3 Channels UHF Automatic Naval Filter Combiner in DBC (T06180617)

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 User handbook

3 CHANNELS UHF AUTOMATIC NAVAL FILTER

COMBINER IN D.B.C.
(ALL CHANNELS IN DOUBLE BRIDGE CONFIGURATION)

T06180617
 T06180617-PI

Handbook Title: 3 CHANNELS UHF AUTOMATIC NAVAL FILTER

COMBINER IN D.B.C. Installation and Use Handbook

Handbook Part Number: T06180617-PI

Handbook Version: 00

Date of Issue: 25– 08 – 2009

Registrazione delle Revisioni

(Revisions Record)

ED. Data M. n° Storia delle Revisioni Approvatore Originatore

(Issue) (Date) (Change (Revisions History) (Approval (Originator)

Request) Authority)

00 25/08/2009 - EMISSION G. BORRELLO G. FRISARIO

(R&D) (Coord.)

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Copying of this document as well as any other utilization and communication of its content
are only admissible with the permission of the originator or other authorized
persons.

According to the law reserve the right of ownership of this drawing with prohibition to
reproduce it or however to notify it to compending business firm third parties without
authorization.

Via Cristoforo Colombo 29/31- 24046 Osio Sotto (BG) Italy

Tel. 035-4181900 – Fax 035-4181999
Email: telsa@telsasrl.it
Web site: www.telsasrl.it
C.S. 100.000,00 € C.F. e P.I. 02456270160
N° Reg. Imprese BG 257450/1996 N° Reg.Ec.Amm. 290917

Printed in Italy

Subject to change

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List of Abbreviations

°C degree Celsius
dB decibel
DB9 D-sub connector
dBm (or dBmW) decibel referenced to 1mW
DC direct current
DUT device under test
g gram
LED light emitting diode
MHz Mega Hertz
mm millimeters
mW milliwatt
RF radio frequency
SWR standing wave ratio
UHF ultra high frequency
V volt
VHF very high frequency
VSWR voltage standing wave ratio
W watt
Ω ohm

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TABLE OF CONTENTS

CHAPTER 1 GENERAL INFORMATIONS AND SECURITY.........................................................7

1.1 INTRODUCTION .......................................................................................................................... 7
1.2 SECURITY RULES ...................................................................................................................... 7
1.3 TEXT WARNINGS........................................................................................................................ 8
1.4 DEVICE DESCRIPTION............................................................................................................... 8
1.4 -1 Working principles............................................................................................... 8
1.4 -2 Physical description ............................................................................................ 9
1.4 -3 Components........................................................................................................ 9
1.5 REFERENCE DATA................................................................................................................... 10
1.5 -1 Electrical Specification ...................................................................................... 11
1.5 -2 Mechanical Specification................................................................................... 11
1.6 INSTRUMENTS, ACCESSORIES AND DOCUMENTS ............................................................. 12
CHAPTER 2 USE ..........................................................................................................................13
2.1 COMMANDS AND INDICATORS .............................................................................................. 13
2.2 STARTING AND PRELIMINARY OPERATIONS ...................................................................... 14
CHAPTER 3 FUNCTIONAL DESCRIPTION .................................................................................14
3.1 DIGITAL MODULE..................................................................................................................... 14
3.2 SUPPLY MODULE..................................................................................................................... 16
3.3 CIRCUITAL DESCRITPION....................................................................................................... 17
3.3 -1 Motors control functional blocks ....................................................................... 17
3.3 -2 RS422 functional block .................................................................................... 18
3.3 -3 RS232 functional block .................................................................................... 18
3.3 -4 Supply block..................................................................................................... 18
3.3 -5 CPU block ........................................................................................................ 18
3.4 EFFICIENCY TESTS.................................................................................................................. 19
3.4 -1 Insertion Loss and isolation.............................................................................. 19
3.4 -2 Return Loss...................................................................................................... 20
3.4 -3 Power Insertion Loss........................................................................................ 20
3.4 -4 In-Band Response and Tuning Time................................................................ 21
CHAPTER 4 PREVENTIVE MAINTENANCE...............................................................................21
4.1 VISUAL TEST ............................................................................................................................ 21
4.2 CONNECTOR TEST .................................................................................................................. 21
4.3 FUNCTIONAL TEST .................................................................................................................. 21
4.4 MAINTENANCE AND REPAIR .................................................................................................. 22
CHAPTER 5 INSTALLATION.......................................................................................................22
5.1 INSTALLATION RULES ............................................................................................................ 22
5.2 PRECAUTIONS AND RECOMMENDATIONS .......................................................................... 22
5.3 PROTECTIONS.......................................................................................................................... 22
5.4 SETTING FOR USE ................................................................................................................... 22
5.4 -1 Unpacking ........................................................................................................ 22
5.4 -2 Inspections ....................................................................................................... 22
5.4 -3 Installation ........................................................................................................ 23
5.4 -4 Mechanical mounting ....................................................................................... 26
5.4 -5 External harness .............................................................................................. 26
5.4 -6 Packing ............................................................................................................ 29

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5.4 -7 Storage ............................................................................................................ 29

INTERFACE_RS232_FILTER V2.0.2.7 SOFTWARE .........................................................................30
WINDOWS 2000 AND XP INSTALLATION ................................................................................................... 30
MOTOR STEPS CHECK....................................................................................................................... 32
TUNING CONTROL .............................................................................................................................. 33
RS232 PROTOCOL MONITOR ............................................................................................................ 33
SYSTEM STATE MONITOR ................................................................................................................. 34
TOOLBAR FUNCTIONS....................................................................................................................... 34
MESSAGES.......................................................................................................................................... 39
PROCEDURE FOR UPDATE SOFTWARE.......................................................................................... 39
PROCEDURE FOR CLEAN ALARM.................................................................................................... 40
PROCEDURE FOR RETUNE AUTOMATIC CAVITY FILTER ............................................................. 41
RETUNING FOR SINGLE CAVITY FILTER ..................................................................................................... 44
FAULT FINDING................................................................................................................................... 45
APPENDIX............................................................................................................................................ 46
INSTRUMENTS, ACCESSORIES AND DOCUMENTS........................................................................ 46

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CHAPTER 1 GENERAL INFORMATIONS AND SECURITY

1.1 INTRODUCTION

This guide refers to the 3 CHANNELS UHF AUTOMATIC NAVAL FILTER

COMBINER IN D.B.C. (ALL CHANNELS IN DOUBLE BRIDGE CONFIGURATION).
Scope of the guide is to give the necessary information for a correct installation, use
and maintenance of these devices.
The repair refers to substitution of modules or elementary components.

1.2 SECURITY RULES

The 3 channels UHF automatic cavity filter works with dangerous voltages: the
installation staff must carefully follow the procedures and rules described in
“CHAPTER 5”; the operational staff must carefully follow the procedures and rules
described in “CHAPTER 2” and “CHAPTER 6”; the maintenance staff must carefully
follow the procedures and rules described in “CHAPTER 4”.
Moreover, the installation, operational and maintenance staff must always respect
the following general rules:
a) do not cause intentional short circuits
b) always use the appropriate instruments to measure voltages and be sure they
have a good isolation (especially the test prods)
c) never carry out installation or maintenance by working alone, in order to receive an
immediate aid in case of accident
d) carefully read this guide before working on the automatic cavity: attempts to work
on little known devices often cause accidents
e) before starting any operation on the automatic cavity filter always check if it is fed
f) work in a well lighted place
g) put a rubber matting under your feet, opportunely dimensioned for the existing
voltages
h) use insulating gloves (for delicate works at least on the free hand)
i) if the device must be fed during an operation, be sure that all the parts usually
grounded are connected to the appropriate terminals
j) if the device must be fed during an operation, always use only one hand (in order
to avoid electric discharge through the heart
k) when the device is not fed, apply the following note on the circuit switch: “THIS
SWITCH MUST REMAIN OPENED; CLOSING OF THE SWITCH AND REMOVAL
OF THIS WARNING CAN BE AUTORIZED ONLY BY …”
l) in particular conditions, dangerous voltages can remain on the capacitors also
when the device is not fed; in order to avoid accidents, discharge and put to
ground the circuits before touching them.

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1.3 TEXT WARNINGS

In this guide the words DANGER, ATTENTION, NOTE have the following meaning:
DANGER: an operation that, if not properly carried out, can be dangerous for the life
of the staff
ATTENTION: an operation that, if not properly carried out, can be dangerous for the
staff
NOTE: an operation that requests a detailed explanation.

1.4 DEVICE DESCRIPTION

1.4 -1 Working principles

System comprising UHF Automatic Cavity Filters combined to a single antenna port
using a Hybrid Double Bridge Combiner schema.

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The automatic cavity filters are resonant cavity band pass filters. The frequency
tuning works in “remote” mode: the operative frequency information come from an
interface unit and are transformed in position information in order to tune the filter by
means of an electromechanical system.

The outputs of several filters can be connected to a single antenna to realize a

multicoupler. The combiner is capable of expansion up to 6 channels.

Any channels can be fed by power grid or batteries (21÷32VDC).

The materials used and the accurate mechanical structure make such devices stable
also for strong temperature gradients.

1.4 -2 Physical description

The filter is realized with a metallic box made of anodised aluminium light alloy of
white colour. Under the upper cover two identical resonant cavities are coupled via
3dB directional coupler; they are automatically tuned through two stepper motors and
a printed circuit board; on the back side of the box there are the connectors for the
electrical connections of the device to other units and the power switches.

1.4 -3 Components
Each channel of UHF Automatic Filter Combiner (T06990608) comprehends:
a. power supply unit
b. Control circuit board
c. Motor driver circuit board
d. front panel
e. automatic cavity filter
f. coupler directional at 3dB (3dB hybrid coupler)
g. load 50Ω
h. back panel
i. connection cables

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The automatic cavity filter is controlled via an RS-422 serial connection from the
radio. During tuning the filter provides an output to inhibit the transmitter via INHIBIT
port.

The filter provides an Alarm output via E-BIT port (External BIT). In the event that the
filter receives an invalid frequency command (e.g. Below 225.000 MHz or above
399.975MHz) the filter provide an Error (Alarm) output or on detection of loss of
communications with the T6/M7 Radio.

The filter is tuneable in 8.33 kHz, 12.5 KHz and 25 kHz steps using the ICAO (and
modified ICAO) formats.
For maintenance purposes it is possible to connect a PC to the filter to run the
diagnostic software as described in Chapter 6.

The Filter shall operate from AC power, defaulting to operation from DC power in the
event of AC power failure.

1.5 REFERENCE DATA

The reference data are the following:

Item Part No Description
3 Channels UHF Automatic Filter Combiner in d.b.c
1 T06180617
(all channels in double bridge configuration)
1 Channel of UHF Automatic Filter Combiner in d.b.c
2 T06990608 (all channels in double bridge configuration) –
Intended as spare for above.

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1.5 -1 Electrical Specification

Frequency range 225 ÷ 400 MHz (UHF)

Channel spacing ICAO 8.33 ICAO12.5 ICAO25
8.33kHz... 12.5kHz 25kHz
insertion loss (3 Channels) ≤ 2 dB
insertion loss (Single Channels) ≤ 1.5 dB
IN / OUT impedance 50 Ω
Return Loss ≥ 12 dB
Operating temperature range -20°C ÷ +55°C
Isolation: 5MHz ch. Separation ≥ 40dB
Maximum RF Power for channel 100W rms ( 400W pep )
Remote control interface
Control Interface to Radio RS422
Maintenance interface RS232
Power supply
Main 110÷230V AC, 48/62Hz
0.4A at AC 230V(±10%)
0.7A at AC 100V(±10%)
DC power supply 21÷32 VDC 2A maximum

1.5 -2 Mechanical Specification

Dimensions: 19-inch Rack Mounting, Height 5U,
Depth 620mm.
Each channel has mounted with 1U vertical
separation between each level.
Drilled for slides, Slide Mounting Faces 440mm
apart.
Fitted with carrying handles on front.
Weight (per channel): <20kg.
Colour of Front Panel: PANTONE 288 U, finish
smooth, gloss 0, painted on Aluminium Alloy EN AW
5005 (with SurTec 650 on surface).

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1.6 INSTRUMENTS, ACCESSORIES AND DOCUMENTS

The instruments, accessories and documents supplied are the following:

QUANTITY DESCRIPTION CODE FOR UHF

3 Filter combiner unit T06990608

3 Feeding T14030012
6 motor driver circuit T14040023
3 Center unit T14040024
3 Front panel T51200629
6 UHF hybrid 225-400MHz T09210605
3 LOAD 50Ω 30W T30100032
2 CONNECTION CABLE T38090020
1 Installation and maintenance instructions T06180617-PI
1 Test report ---
1 Certificate of conformity ---

The instruments and accessories that are necessary but not supplied are the
following:

DESCRIPTION QUANTITY
Network analyzer HP 8713 or equivalent 1
Attenuator 10dB 1
Load 50Ω 1
Amplifier 1
Transmitter 1
Power meter mod. HP 432 or equivalent 1
Oscilloscope double trace (50MHz) 1
Tester 20 KΩ/V 1
Aspirator 1
Bristle brush 1
Clothes 1
Solvent type: “Electro Contact Cleaner” ---
Maintenance tool case 1

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CHAPTER 2 USE

In this chapter the information and operational procedures necessary to correctly use
the UHF filters and Combiner are listed.

2.1 COMMANDS AND INDICATORS

All the commands and control indicators are positioned on the back and rear panel.
The following table lists their descriptions, functions, locations and labelling:

Nr. LABEL TYPE FUNCTION LOCATION

1 RADIO Nf connector RF to Radio Rear
2 ANTENNA Nf connector RF to Antenna Front
connection to the serial line
3 SERIAL 8-way RJ48 socket Rear
RS422
9-pin D-type female
4 RS-232 RS232 for maintenance Rear
connector
4-pin STX plug
5 DC POWER for external battery feeding Rear
(NLT4MP)
for primary power input
6 AC POWER 3-pin IEC plug Rear
connection
7 ON/OFF Switch for power supply Rear
8 COMBINER Nf connector RF to next channel Front
9 GROUND Screw for ground screw Rear
10 DC - Fuse Fuse holder (5A) protection Rear
11 AC - Fuse Fuse holder (2x1A) protection Rear
indicate the Inhibit output is
12 FAC 8-way RJ48 socket Rear
active
13 BIT 8-way RJ48 socket indicate if an alarm is active Rear
14 Display Window Frequency Display Front

9 6 5 4 3 12 13 14
2

11 7
10

Rear panel Front panel

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8
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2.2 STARTING AND PRELIMINARY OPERATIONS

Put the switch 7 on “ON”; the device goes on “TUNED” and the display shows (after
the automatically research of the mechanical zero) the frequency previously set when
the device was switched off.
< TUNED >
F=230.00MHz

CHAPTER 3 FUNCTIONAL DESCRIPTION

3.1 DIGITAL MODULE

As principal function, the digital

module generates the motors control
signals for cavity tuning. The digital
module generates the control signals
of the chosen resonant frequency;
such control signals make the motors
move and each resonant line changes
its length in order to make each cavity
to resonate at that frequency. An
optical encoder checks the reference
zero, a controller counts the steps of
the motors and sends this number to a
table of the EEPROM (written from the
supplier during the filter tuning); this
table sets the correspondence
between the resonant frequency and
the number of steps the motor must move in order to have the correct resonant line
length. Anytime the device is started, the system first repeats the zero, then goes to
the last tuned frequency.
The digital module is controlled by a central processing unit (CPU); a program
memory (FLASH EPROM) contains the necessary instructions; a non volatile
memory (EEPROM) retains the data concerning with the tuning in absence of feeding
(that’s why the system goes to the last tuned frequency when the device is started).
The digital module manages the interface with the internal modules; such interface is
executed by I/O ports by means of matching nets of the signal level.
The digital module also works as interface between the device and the operator: the
central unit periodically reads the state and the temperature of the system and shows
them on the display together with the received commands. The operations are
remote executed by a RS232 interface and the software Interface_RS232_Filter.exe.
The central unit draws the necessary informations from a serial synchronous line
RS232 @9.6KBaud.
Finally the digital module contains a voltage regulator to generate +5Vdc for the
electronics of the digital module itself.
NOTE: the software “Interface_RS232_Filter.exe” can be requested to TELSA s.r.l..
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 1 2 3 4 5

1 1

1 24Volt 5Volt
Batteria
CN9
1

Alimentatore 1

SIO_BUS
CN10
IC1 J8
IC2 ATMEGA128L JTAG Port
SPIA Batteria 1 IC6 5Volt MC74HC244
SPIA Rete LM2575 DECODER

CN12

2 2

U2
RS485 (Optional)
CPU - DATA - BUS MAX485
CHIP-SELECT-BUS

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J3

DISPLAY_RS MOTOR DRIVER 1 MOTOR DRIVER 2

L6208PD L6208PD
DISPLAY_R/W
DISPLAY_EN Enable 2
Enable 1
DB0
DB1
DB2
3 DB3 1 3
RS232
DB4
DB5
The blocks scheme of the digital module is the following:

DB6
DB7
3 RxD

2 TxD

Keyb0 P1
Keyb1
Keyb2
Keyb3

1 1 1 1

(Opzional)
J8 J10 J9 J11 Schematic
Layer: View from:

Keyb4 CAVITA' 1 CAVITA' 2 Author: G. Frisario (P&S) TELSA s.r.l.

Keyb5
Keyb6
Keyb7 Document: Schema Blocchi MODULO DIGITALE
SIZE

A4 Date 24/10/2005
1 2 3 4 5
T06180617-PI
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3.2 SUPPLY MODULE

The supply module has the function to generate the working voltages for all the
filter’s electronics. It contains a transformer, a filtering circuit and a regulating circuit.
The transformer is fed with voltages 110/220 Vac ± 10%. The filtering circuit is
connected to an external battery.
A part of the voltage necessary at the digital module to measure the existing voltage
is drawn from the regulator circuit. The regulator circuit stabilizes the voltage from
the filtering circuit at +24 Vdc to feed the transistors bridges that control the step by
step motors; this voltage is also sent to the digital module to measure the existing
voltage. The regulator circuit also contains a protection circuit for the delivered
current, which stops the stabilized voltage production in the supply module.

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3.3 CIRCUITAL DESCRITPION

3.3 -1 Motors control functional blocks

Two identical blocks, called “MOTOR DRIVER 1/2”, control the step by step motors;
each block contains an integrated that controls a motor and that is directly
controlled by the CPU. Each driver controls the motor in “chopper” mode; step
levels and duty cycle are a function of the potential drop on the series resistances of
the motors windings:
R76 = 0.5 Ω (1W) Æ Motor 1 – winding A
R77 = 0.5 Ω (1W) Æ Motor 1 – winding B
R74 = 0.5 Ω (1W) Æ Motor 1 – winding A
R75 = 0.5 Ω (1W) Æ Motor 1 – winding B
The circuital part comprehending the resistors R21, R69, R51, R49, R50, R52, the
capacitors C7, C19, the MOSFET Q1 and the comparator IC4A allows to verify if
motor 1 has reached the end of stroke position. The circuital part comprehending
the resistors R23, R70, R54, R55, R56, R57, the capacitor C8, the pMOS Q2 and
the comparator IC5A allows to verify if motor 2 has reached the end of stroke
position. The jumper J4 is used to mask the control during some particular tests and
must not be inserted.

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3.3 -2 RS422 functional block

The integrated U2 and U4 allow implementing a serial Full–Duplex Multidrop
RS422.

3.3 -3 RS232 functional block

The integrated IC3 allows implementing a serial Half–Duplex RS232.

3.3 -4 Supply block

This block feeds the control circuit board with 24 V – 4 A. Of the two tensions at the
input, the control circuit board uses the greater one.
The circuit with IC6, L2, C27 and C40 generates (from the 24 V) the 5 V necessary
to the microprocessor and to the peripherals.

3.3 -5 CPU block

The microprocessor used on the control circuit board is the ATMEGA128L (IC1)
with the following characteristics:
ARCHITECTURE → 8-bit Advanced RISC Microcontroller
EEPROM → 4 Kbyte
SRAM → 4 Kbyte
System Reprogrammable Flash → 128 Kbyte
In circuit-Program and debug → JTAG port (IEEE std.1149.1)
In-System Programming by On-chip → SPI
Speed Grades → 8 MHz
Operating Voltages → 2.7 V - 5.5 V
ADC → 8 analogical input lines
Microprocessor I/O:
AC0 – AC7 → 8bit data BUS for display
PE3 – PE5 → 3bit BUS for display control
PD2 – PD3 → RX/TX of serial RS232
PF1 – PF2 → end of stroke sensors
PE6 – PE7 → end of stroke sensors activation
PB0 – PB7 → KeyB0–KeyB7 keyboard reading;
PC0 – PC7 → DB0–DB7 data writing/reading on/from display
PD4 – PD7 / PG0 – PG1 / PA0 – PA7 → motor driver control 0/1
The microprocessor uses internal resources of memory and code; it activates the
external lines only when, at regular time steps, it verify the keys pressure, it resets
the display or receives a new frequency from RS232 (or RS422).

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3.4 EFFICIENCY TESTS

3.4 -1 Insertion Loss and isolation

• Define on the Network Analyzer the following frequency range: START=220MHz,

STOP=410MHz, then calibrate (full 2-port) by following the user guide instructions.
• Connect the Network Analyzer to the combiner and the load the free connectors.
• The cavities have been already tuned on the desired frequencies; in order to
change the resonant frequencies of the channels for the single channel using the
radio or maintenance software via RS 232 interface.

Fig. 1 Fig. 2

Fig. 3
Verify that I.L. < 2dB at the desired frequency on which the channel is tuned (see
fig. 2)
Verify that I.L. < 1,5dB at the resonance frequency f0 for single channel (see fig. 1);
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Verify that the Isolation at 5MHz separation ≥ 40dB (see fig. 3)

• Instead of a network analyzer is possible to use a signal generator and a spectrum

analyzer with a instrument setup like the following. Keep in mind to set on Max Hold
command and to sweep frequency by the signal generator in the desired band.

3.4 -2 Return Loss

Set the network analyser and connect it to the filter as previously illustrated. Verify
that the Return Loss is > 12dB over all band.

3.4 -3 Power Insertion Loss

It is necessary a signal generator, an RF power amplifier and two VSWR meters. A
typical measurement setup is shows below:

The power F1 must to be 200 W.

To evaluate power insertion loss compare the power delivered to the DUT (F1) to
the power delivered to the load (F2). Insertion Loss must to be < 2 dB.
To evaluate power return loss compare the power delivered to the DUT (F1) to the
power reflected by the DUT (R1). Return Loss must to be > 12 dB.

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3.4 -4 In-Band Response and Tuning Time

Set the network analyser and connect it to the filter as previously illustrated; repeat
measurements of paragraph .3-4.1, 3-4.2 by steps of 2,5MHz. Using a chronometer,
verify that the tuning time is ≤ 25 sec.

CHAPTER 4 PREVENTIVE MAINTENANCE

In the following table the list of the programmed maintenance actions is shown; the
table contains the suggested periodicity (M=monthly, S=semi-annual), the
requested operator level and the reference paragraph of the guide.
PERIODICITY OPERATOR LEVEL MAINTENANCE REF.
M OPERATOR VISUAL TEST 4.1
S TECHNICIAN CONNESTORS TEST 4.2
S TECHNICIAN FUNCTIONAL TEST 4.3

The necessary instruments, accessories and materials for the maintenance are:
DESCRIPTION QUANTITY
BRUSH 1
CLOTH ---
UN-OXIDATIVE SPRAY 1

4.1 VISUAL TEST

The necessary instruments, accessories and materials are: brush, cloth. Check and
clean the external sides by using a brush and a soft (and dampen if necessary)
cloth. Check the state of superficial treatments, the readability of labels and writings.
ATTENTION: do not use solvents to clean painted parts and be careful to avoid
accidentally commutation on the front panel.

4.2 CONNECTOR TEST

The necessary instruments, accessories and materials are: brush, un-oxidative

spray. Check the functionality of coupling devices. Check the cleaning of the
connectors body. Check the oxidation of contacts. If necessary remove dust and dirt
by using the brush and clean the contacts by using the un-oxidant spray.

4.3 FUNCTIONAL TEST

Check the functionality of the device as explained in paragraph 3.4. Neither

instruments, nor accessories and materials are necessary.

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4.4 MAINTENANCE AND REPAIR

The device does not need a scheduled maintenance.

In case of bad-working the device cannot be repaired on field and must be sent to
the supplier.

CHAPTER 5 INSTALLATION

5.1 INSTALLATION RULES

The device has a “RACK-MOUNTING” configuration and can be installed inside any
483mm wide structure.
The device must be connected to a primary feeling (battery or power grid).

5.2 PRECAUTIONS AND RECOMMENDATIONS

The installation must be carried out complying with the security rules, in order to save
people and structures both during the installation phase and after.
The 220V 50Hz feeding peg must be connected to a outlet having a suitable round
connection.
The fixing of the unit must be carried out in compliance with the room availability,
taking in account the necessary space to extract the filter and to allow movements of
the operator during installation, maintenance and use of the unit.

5.3 PROTECTIONS

An inversion of battery polarity does not cause damages.

In order to preserve operators, working voltages have been limited below 30V
(except, obviously, the primary input voltage).

5.4 SETTING FOR USE

5.4 -1 Unpacking
Unpack the filters following a normal procedure; only be careful to not damage the
device.
It is suggested to do it in number of at least 2 people.
Hold the package in all its parts.

5.4 -2 Inspections
After unpacking the filter, it is suggested to inspect it in order to check that none of its
part was damaged during transportation.
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In case of damages or missing parts, please send an official report to:

TELSA s.r.l.
via Cristoforo Colombo 29/31
24046 Osio Sotto (BG)
ITALY

5.4 -3 Installation
• For a correct working of the filter, the ambient temperature should not exceed
+60°C.

• Unpack each tray and the cables from their packages.

• Mount each tray in the rack looking at the correct part number and serial number;
each tray is also identified by a progressive number to make easier the mounting
(1/n,2/n…n/n).
• In Fig. 4 the 3 channels combiner schemes are shown as a reference. For N
channels systems the schema are similar; in some cases an additional very long
cable is used for the connection between channels in different racks.

Fig.4 – Cabling connection scheme

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CODE T06180617
SER.NUM XXXXXXXX
FREQ.Mhz 225÷400
Subrack 1/3

CODE T06180617
SER.NUM XXXXXXXX
FREQ.Mhz 225÷400
Subrack 2/3

CODE T06180617
SER.NUM XXXXXXXX
FREQ.Mhz 225÷400
Subrack 3/3

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CONNECTION
CABLE

CONNECTION
CABLE

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5.4 -4 Mechanical mounting

The filter is designed for a standard 5U 19” rack mounting; a vertical space of
about 168mm and a width of about 650mm are requested.

5.4 -5 External harness

The connectors to be used to connect the filter to other external units are the
following, positioned on the back panel:
Radio Frequency (RF) input connector
8-way RJ48 socket connector (RS422) serial communication
8-way RJ48 socket connector (FAC) Inhibit input power
8-way RJ48 socket connector (BIT) for alarm indication
DB9 connector (RS232) for maintenance interface
A.C. power supply connector
D.C. power supply connector (battery)
The pin functions of the DB9-RS232 connector are the following:
Pin 5 Pin 1

Pin 9 Pin 6

PIN SIGNAL DESCRIPTION

1 GND 0V
RS232. 9600 baud, 8 data bits, 1 stop bit,
2 transmit data
no parity, no handshaking (8n1)
RS232. 9600 baud, 8 data bits, 1 stop bit,
3 receive data
no parity, no handshaking (8n1)
5 GND 0V
4, 6, 7, 8, 9 - -

The pin functions of the RJ48 - RS422 interface connector are the following:

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 T06180617-PI

PIN Signal Description

1 data out (-) RS422 differential asynchronous data,
9600 baud, 8 data bits, 1 stop bit,
2 data out (+) no parity, no handshaking (8n1)
3 - not connected
4 data in (+) RS422 differential asynchronous data,
9600 baud, 8 data bits, 1 stop bit,
5 data in (-) no parity, no handshaking (8n1)
6 - not connected
7 - not connected
8 - not connected

The pin functions of the Facilities connector an 8-way RJ48 socket used for
connecting to associated parts of a system

PIN Signal Description

Open collector NPN transistor grounding output, 200mA max, n/o (via 56V
1 Inhibit
transient suppressor and 1nF to 0V)
2 - not connected
3 - not connected
4 - not connected
5 - not connected
6 - not connected
7 Ground 0V
8 - not connected

The pin functions of the BIT connector an 8-way RJ48 socket used whenever fail
filter.

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 T06180617-PI

PIN Signal Description

1 - not connected
2 E-BIT (A) closing contact relay output to provide the E-BIT (Alarm) indication
3 - not connected
4 - not connected
5 - not connected
6 - not connected
7 Ground 0V
8 - not connected

The pin functions of the AC power supply connector are the following:
A ground
B -C power grid feeding (C.A.)

The pin functions of the DC Supply connector are the following:

1+
1- 2-
2+

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 T06180617-PI

5.4 -6 Packing
Put the unit into the original package, in the same way it was arranged at the
receipt; insert into the package the list of the material and close it.

5.4 -7 Storage
The storage does not request any particular behaviour.

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 T06180617-PI

INTERFACE_RS232_FILTER V2.0.2.7 SOFTWARE

Windows 2000 and XP installation
Copy the files: Vcl50.bpl, borlndmm.dll, cc3250mt.dll in: ..\Winnt\system32.

From: Control panel / International layout / Numbers choose: none batching.

Interface_RS232_Filter (version 2.0.2.7 or next) is the application for the
control and the calibration of the motorized filters in the VHF and UHF
bands.
The functionality of the application version 2.0.2.7 is bonded to the
firmware version 1.1.3.2 or next and to the Hardware T05120410 or
T05120604.
A complete compatibility of the software is granted for the FW versions for a compatibility
index = 1 (version 1.x.x.x) for filter VHF.

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 T06180617-PI

After having powered the filter, connect the motorized filter to the serial port COM1 and
start the Interface_RS232_Filter software.

Dynamic monitoring
RS232 protocol

Function
menu bar
System
reset
Messages

Motor step
check
System state
monitor Monitoring of the
position sensors
and motors

Tuning control
Reading of the Internal
EEPROM cavity
memory in the temperature
Addr voice
System state
monitor start up
REMOTE CONTROL INTERFACE
The application allows to monitor and check the automatic cavity both in UHF and VHF band.
At the start-up of the application the software reads the hardware’s system configuration and sets
up the adequate raceway
The system has two functional modes: operating mode and calibration mode.
With the operating mode it is only possible to change the filter tuning.
In the calibration mode it is possible to verify and memorize in the EEPROM the
correspondence between motor steps and channels. Besides, it is possible to change the
set thermal compensation from the Configuration / Set Thermal Compensation.
From the same menu it is possible to activate or deactivate the operating or calibration
mode.
In order to activate the calibration mode it is necessary to deactivate the thermal
compensation from the Configuration / Set Thermic Compensation menu, which is
accessible only if the operator gets the password for the automatic cavity calibration:

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 T06180617-PI

MOTOR STEPS CHECK

In the calibration mode it is possible to control the motors by steps and towards the
desired direction. The function keys for the control realization are:
- ParkMotor Æ it puts the filter in the Park Motor position
- StepMotorONE-StepMotorZERO Æ it moves the motors step by step in an
independent way
- Motors Æ to contemporary move the motors
- Stop Æ to block the movement of the motors in any time
- CW Æ it is the direction in which the steps are increased from the stand-by position
(from the low frequencies towards the high frequencies) until a maximum of 50000 steps.
118 156
f[MHz]

PARK

STEP
50000 0
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 T06180617-PI

TUNING CONTROL
The channel is measured in MHz and can be set up in the Frequency range or as a
normalized channel referring to the relation:
F × 1000 − 108000
INT ( ) F = frequency[MHz]
8.333
The pressure of the TUNE key allows to tune the filter on the channel in correspondence
of the set frequency in the Frequency or Channel range.

RS232 PROTOCOL MONITOR

If the serial port COM1 results opened at the start-up of the application
“Interface_RS232_Filter”, than the protocol monitor will have the following aspect to
indicate that the connection to the filter is on:

If COM1 port is busy or not working, the signal RS232 will be red coloured:

If the serial port is free, than there is no communication with the filter (because the filter is
not powered or is not correctly connected to the computer serial port; the serial port can be
set up between COM1 and COM5) and the monitor will look like:

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 T06180617-PI

SYSTEM STATE MONITOR

The monitor of the system identifies both the position of the motors and the channels on
which the filter is tuned.

TOOLBAR FUNCTIONS
All the available functions can be started up by the menus as listed below:

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 T06180617-PI

- Exit Menu: to exit from the application

- EEPROM Menu:
o Read EEPROM: put into the Addr field the address of EEPROM (from 0x000
to 0xFFF); it is possible to read the memorized value in the EEPROM and on the
display
o Write EEPROM: to memorize the value, in Val, to the address in Addr (only in
calibration mode)

o Write Channel: to memorize the correspondence between the number of

steps and the chosen channel in Frequency range (only in calibration mode)

- Menu Utility:
o Downloads: to update the firmware of the electronic control card (only in
calibration mode)
Create BIN file: transform the filled file from HEX to binary format

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 T06180617-PI

Downloads: load the binary file into the microprocessor

Read_EEPROM: to read and save the EEPROM in the apparatus
Write EERPOM: to update the EEPROM memory in the apparatus
where are the filter calibration data.

- Password: to access to the calibration functions, firmware update and EEPROM memory
writing.

- Configuration:
o Preset System: to set UHF or VHF filter band

o Read system configure: to

read the system hardware
configuration
Hardware version
Firmware version
Product code
Serial Number
Firmware Part Number
Manufacturer: Telsa Srl
Checksum: for the control of the

36
 T06180617-PI

firmware correctness

o Set PID: EEPROM writing of the product ID (only in calibration mode)

o Set Thermal parameter: to set the thermic compensation parameters and the
calibration mode

[T0;T1]: space where the thermic compensation is off .

If T0= T1=0 the compensation is on in all the
temperature space between [-10°C ; +55°C]
Ttarature: at this temperature the laboratory calibration was made
Tactual: internal temperature of the sensor
Factor scale Motor0/1: angular coefficient for the calibration
right line (not supported)
Enable Compensation: to activate or deactivate the calibration

37
 T06180617-PI

mode and the thermic compensation

Write Param.: to make effective the changes made

o Serial line configuration: for the serial port selection COM1-COM5.

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 T06180617-PI

MESSAGES
System messages are showed in the Status Window:

The Temperature field shows the system internal temperature on which the thermal
compensation is conducted.

PROCEDURE FOR UPDATE SOFTWARE

Step 1) Disconnected MARC connector from the filter;
Step 2) Connect RS232 from filter to the PC on COMx (prefer COM1 )

Step 3) Run Interface_RS232_Filter (software for maintenance cavity filter T18010008);

Step 4) open Configuration Menu and Serial line configuration and select a COMx

Step 5)copy main_T18030013_v1132.hex in directory of the software Interface_RS232_Filter

39
 T06180617-PI

Step 6) Open Menu Utility and in Create BIN file menu transform the file
main_T18030013_v1132.hex from HEX to binary format pushed Go button.

Step 7) Open Downloads menu for load the binary file into the microprocessor

Step 8) Push Start button

Step 9) Push Start button another time and wait the completed downloads.
Step 10) Connect MARC connector on R6

PROCEDURE FOR CLEAN ALARM

Step 1) Disconnected RS422 connector from the filter to the radio;
Step 2) Connect RS232 from filter to the PC on COMx (default COM1 )

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 T06180617-PI

RS485 RS232

Step 3) Run Interface_RS232_Filter (software for maintenance cavity filter T18010008);

Step 4) open Configuration Menu and Serial line configuration and select a COMx
Step 5) Clean Alarm
Write 00 value in EEPROM at the address 000 and 400

Addr = 000 Val = 00

Addr =400 Val = 00

Step 6) Reset System

PROCEDURE FOR RETUNE AUTOMATIC CAVITY FILTER

Step 1) Turn on the Automatic Cavity filter;
Step 2) Disconnected MARC connector from the filter;
Step 3) Connect RS232 from filter to the PC on COMx (prefer COM1 )

41
 T06180617-PI

Step 4) Run Interface_RS232_Filter (software for maintenance cavity filter T18010008);

Step 5) open Configuration Menu and Serial line configuration and select a COMx

Step 6) CALIBRATION FILTER

To access the calibration must log in calibration and have the password.
Utility menu / password to enter the password and then press enter

If the password is correct, you have write access to memory EEPROM par storing calibration
table.
If the StepMotor buttons are disabled as in the following:

Configuration menu / Set Thermic Parameter disable the thermal compensation and push
button Write Parameter

42
 T06180617-PI

As a first step must insert the number of steps that you want to do to the engine. To this
should be written at the engine that you want to move a certain value and select the button
StepMotorONE if we want to move the engine or a StepMotorZERO if it wants to move else.
For single cavity filter with one motor control, you have only MOTOR ZERO control.

- CW Æ it is the direction in which the steps are increased from the stand-by position
(from the low frequencies towards the high frequencies) until a maximum of 32000 steps.

118 [225] 156 [400]

f[MHz]

CW PARK CCW

STEP
50000 0

To calibrate the filter must operate on two engines making him do the steps in one direction
or the other (CW or CCW) in order to obtain the desired filter.
Once formed the mask filter as specified by the frequency of testing should be saved. For this
menu EEPROM / Write Channel stores it in memory Microprocessor steps at the frequency

43
 T06180617-PI

written in the Channel. By pressing the arrow top/down, set the channel to the next store and
repeat the calibration procedure to form the masks to the new frequency.

NOTE: storing frequency is permitted only in the multiple frequencies 0.5MHz [for UHF
2.5MHz] set through the top/down arrow.
Retuning for single cavity filter
Detuning freal< frequest for single cavity filter

Reduce the total step e.g. 10 steps (CCW)

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 T06180617-PI

Detuning freal> frequest for single cavity filter

In this case is necessary increase the total step e.g. 10 steps (CW)
To get an accurate calibration reduce the number of approximations for
next step.

FAULT FINDING

Defection Cause What to do

Remove the motor alarm. Look to the
The motor or its
Software user manual. If the motor alarm
cabling cable is
will be not fixed than contact the supplier
The filter goes on damage
(Telsa)
<MOTOR ALARM>
Remove the motor alarm. Look to the
on display
The optoisolator or Software user manual and try again. If
its cable is damage the motor alarm will be not fixed than
contact the supplier (Telsa)
The filter is switched
off (look at the green Switch on the filter
The filter doesn’t power LED)
respond Change the fusible
One of the three
DC fuse at 5A
fusible are burned
AC fuses at 1A
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 T06180617-PI

The filter doesn’t

Synchronization or Control the connection between the filter
respond to the radio
communication and the radio by RS422 (SERIAL) and
commands
problem reset the filter
<COM ALARM>
The filter tunes the Connect rightly the RF cables to the
Maybe the RF
radio frequency but filter. Retune the filter via RS232
cables to the filter
the radio show the interface software for maintenance (see
are not connected
VSWR alarm CHAPTER 4)
The power supply
The back-up battery unit of the filter
Contact the supplier (Telsa)
goes fast low doesn’t work
correctly
For any other kind of defetions Contact the supplier (Telsa)

APPENDIX

INSTRUMENTS, ACCESSORIES AND DOCUMENTS

The supplied accessories and documents are the following:

QUANTITY DESCRIPTION CODE FOR UHF

1 Filter Unit T06180617

1 Single channel T30102251
1 Center unit board T14040024
3 Motor driver board T14040023
1 Front panel T51200629
1 Installation and maintenance instructions T06186017-PI
1 Software Interface_RS232_Filter.exe v. 2.0.2.7 T18010008-SW
1 Firmware rev 1.1.3.2 T18030013-FW
1 Test report ---
1 Certificate of conformity ---

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 T06180617-PI

The instruments and accessories those are necessary but not supplied are the following:

DESCRIPTION QUANTITY

Network analyzer HP 8713 or equivalent 1

Attenuator 10dB 1

Load 50Ω 1

Amplifier 1

Transmitter 1

Power meter mod. HP 432 or equivalent 1

Analogical oscilloscope double trace (50MHz) 1

Logical states analyzer 16 channels 1

Tester 20 KΩ/V 1

Aspirator 1

Bristle brush 1

Clothes ---

Solvent type: “ELECTRO CONTACT CLEANER” 1

Maintenance tool case 1

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