300k w transmitter

Presentation on

Thales 300 kW MW transmitter

by

R.Narasimha Swamy,

Superintending Engineer, AIR, Bangalore

C o n n e c t io n o f mo d u le s in s e rie s

1

2

3

4

5

V

V

V

1

2

3

4

nV n

V n

V 2

V 1

Vo

C o n n ec tio n o f m o d u les as s em b liesin p ar allel

O u t p ut

M 1 M 1 2 8

M 1 2 9 M 2 5 5

90 O

1 2 0O ut p ut

Vse

ries

Out

put

Principle of RF power generation

TYPE SERIAL PARALLEL MIXED

O P E R A T IO N

M O D UL E VO L T A G E A D D E DSA M E C UR R E NT

M O D UL E C UR R E NT AD D EDS AM E VO L T A G E

M O D UL E VO L T A G E A NDC UR R E NT

AD D E D A ND C O M B INE D

S T A B IL IT Y W IT H O NE O RM O R E M O D UL E O UT O F

O R D ER

ST A BL EPO W E R D E C R E A SE S

UNS T AB L EPO W E R R E M A INS C O NST A NT

S T A BL E UND ER C O ND IT IO NSM AL L UNB AL A NC ED VO L T AG E

D IF F E R ENC E

D ISAB L ED M O D UL EM O D UL E F AUL T A L L O W E D

S HO R T -C IR C UITT HE NO R M AL T R ANS IS T O R

F AIL UR E M O D E

O P EN C IR C UITNE E D A D D IT IO NAL

PR O T E C T IO N

S HO R T C IR C UIT L IM IT E DNUM BE R O F F A UL T Y M O D UL E

L IM IT ED

L IM IT A T IO N HIG H V O L T AG E L INE L E NG T HL O A D VA R IA T IO N

HIG H C UR R ENTL O W IM P ED A NC E

INC R E AS E D L O S S ES

VO L T A G E ANDC UR R E NT C O M BINED

T HO M C AS T S O L UT IO N1 2 0 T O 1 6 0 M O D UL E S

IN SE R IA L1 5 0 kW

NIL2 L INES O F 1 2 8 M O D UL E S IN

S ER IA L4 0 0 kW

P HA SE VA R IA T IO N A L L O W ED F O R BID D E N A L L O W ED

Choice of combiners

Functional Blocks• High current, HT DC power supply units for powering the

MOSFETs of the PA and low voltage regulated DC power supplies for the control electronics

• RF Pilot source and RF Driver amplifier units

• Array of 255 RF Power amplifiers connected in series/parallel combination and associated control, distribution and monitoring electronics.

• RF Adaptation Unit for matching and combining the left and right RF lines

• Low pass RF Filter unit for reducing the spurious harmonics.

• Modulation Encoder for controlling the switching of all the 255 modules.

Contd.,

Functional blocks Contd.,

• Control and management electronics consisting of embedded 16-bit microprocessor, digital input/output boards, signal-conditioning circuits, fast blocking boards etc for data acquisition and overall control and supervision.

• Various types of sensors, instrumentation and associated signal conditioning electronics for monitoring the health of transmitter and sub systems.

• Interlocking and grounding arrangement for safety measure.

• Man machine interfaces for annunciation and control.

• Water-cooling (Hydraulics) for PA MOSFETS and high power rectifier diodes and sophisticated processor based ventilation system for air cooling.

• 800 kW Dummy load and associated heat exchanger.

RF 1

RF 2

EX TRF

EN CO D ER

EN CO -D ER

AM P LIF -IER

EXCI

TER

D EM ULT IP LE-X ER

P O W ERIN T ERF A C E

D IGIT A LH O LD

LA T C H

O P T OCO U-P LER

RF 1 IN

RF O UT

RF 2 IN

EX T .

M 1J 2

J 1

EM ER G EN CY M O D ULE CUT O F F

CLO C K

RF F O R P HAS E

D AUG HT ER BO ARD

M3 1

M OD U LE 1

D ED ICAT ED M O D ULE CO M M AN D

M O D U L E O N

C U T O F FJ1 5

4 S T A T EM O D U L EO N /O F F

C O M M AN D

T H

T1

T 2

REM O T ED IS T RIBUT IO N

R F 1

R F 2

D M 1

P ILO T -1

P ILO T -2

P ILO TC/O

J1 3

16

1732

J1 1

1 2J

1 2J

1 2J

16

17

R F 1

D MM 3 2

RF flow

L E F TD I S T R I B U T I O N

B O A R D

241

225240

129144

145

161176

177

193208

209

113

11797

17

161

49

4633

81

8065

SP A R E


B O A R D


B O A R D


B O A R D

R FA M P L IF IE R M O D U L E S

L E F T C H A N N E L

R I G H TD I S T R I B U T I O N

B O A R D


B O A R D


B O A R D


B O A R D

EN C O D ER

A M P L I .A S S E M B L Y

D


C


B


A

GES M O D R A C KM O D U L E S

C O M M A N D

R I G H T C H A N N E L

RA

CK

4(6

4 M

OD

ULE

S)R

AC

K 3

(64

MO

DU

LES)

RA

CK

2(64 M

OD

ULES)

RA

CK

1(64 M

OD

ULES)

D M : D ED ICAT ED M O D ULE

A M P L I FI ER M O D UL E D I S TR I B UTI O N ( 98 /0 3 0 7 A )

A M P L IF IE R B L O C K L A Y O U T

256D M

192D M

160D M

32D M

64D M

96D M

128D M

224D M

B O T T O M T O P

B L O C K S C H E M A T I C O F 3 0 0 K W T R A N S M I T T E R

T r. T r.

11 K V/ 415V750K VA

T R F -2

11K V

P O W ERT R A N S F O R M ER

P A#17M A N A GEM EN T

A N DC O N T RO L

E N C O D E RA M P L I F I E R

C I R C U I T

B L O C KM M I E X C I T E R

REM O T E M M I

R EM O T ED IS T RIB U T IO N C IR CU IT

LEF T LIN E

A D A P T A T IO N U N IT

P A # 1

H Y D R A U L ICS Y S T E M

REC T IF IER

M A INREC T IF IER

A U X IL IA R YR E C T IF IE R

M A L T A N DL O C K I N GSY ST E M

RF F ILT ER

R F C H A N G E O V E RS W IT C H

D U M M Y LO A D

M A T C H IN GU N IT

50K WM W

V E N T I L A T O R# 2

V E N T I L A T O R# 1

900K VA A VR

125 K VAD G S ET

P O W ER S U P P LYEN C LO S U R E

A M P LIF IER B LO C K

P ILO T -1 P ILO T -2S ELECT IO N B O A R D

RFC M D S

R FS IGN A L

B LO C KIN T ERN A L P O W ER S U P P LIES

VLVP O W ER

S U P P LIES

410V

LV IN P U T

ELC T R O T EC H N ICA L R A C K

F A U LTCO M M A N D

H Y D R A U L I C SY ST E MV E N T I L A T I O N SY ST E M VEN T ILA T O R

EX H A U S T

RF S IGN A LLEF T T H E

R F S IGN A LR IGH T LIN E

A M P L IF IE R M O D U L E S A S S E M B L IE S

-Vin t

330V 330V

330V

LV IN

PU

T T

OEL

ECT

ROT

ECH

NIC

AL

RACK

R FT R A N S F O R M ER

1200A

LVG

PS

EXTE

RNA

L

P A # 16 P A # 32

T R F -180 0A

800A50K W LT R O O M

T x HALLHEAT IN G

1200

A

630A

1600

A

1200

A

100A

SPAR

E

AUD

IO R

ACK

HYD

RAU

LICS

DU

MM

Y LO

AD

VEN

TILA

TO

R

FR O M O UT S ID E

F R O M E T

R A C K

Functions of distribution board Distributes the RF signal received from the RF Exciter board to 31

numbers of individual PAs used for coarse RF power generation. Routes the RF signal received from the Encoder board to the

dedicated PA module for fine control. Routes the VINT DC power supply to the individual PAs for MOSFET

H-bridge control. On command from the control system, health status of the PA

modules on the basis of presence of +330V and VINT DC power supply on the MOSFETs and forwards it to control system through 4253 card #1 by polling method.

The daughter board mounted on the distribution board decodes the 4th state command signals received from the Encoder board and distributes the command to the individual PAs after providing necessary optical isolation.

Features of PA • Designed to produce 2.34 kW of RF power under dynamic

operating conditions. • They are used as high speed RF switches working in class D

mode. Hence power conversion efficiency of these amplifiers is very high.

• Employs industry standard reliable MOSFET of reputed make in H-bridge topology as switching elements.

• During normal operation, they dissipate around 400 Watt of heat to be extracted by circulating water through their heat sink.

• Simple electronic design ensures ease of servicing.• Reliable mechanical design ensures efficient heat extraction.• Provided with ultra fast fuse to isolate the H-bridge in case

of failure of MOSFET to prevent over loading of drain power supply (+330V).

Principle of H bridge

R EL A Y(A )

+ 1 2

.+ -

G R O UND(C O M M O N)

+ -

+ 1 2

R EL A Y .

R EL A Y

R EL A Y.

R EL A Y

R EL A Y .

(A )

(C )

(B )

(D )

+ 1 2 + 1 2

.+ -

.

+ -

+ 1 2

(A ) (B )

(C ) (D )

PNP

NPN

G R O UND

+ 1 2

PNP

NPN

G R O UND

F I G UR E : R F AM P L I F I E R F UL L Q UAD BR I D G E D O P E R AT I O N

- +

C O M B IN E RT R A N S F O R M E R

O F F O N

+ 3 3 0 V

Q 1 0 1 & Q 1 0 2 Q 2 0 1 & Q 2 0 2

+ 3 3 0 V

(A ) Q 1 0 1 , Q 1 0 2 , Q 2 0 3 & Q 2 0 4 O F F Q 2 0 1 , Q 2 0 2 , Q 1 0 3 & Q 1 0 4 O N

-+

C O M B IN E RT R A N S F O R M E R

+ 3 3 0 V + 3 3 0 V

Q 1 0 1 & Q 1 0 2O N

Q 1 0 3 & Q 1 0 4O F F

Q 2 0 1 & Q 2 0 2O F F

Q 2 0 3 & Q 2 0 4O N

(B ) Q 1 0 1 , Q 1 0 2 , Q 2 0 3 & Q 2 0 4 O N Q 2 0 1 , Q 2 0 2 , Q 1 0 3 & Q 1 0 4 O F F

O F FQ 2 0 3 & Q 2 0 4

O NQ 1 0 3 & Q 1 0 4

(C ) O U T P U T W A V E F O R M S

+ V

0

+ V

T O R R O I D A LT R A N SFO R M E R

PI L O T B O A R D 2

PI L O T B O A R D 1

PI L O T C O M M A ND B O A R D

S A F ETY D EV I C EM EA S UR EM ENT B O A R D

Micro Proces s or B oard (S B C 33 0)

FA S T B L O C K I NG B O A R D( C B R )

I /O B O A R D M PL 4 2 5 3

ETH ER NET C O NNEC TI O N B O A R D (L A N)

I /O B O A R D M PL 4 2 5 3

I /O B O A R D M PL 4 2 5 5

I /O B O A R D M PL 4 2 5 5

ENC O D ER B O A R D

BACKPLANE

BOARD

Trans mitter

G96

GESBUSBOARD

E N C O D E R A M P L I F I E RC I R C U I T

VLV PO W E RS U PPL I E S

R F FI L TER

P O W E R S U P P L YE N C L O S U R E

A D A P T A T I O N U N I T

G R O U N D A N D I N T E R L O C K I N GS Y S T E M

RF EXCITER

Elec

tro

tech

nica

l Rac

k

B LO C KM M I

E X T E R N A L

R e m o te M M I

H Y D R A U L I C C I R C U I T

V E N T I L A T I O N S Y S T E M

P O W E R U N I T

D ig ita l a u dio in pu t

A n a lo ga u dio in pu t

Signal Source

RHS header current phase Sensors mounted at the output of each RF header lineLHS header current phase

VINT DC power supply voltage

From PS rack

Incoming 3, LT voltage

+330V DC PS current Hall effect sensor in PS cabinet

+330V DC PS voltage Voltage divider in PS cabinet

RHS header current Sensors mounted at the output of each header lineLHS header current

Output RF power Directional coupler

Output RF VSWR Directional coupler

Exciter RF output voltage

Sample of Exciter voltage

Functions of Encoder board

• Number of modules to be switched depends on:

Instantaneous amplitude of the modulating audio signal.

Audio attenuation level set by the user.Modulation type i.e. AM-DSB/DCC chosen

by the user.Number of faulty module in the

transmitter

Dedicated module Number

Module position

Proportionate output

1 32 5.1 0.3

2 160 4.7 0.3

3 64 3.8 0.3

4 192 3.1 0.3

5 96 2.3 0.3

6 224 1.6 0.3

7 128 1.0 0.3

8 256 (not used)

0

Modul at ion St r at egy Funct ional Ar chit ect ur e

N(t ) - N( t + 1 )

MemoryDelay

R o ta t io nC lo ck

Pro ce s s in g S t ra t e g y

5

R o ta t io n C lo ck

En v e lo pePro ce s s in g

B a n k A B R o t a t io n pro ce s s in g+ C o m pu ta t io n N( t ) - N( t+ 1 )

B a n k C D R o ta t io n pro ce s s in g+ C o m pu t a t io n N( t ) - N(t + 1 )

B a n kA B C D

R e pa rt it io n

R FPro ce s s in g

R F

S lo peProce s s in g

N (t+n )N (t)

S tandard M odulesM (1 - 124)

Envelope

RA M D P A

RA M D P B

RA M D P C

RA M D P D

Fro m co n t ro l S y s t e m ( G e s m o d) R e a l t im e t a ble o fO pe ra t io n R F M o du le s

2 x 31

2 x 31

2 x 31

2 x 31

D e d ic a t e d m o d u le s m (1-7) C lo ck M

C lo ck M

S +

S -

M UX mDis tributor

pos ition S lopeproces s ing and phas e delay

optimis er7

S lope S ign Contro l

Neg ative S lopeproces s ing and phas e delay

optimis er

3

21

4

7

3

6

6

6

1 11 08

9

9

6

M O D U L E O N

M O D ULE O N

D IR E C T IO N O FR O T A T IO N

N E X T M O D U L E T O B E S W IT C H "O F F "

N E X T M O D U L E T O B E S W IT C H "O N "

Module rotation

The next module to be switched ON is the one which has been OFF for the longest time.The next module to be switched OFF is the one which has been ON for the longest time.The principle ensures equal distribution of thermal and electrical stress over the modules.

Fault reports compiled from

• Imphal• Sri Nagar• Jodhpur• Indore

Normal faults

• PA failure• Failure of opto couplers• Failure of polling mechanism due to

problem in distribution board• Faults due to cooling

Maintenance tips• Keep transmitter free from dust and suit• Ensure proper connectivity• Air conditioning is must• Introduce surge protectors on mains• Keep a watch on the feeds and investigate the

matter immediately, in case of abnormality • Do not ignore faults which includes tripping of

the transmitter without indication

Abnormal faults

• Failure of Encoder card connectivity• Problems in daughter board• Failure of PS of driver module• Problem in VCC (PS 323, A1, +5V) of

Encoder board• Micro switch problem of KM1 and KM2

Technology

300k w transmitter