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KN 1000
User’s Manual
Release 2.0
WARNING
To avoid risks of electrical shock or fire, only technical trained personnel should attempt procedures specified in this
manual.
WARNING
When the protective covers of any device or component connected to a 110 ÷ 240 Vac source by a power cord are
removed, voltages and currents dangerous to life may be exposed.
WARNING
Contact with 110 ÷ 240 Volts of alternating current and associated direct current and voltages can be fatal.
1 DANGEROUS 1
RISK OF ELECTRICAL SHOCK
DO NOT OPEN COVERS
CAUTION
To reduce the risk of electrical shock, do not remove the cover (or the back). Refer to trained personnel.
This installation shall be done by a qualified person and shall conform to all the local codes.
NOTICE : ALL THE SPECIFICATIONS AND TECHNICAL INFORMATION IN THIS MANUAL ARE SUBJECT TO CHANGE WITHOUT
NOTICE.
CONTENTS
1 KW VHF FM POWER AMPLIFIER ..................................................................................................................... 4
1.1 GENERAL DESCRIPTION ............................................................................................................................... 4
1.2 MECHANICAL CONSTRUCTION .................................................................................................................. 5
1.3 FRONT PANEL ................................................................................................................................................. 6
1.4 GENERAL BLOCK DIAGRAM ....................................................................................................................... 7
1.5 BLOCK DIAGRAM DESCRIPTION............................................................................................................................ 8
2 TECHNICAL SPECIFICATIONS ......................................................................................................................... 9
2.1 ELECTRICAL CHARACTERISTICS ............................................................................................................... 9
2.2 POWER REQUIREMENTS ............................................................................................................................... 9
2.3 OTHER CHARACTERISTICS .......................................................................................................................... 9
2.4 MECHANICAL CHARACTERISTICS............................................................................................................. 9
3 KN500 AMPLIFIER UNIT ................................................................................................................................... 10
3.1 GENERAL DESCRIPTION ............................................................................................................................. 10
4 100W PREAMPLIFIER STAGE .......................................................................................................................... 11
4.1 GENERAL DESCRIPTION ............................................................................................................................. 11
4.2 GENERAL ELECTRICAL SCHEMATIC ....................................................................................................... 12
4.3 COMPONENT LAYOUT ................................................................................................................................ 13
4.4 COMPONENTS PART LIST ........................................................................................................................... 14
5 250 W FM AMPLIFIER STAGE .......................................................................................................................... 15
5.1 GENERAL DESCRIPTION ............................................................................................................................. 15
5.2 GENERAL ELECTRICAL SCHEMATIC ....................................................................................................... 16
5.3 COMPONENT LAYOUT ................................................................................................................................ 17
5.4 COMPONENTS PART LIST ........................................................................................................................... 18
6 POWER SUPPLY CIRCUITS .............................................................................................................................. 19
6.1 GENERAL DESCRIPTION ............................................................................................................................. 19
6.2 GENERAL ELECTRICAL SCHEMATIC (CONTINUOS OPERATING MODULE) ................................... 20
6.3 GERAL ELECTRICAL SCHEMATIC (VOLTAGE VARIABLE MODULE) ............................................... 21
6.4 COMPONENTS LAYOUT .............................................................................................................................. 22
6.5 COMPONENTS PART LIST ........................................................................................................................... 23
6.6 SWITCHING MODULE (DB 9610-002): GENERAL ELECTRICAL SCHEMATIC.................................... 24
6.7 SWITCHING MODULE (DB 9610-002): COMPONENTS LAYOUT ........................................................... 25
6.8 SWITCHING MODULE (DB 9610-002): COMPONENTS PARTS LIST ...................................................... 26
6.9 POWER SUPPLY UNIT GENERAL SCHEMATIC ...................................................................................... 27
6.10 POWER SUPPLY UNIT LAYOUT ............................................................................................................................ 28
7 THE ALC PROTECTION BOARD ..................................................................................................................... 29
7.1 GENERAL DESCRIPTION ............................................................................................................................. 29
7.2 GENERAL ELECTRICAL SCHEMATIC ....................................................................................................... 31
7.3 COMPONENTS LAYOUT .............................................................................................................................. 32
7.4 COMPONENTS PART LIST ........................................................................................................................... 33
8 CONTROL UNIT ................................................................................................................................................... 35
8.1 GENERAL DESCRIPTION ............................................................................................................................. 35
8.2 GENERAL ELECTRICAL SCHEMATIC ....................................................................................................... 36
8.3 COMPONENTS PART LIST ........................................................................................................................... 37
8.4 CONTROL UNIT LAYOUT..................................................................................................................................... 38
9 INPUT SPLITTER AND OUTPUT COMBINER............................................................................................... 39
9.1 GENERAL DESCRIPTION ............................................................................................................................. 39
9.2 GENERAL ELECTRICAL SCHEMATIC ....................................................................................................... 40
9.3 PHISICAL REALIZATION ............................................................................................................................. 41
KN500 UNIT is briefly described in the block diagram description (see 1.5); in
particular the RF signal coming from the power splitter (located in the control unit)
drives a 100 W FM amplifier; in the input of this amplifier there is a switching circuit
that shunts on a dummy load if the sudden RF signal reaches a dangerous level.
This protection is realised using the ALC (Automatic Level Control) board.
The 100 W output signal is splitted by a 90° hybrid coupler and sent to the two
250 W FM amplifiers input.
The final amplified signal, obtained combining 250 W amplifiers output is filtered
by a low pass filter:
Note a control on the 250 W amplifier with a NTC temperature that constitutes
one ALC protection board input.
Moreover there is a directional coupler that checks forward and reflected signal.
100W FM amplifier has a switching type power supply, controlled by the ALC
(Automatic Level Control) board.
In fact Q1 MRF 317 transistor supply is realised to achieve an eventual power
output reduction, in case of troubles; this reduction is possible thanks to a switching
module with its output voltage controlled by the protection board; moreover, the
amplifier can be interdicted by the direct polarization of D1 and D2; the interdiction
voltage comes always from ALC Board 9106-134.
The amplifier is class “C” polarized, for high efficiency.
The MRF 317 technical data are the following:
- 30÷200 Mhz frequency range
- 24 Vdc voltage supply
- 100W Output power with 9 dB Minimum gain
- 60% efficiency (typical)
The general electrical scheme contains a 90° Hybrid divider (9106-132) for 250
W stages drive signals generation; this hybrid divider is external to the 100 W amplifier
board.
. WARNING: DO NOT TOUCH THE 90° HYBRID DIVIDER, IT IS
FACTORY REALISED AND CALIBRATED.
Looking at the general block diagram of chap. 1.4 (drawn also on the front panel),
each KN500 unit power supply consists of three switching modules, each delivering
28V 12A in continuous operation, and one switching modules with a variable voltage in
the range 0÷24V; these devices have a permanent current protection .
The first three are connected in parallel to supply final stages, the fourth,
controlled by ALC, supplies the preamplifier stage with a variable voltage in the range
0÷24V, this facility allows to reduce automatically the output power when this is
required.
NOTE: on the next pages two switching modules are described. Functionally they
are equal and you can find either one or the other.
The ALC protection board has to control the preamplifier supply voltage and its
output power following the priorities listed above:
A) In the starting turning on phase, the ALC protection board introduces a delay
time, factory set calibrated; this delay avoids initial too high level output power supply.
The LED “VSWR” with LED “50Ω“ lights at the beginning, indicating the
proper working of this delay circuit.
B) In normal working conditions the output power is maintained at a constant
level (factory set) even in presence of mains voltage fluctuations; when we approach to
the maximum output power the “PWR” green LED lights. This shows the proper
working of the equipment.
In practice this LED lights 50 W before the maximum output power level.
C) in presence of impedance mismatch on the antenna circuit, the output level is
reduced gradually in order to maintain the power reflected by load at a value lower than
60 W (“VSWR” red LED); in case of sudden mismatch (short circuit or cable break) an
instantaneous shut down of RFD exciter occurs for about 10 seconds, in order to allow a
gradual automatic protection intervention, this guards the power transistor safety.
The power regulation circuit, in fact, has a relative long response time; it cannot
ensures by itself a prompt intervention in case of sudden variations of reflected power.
D) If there is an excessive driven signal, the input switch activates, and this
condition is signalised by 50 Ω LED lighting; during the driver power shut down, there
is no risk of damage for the exciter because, as we described above, it is connected to a
dummy load.
E) If a fault in a 250 W module (included a total power down) occurred, AL
would reduce the output power, in order to limit the dissipation on the termination
resistor in the second hybrid coupler at about 80W, signalling this fault lighting the
“UNBAL” red LED. Although in this condition there isn’t a total service interruption
that allows a safe reduced power transmission, IT IS BETTER TO CONTACT DB
SERVICE AS SOON AS POSSIBLE.
This rack contains an automatic switch that controls the whole system power
supply.
For avoiding that turning on the general switch causes a release of the mains
contactors, there are NTC resistors, that allows a soft start in every conditions; this NTC
limits the inrush current flowing trough the filter capacitor during the first moments.
Moreover the rack contains a meter to read forward and reflected power; this
signal is taken from a temperature compensated directional coupler by means of
connection using “FWD” and “REF” plugs, selected by the user.
On the front panel there are ON/OFF indicator and power on push-button.
10 INSTALLATION
10.1 SYSTEM LAYING
A) Connect a load (50Ω antenna or dummy) to the connector located on the rear
control unit panel
B) Make sure the general switch is in on “0” position.
C) Connect an FM exciter (Pout<20W RMS) to the RF input located on the front
panel of the power control unit.
D) Check forward and reflected power for each amplifier using power control unit
meter: connect “MEAS. PLUG IN” socket to “FWD” or “REF” sockets on the amplifier
rack using the pin terminated cable; the values in Watt units can be read on the abacus
printed on the front panel of the power control unit.
In the following table the principal troubles system , the anomalies associated and
the possible solutions are listed.
-The “UNBAL“ LED lights Malfunction in one power stage Contact as soon as possible DB
service; meanwhile the
amplifier can keep on working
at reduced power
-The “VSWR“ LED lights Antenna malfunction If the indication of the forward
power doesn’t move far from
the rated value (i.e. 600W
instead of 1000W), there is an
impedance mismatch; if, instead
forward power is very low,
equalling in practice reflected
power, it is likely a break or a
short circuit in the output
coaxial cables. Though KN1000
in any case a safe operation is
assured, the radiated power will
result very low, suggesting a
maintenance intervention on the
antenna system
-The “OVERHEAT“ LED The blower does not work or The ALC board reduces
lights the room temperature exceeds automatically the output power
the maximum ratings level;
verify the blower functionality
and the room temperature; if
they are regular contact as soon
as possible DB service