used the off air transmitter is muted Its filament and blowers should be able to operate The local key switch is not required for routine load testing If a transmitter change occurs while load testing the off air transmitter both transmitters will be muted while the switch is moving With a convection load an external switch should be connected to the load interlock terminals A switch is usually preferable to a permanent jumper so that when the site is unattended the off air transmitter is not allowed to run into the load An external load interlock switch might also be desirable with Altronic loads This is due to the nature of their tally contact operation whenever power is applied their tally contacts close and will open only if the load overheats This could allow operator error to turn on an off air transmitter While the load would theoretically not be damaged the heat from the extra transmitter and the load could cause problems in many transmitter buildings given some time As an alternative to an external load interlock switch the Altronic load could be disconnected from power when the site is unattended PLATE ON AND OFF CONNECTIONS Plate on and off closures have been added to the standard TRC 1 to make the TRC 1P Terminals TB2 1 to TB2 8 are the 4 closures The plate
5. internal jumper plugs to select control voltage The Dielectric 60000 series switch will operate from DC or 120VAC commands but the cable wiring is different Generally DC control is preferred The controller has internal jumper plugs to select DC or AC command voltage Another control option is possible with 60000 series coax switches if the control board on the switch is damaged or removed the FM controller can operate the switch by wiring directly to the 3 terminal motor the controller must be set for 120VAC commands The 60000 switch motor has one winding for CW and one for CCW Andrew Delta and MCI coax switches can be used with the controller using a modified connection chart provided as needed AUTO TRANSFER CONNECTIONS The key switch selected auto transfer will change to transmitter 2 if transmitter 1 fails and will turn on transmitter 2 To use auto transfer a transmitter 1 on signal must be provided to the controller This can be done two ways a floating contact closure closed on or a 5 volt signal capable of about 70mA 5 volts on The 5 volt terminals are connected directly to the coil of a small relay and not grounded The 5 volt relay coil has a parallel diode for back voltage suppression so polarity matters terminal 12 is positive The transmitter 1 on closure or 5 volt signal can come from the transmitter or any external device such as an RF power detector or suitable modulation monit
6. 330 995 9642 INSTALLATION AND SERVICE MANUAL TRC 1P COAXIAL SWITCH CONTROLLER Oct 2010 1 Control Remote Remote Transm Dummy Plate 0 Switch Motor Auto tr OPERATI Front p Load in Auto tr Auto tr Control Control Interco Additio Compone 50000 c 60000 c FM switch controller general 2 ler connections 3 command inputs 3 control status outputs 3 tter interlocks 3 oad connections 4 n and off connection 4 position tally connections 4 ontrol voltage 5 ansfer 10 5 6 anel status indicators 7 terlock 7 7 ansfer 7 ansfer Cont 8 schematic diagram 1 9 schematic diagram 2 10 nnection chart for 50000 and 60000 11 nal coax switches 12 nt layout
7. SW1 POS 2 COMMAND D D 29 9 5 oP RAEN FUSED 120 VAC a 3 oF P1 9 B B D NEUTRAL ANDREW 24VDC ONLY DELTA 120VAC ONLY 24V BE CORRECT FOR EVERY MODEL ANDREW REQUIRES REVERSE POLARITY HEADER MCI MAY HAVE 5V CONTROL RELAY CHANGE TO 12V OR TERMINAL NUMBERS FOR DELTA ANDREW MCI MAY NOT TRC 1P COMPONENT LAYOUT oS DC TERMINALS 24V POWER SUPPLY AC TERMINALS onean RAIL
8. ler would not transfer Tunwall Radio LLC 1312 Suffield Oaks Lane Suffield OH 44260 330 995 9642 stevetunwall tunwallradio com 8 THE INTERNAL VOLTAGE JUMPERS MUST BE IN THE CORRECT POSITIONS 24 OR 12 TRC 1P INPUT AND OUTPUT CONNECTIONS BLUE ARE TO DIELECTRIC 50000 SWITCH SEE INTERCONNECTION PAGES FOR 60000 AND OTHERS DRAWN BY S TUNWALL NC lt 3A VDC 120VAC n L FUSE T 24 VOLT POWER E N SUPPLY 1 E G DC FUSE TX2 STATUS LOCAL IND e 7 gt lt TX1 STATUS INPUT COM 0 2 TB1 4 3 5 O O O STATUS 2 9 P2 INPUT 0 OUTPUT 0 5 8 S POS 1 TALLY O O TX 1 STATUS 5 MICROSWITCHES P3 OUTPUT 1 6 ii 5 TX 2 STATUS 9 L POS 2 TALLY o
9. o 1 915 POS 1 CMD 7 1 1 Im SWITCH CONTROL INPUT OUTPUT 13 POLARITY HEADER REMOTE CONTROL 2 KISE INPUT 2 5 4 P6 N RELAY CONTACTS J SWITCH CONTROL COM 3 INPUT 3 TX 2 SEL INPUT 4 9 5 P7 AUTO T POS 2 CMD D TO SWITCH CONTROL INPUT m14 REVERSE COAX OUTPUT 3 8 SWITCH POSITIONS 10 O 2 NORMAL TRANSMITTER 13 1000 8 50 10k ON CLOSURE 7812 DIELECTRIC ETC MAINTAINED 14 ree FOR TX ON MAIN TX O 5VRELAY gt alt TX 1 AUTO READY 11 13 13 TRANSMITTER a peza TET ON RELAY COIL K4 5V gt TB1 12 8 LOAD READY IND i TARA DUMMY LOAD 8 LOAD INTERLOCK TALLY amp P T 2 15 OUTPUT 4 i TX 1 INTLK TX 1 INTLK gt COM5 17 2 K6 OUTPUT5 TUNWALLRADIO LLC O TX 2 INTLK TRC 1P ee en A O P9 TRC 1 WITH PLATE ON AND OFF ADDED OCT 2010 SHEET 1 OF 2 9 O TRC 1P PLATE ON OFF CONTROL FROM PAGE 1 GND 24 Oo AROMAT PLC EXPANSION MODULE INPUT COM OUTPUT COM O 20 21 NPUT 22 O NPUT 23 O PLATE OFF TX 1 NPUT 24 O NPUT 25 PLATE ON TX 1 INPUT 26 NPUT 27 O OUTPUT 25 PLATE OFF TX 2 OUTPUT 26 PLATE ON TX2 OUTPUT
10. off closures are momentary and operate immediately when either transmitter change command is issued The plate on closures are momentary and operate when the switch sequence is complete at the same time the transmitter interlock is restored SWITCH POSITION TALLY CONNECTIONS The controller needs to know which position the coax switch is in to operate the transmitter interlock closures and position change commands These connections are made to AMP connector pins 1 4 The controller will work with any switch port arrangement The needed logic is selected by the presence or absence of a terminal strip jumper between terminals TB1 9 and TB1 10 Tunwall Radio LLC 1312 Suffield Oaks Lane Suffield OH 44260 330 995 9642 stevetunwall tunwallradio com 4 If transmitter 1 is connected to the antenna when the switch is in position 1 no jumper is needed If transmitter 1 is connected to the antenna when the switch is in position 2 the jumper is needed If the jumper no jumper is wrong the front panel position indicator pairs will operate backward and the wrong transmitter interlock will close Note Dielectric 50000 switches have a mechanical position indicator Other switches may have a similar indicator Any switch manual should provide position port connection drawings MOTOR CONTROL VOLTAGE The controller is compatible with Dielectric 50000 series coax switches that have 12 VDC 24 VDC or 120 VAC motor control relays The controller has
11. or Circuit modifications or additions may be required Either signal will light the TX 1 PLT ON indicator on the back of the controller This indicator should be checked before turning the auto key switch on Tunwall Radio LLC 1312 Suffield Oaks Lane Suffield OH 44260 330 995 9642 stevetunwall tunwallradio com 5 Note the following transmitter 2 plate on closure is part of the standard TRC 1 which does not have complete plate on off closures This closure a duplicate in the TRC 1 could be used for transmitter 2 plate on or to control something else Auto transfer will turn on transmitter 2 with a momentary relay contact terminals TB1 19 and TB1 20 This momentary closure comes from a capacitor and relay arrangement When the transmitter 2 status indicator comes on in auto only a 1000 mfd capacitor will charge through the coil of K3 energizing the relay for about 1 second When the transmitter 2 status indicator is off the capacitor will discharge in about 30 seconds through a 10k resistor A series diode keeps the transmitter 2 status indicator pair from lighting through the coil of K3 when transmitter 1 is on the antenna K3 will not do anything unless the auto key switch is on OPERATION The two front panel pushbuttons are the local controls for selection of transmitters 1 and 2 to the antenna If the front panel pushbutton for the transmitter already on air is pushed nothing will happen A switch change command locks out the othe
12. r for the duration of the switching sequence The switching sequence is e transmitter interlock connections open 1 second delay e coax switch operation as long as it takes up to 30 seconds e interlock delay of 0 2 seconds at completion of switch movement this allows the coax switch settle mechanically e transmitter interlock s on During the transfer sequence the status indicator pair for the position being switched to will flash When the coaxial switch is moved manually the transmitter interlocks will open protecting the switch and transmitter as much as possible but this should not be done with transmitter s on The coax switch must move slightly before its position switch is activated which means that its contacts will be moved slightly under power which is not desirable If the switch is moved manually when it makes either position there will be a 0 2 second delay before the interlock s is restored The controller has terminals for remote position change commands These work exactly as the front panel pushbuttons unless the controller is in local In local only the front panel pushbuttons are active Tunwall Radio LLC 1312 Suffield Oaks Lane Suffield OH 44260 330 995 9642 stevetunwall tunwallradio com 6 FAILURE TO COMPLETE SWITCH After a switch sequence has been started if the coax switch doesn t complete its position change neither interlock will be completed The controller will then reset after 30 seconds
13. s 3A If a Dielectric 50000 switch is used the AC fuse should be about 3A For other coax switches that do not get motor power through the controller a 1A fuse could be used The coax switch or RF contactor is connected to a 9 pin AMP socket on the rear panel All other connections are made to barrier strip terminals Tunwall Radio LLC 1312 Suffield Oaks Lane Suffield OH 44260 330 995 9642 stevetunwall tunwallradio com 2 CONTROLLER CONNECTIONS Schematic drawings and interconnection charts are provided for Dielectric 50000 60000 Andrew Delta and MCI coax switches Some variations in non Dielectric internal wiring turn up occasionally so wiring should be verified if the original switch documentation is available Connections to the coax switch are on the 9 pin AMP socket All other connections are to barrier strip terminals REMOTE COMMAND INPUTS Controller terminals TB1 1 to TB1 3 are the remote position select connections Floating relay contacts are best but open collector equipment may be compatible depending on its polarity and operating voltage REMOTE CONTROL STATUS OUTPUTS The remote control status outputs terminals TB1 4 to TB1 6 are connected through diodes to the front panel status indicators The PLC used in the controller has a limited number of outputs so the two status functions are combined The remote control status outputs are compatible with most remote control systems The only requirement is that one s
14. s fuse should be about 3A with Dielectric 50000 switches The installer may choose to use larger fuses The controller s internal power wiring is 18 ga AUTO TRANSFER The optional key switch selected auto transfer will change to transmitter 2 if transmitter 1 fails To use auto transfer the controller requires a continuous signal to indicate that transmitter 1 is on described in the auto transfer paragraphs in the connections section of the manual The rear panel transmitter 1 indicator should be checked before turning the auto key switch on Tunwall Radio LLC 1312 Suffield Oaks Lane Suffield OH 44260 330 995 9642 stevetunwall tunwallradio com 7 In auto transfer iftransmitter 1 fails for 5 seconds the controller will switch to transmitter 2 If transmitter 1 fails for less than 5 seconds but comes back on the 5 second timer will reset Whenever the auto key switch is on a change to transmitter 2 whether local remote or automatic will not flash the front panel transmitter 2 status indicator pair during the change The indicators will light normally when the coax switch is in the transmitter 2 position Auto transfer may not be appropriate for all stations Failure of one power line phase might cause an unintended transmitter change if the rack power didn t drop out If the transmitter s plate on status is used to provide the on signal to the controller and the exciter IPA fails there could be nothing on air but the control
15. tate of the circuit is ground or near ground The PLC output relays cause terminals TB1 2 and TB1 3 to go near ground when a remote status indication is desired The series diodes keep the controller s front panel indicators from lighting through the remote control s pull up resistors TRANSMITTER INTERLOCKS The transmitter interlock terminals TB1 15 to TB1 18 are connected to the interlock or mute terminals of the transmitter s Older transmitters that do not have terminals designated for this purpose may have connections for remote plate off If this circuit requires a continuous closure to keep the plate on the controller s interlock terminals may be wired in series with the transmitter remote control circuit In older transmitters the interlock or remote plate off circuit may be 120VAC The PLC relays are rated for 250VAC at 2A The installer should decide whether to connect AC control circuits to the controller It is generally recommended to install DC relays in the transmitter The interlock logic normally open normally closed can be reversed with internal jumper plugs as shown on the component layout page Tunwall Radio LLC 1312 Suffield Oaks Lane Suffield OH 44260 330 995 9642 stevetunwall tunwallradio com 3 DUMMY LOAD CONNECTION The tally terminals of load should be connected to controller terminals TB1 7 and TB1 8 The PLC has been programmed to operate correctly with a dummy load contact closure when the
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