TABLE OF CONTENTS

Section                                                                                                                    Page

Description of Capabilities and Functions.                                                               2

Modes of Operation                                                                                                  3

            a) Local                                                                                                          3

            b) Remote Computer                                                                                    3

            c) Remote 422                                                                                                3

            d) Remote STD                                                                                              4

            e) Manual Operation                                                                                     5

            f) 1:2 Automatic mode without Priority                                                      6

g) 1:2 Automatic mode with Priority                                                           7

h) 1:1 Automatic mode                                                                                 8

Fig. 1  Dip Switch Locations.   S1-S5 Settings                                                        9

Fig. 2  PCB A3                                                                                                          10

Fig. 3  Remote connector J3                                                                                     11

Types of Faults                                                                                                          11

a)      N.O. and N.C. Defined                                                                           12

Priority leds and command                                                                                      12

Setting Up Current Monitoring                                                                               13

Monitoring Amplifier A current with a volt meter                                                15

Setting the DELTA voltage                                                                                      16

Fault operation                                                                                                          18

Switch Operation                                                                                                      19

Front Panel leds                                                                                                        20

Front Panel Label                                                                                                     21

Factory Settings                                                                                                         22

Notes                                                                                                                           23

Appendix A   (Computer Protocol)                                                                         24

Appendix B    (Schematics)                                                                                       25

Appendix C   (Bias Tee type)                                                                                   26

Appendix D   (Coax Switch type)                                                                            27

Appendix E    (Power supplies type)                                                                        28

LOCAL CONTROLLER – GENERAL DESCRIPTION  

DNL-5  1:2 downlink controller

Rev-A

DNL-5 INFO.doc

1)                  Capabilities and Functions

The DNL-5 is a 1:2 downlink amplifier controller.  

Each Amplifier is powered by its own power supply (24v).

The controller contains 3 LNB power supplies, 1 separate 28V switch power supply (negative common on switches), 1 logic power supply, 2 co-ax switches, 3 bias tees, low power load, Universal AC inputs.  TUV Approved.

High quality .141 Polycoat Semi Rigid cable used internally.

Amplifier current draw accessed via computer port.

Two types of fault inputs may be monitored.

      1)  Dry contact closures where polarity may be set via dip switch setting.

a.       Set S5-1 to “Off” for normally open fault input.  (Closure=fault)

b.      Set S5-1 to “On” for normally closed fault inputs. (Open =fault)

2)      Supply current being provided by the controller. (See AMPLIFIER CURRENT MONITORING SETUP  later in this document.)

Separate Fault type enables:

a.       Set S5-2 to “On” to enable dry contact fault inputs.

b.      Set S5-2 to “Off” to disable dry contact fault inputs.

c.       Set S5-3 to “On” to enable current monitoring faults

d.      Set S5-3 to “Off” to disable current monitoring faults

The DNL-5 may be used as a 1:1 controller.  (Set S4-1 to “On”)

User selectable computer protocol.

(See Computer Protocol later in this manual.  Use dip switches S1-S3….refer to Fig. 1)

Priority Selection may be used to give one amplifier preferential treatment in automatic mode over the other.

Remote Dry contact status indicators available for [A-online, B-online, C-online, Fault A, Fault B, Fault C, Manual, Automatic, Local, Remote]  Commands for [S1,S2 switches, S3,S4 switches, Manual select, Automatic select].

Front panel display for Mode settings, RF path, Amplifier Fault status, and Priority setting.

Local Mode:   Local led is lit.

            Refers to operating the controller locally.  Changing switch positions, priority selection, and selection of the control point (Locally or Remote) is accomplished via the front panel controls.

Remote Computer:   RS232/RS485 led lit.

Refers to operating the controller via the computer interface port.  Changing switch positions, priority selection, system status, along with various queries can be made via the computer port.                     

Note: Queries can be made from the computer port at any time.  In order to enter any commands via the computer port, the controller must be in Remote RS232/485 mode.

See Appendix A for computer Protocol information.

Remote 422:   422 led lit.

Refers to operating the controller via a remote panel that would be connected to the RS422 port at the rear of chassis.  The remote panel is an optional panel that may be used for remote operation that has the same appearance as the Local front panel.  The software that operates this panel is proprietary to C&M Systems.  Contact factory for availability of remote panels.

One handy local use for the 422 port is as follows.  If it is desired to lock out all front panel commands, simply place the controller into remote 422.  Since the remote front panel doesn’t exist, no commands will ever come in, and no accidental control changes can be inadvertently entered.

Remote STD: STD led lit.

Refers to operating the controller via the Remote STD port at the rear of chassis.  The indicators and commands available at this port are outlined on the Rear Chassis Interconnect page (beginning of this manual).  The indicators are always active and function during all modes.  The controller must be in Remote STD mode in order to enter a command via this port.

Note: Each indicator relay that is mounted on the main pcb has an associated led mounted on the main pcb.  A lit led says that a command is going out to the associated relay.  A command out to a relay closes the contacts on the relay.

Please Note:

Pins 1,2,3,4 are open on J6.

However, if S1 supplies a second set of position contacts on pins 7,8,9 (7-position 1 indicator, 8-indicator common, 9-position 2 indicator) on Rear chassis J1, these position contacts will show up on pins 1 and 2 on J6 (RMT STD).

Likewise, if S3 supplies a second set of position contacts on pins 7,8,9 (7-position 1 indicator, 8-indicator common, 9-position 2 indicator) on Rear chassis J2, these position contacts will show up on pins 3 and 4 on J6 (RMT STD).  indicator common is J6 pin 5.

Manual mode:  Manual led lit.

Refers to a command being entered via some user interface point of control.  No automatic switching takes place while in manual mode.  No priority leds are lit while in manual mode.  ( The exception to this is when the controller is being operated in a 1:1 automatic configuration.  While in a 1:1 automatic configuration, both priority leds are lit.)

Mode status and Priority status is saved on internal memory.  The controller will “remember’ the last status set.

1:2 Automatic mode without Priority:  Auto led lit. No Priority leds lit.

Operations in a 1:2 mode.

No manual switch commands will be accepted by the controller while in automatic mode.

Priority commands are permitted.

IMPORTANT

A FLASHING Auto led signifies that the controller cannot function in automatic.  This could be due to:

            a) Switches not being connected, (more specifically, not reporting a position.)

            b) The highest level of priority has been met.

            c) The standby amplifier has a fault condition.

Amplifier B is always considered the backup amplifier.

No priority leds are lit when in Automatic.

1:2 Operation without Priority:

To enter this mode, both waveguide switches must be in position 1.  That means that both amplifier A and amplifier C are online, with amplifier B working into a load.

In the event of a failure on amplifier A, the controller will switch S1 and S2 to position 2.  This will place amplifier B online and terminate amplifier A.  At this point, the automatic led will flash, indicating that no further action with be taken in automatic mode.

In the event of a failure on amplifier C, the controller will switch S3 and S4 to position 2.  This will place amplifier B online and terminate amplifier C.  At this point, the automatic led will flash, indicating that no further action with be taken in automatic mode.

In the event of a failure on amplifier B (the back up amplifier), the controller will do no switching.  At this point, the automatic led will flash, indicating that no further action with be taken in automatic mode.

1:2 Automatic mode with Priority:  Auto led lit.  Priority led lit.

Operations in a 1:2 mode.

While in automatic, if an amplifier has priority, the priority associated with that amplifier will be lit.  Note that the back up amplifier cannot have priority.

While in automatic mode with priority, everything from the previous section applies to the operation of automatic mode.

Here’s the difference.

If a faulted amplifier is backed up, and it is not the priority amplifier, the controller continues to function in automatic.  Should the priority amplifier fail, amplifier B changes the switches in order to backup the priority amplifier.  When the priority amplifier has been placed online, then automatic has reached then end of its cycle.

Example of automatic with priority on C:

Amplifier C has priority.

All switches are in position 1.

No faults exist.

Amplifier A fails…..S1, and S2 go to position 2…..placing amplifier B online.

Should Amplifier C fail, Then

Amplifier C fails,,,,,,S1 and S2 go to position 1, S3 and S4 go to position 2…..placing amplifier B online backing up amplifier C.

Example of automatic with priority on A:

Amplifier A has priority.

All switches are in position 1.

No faults exist.

Amplifier C fails…..S3, and S4 go to position 2…..placing amplifier B online.

Should Amplifier A fail, Then

Amplifier A fails,,,,,,S1 and S2 go to position 2, S3 and S4 go to position 1…..placing amplifier B online backing up amplifier A.

1:1 Automatic mode:  Auto led lit.  Both priority leds lit.

For 1:1 mode operations.

No manual switch commands will be accepted by the controller while in automatic mode.

Priority commands are not permitted.

IMPORTANT

A FLASHING Auto led signifies that the controller cannot function in automatic.  This could be due to:

a) Wave guide Switches not  connected, (more specifically, not reporting a position.)

            b) The standby amplifier has a fault condition

The DNL-5 controller can be used as a 1:1 controller by setting dip switch S4-1 to the “ON” position.  With this setting, only the positions of S1 and S2, along with the fault status of amplifier A and amplifier B are displayed on the front panel.  Also illuminated are BOTH priority leds.

Both priority leds being lit simply signifies that the controller is in a 1:1 mode.  There is no “priority” in the 1:1 mode per se.

The automatic operation of the DNL-5 while in the 1:1 mode is as follows:

The online amplifier (amplifier transmitting out) will be backed up by the amplifier that is being terminated.  The controller will remain in automatic mode (no blinking automatic led) as long as both amplifier are in a no fault condition.

If a failed amplifier gets backed up by the “other” amplifier, and then later recovers, it then becomes the backup amplifier and automatic resumes (automatically).

 FIG. 1

Right Side Of Main PCB.  Note Dip Switch Locations.

Pay close attention to orientation and Pin 1 on Dip Switches.

Switch 1 is located near Pin 1 on all dip switches.

S1-S3 used for Computer Protocol setup.

S4-1 “Off” for 1:2 operation.

S4-1 “On” for 1:1 operation.

S5-1: “Off” for normally open fault inputs. (closure for a fault)

S5-1: “On” for normally closed fault inputs. (open for a fault)

S5-2: “Off” ignore closure fault inputs.

S5-2: “On” Monitors fault inputs. 

S5-3: “Off” Do not monitors amplifier current levels S5-3: “Off”.

S5-3: “On” Monitor amplifier current levels for faults.  (outside “window” causes

fault)

(monitored faults effect automatic function)

FIG. 2     PCB 3……..Analog PCB.

PCB A3 is mounted on top of the right side of main PCB A1.

Types of Faults:

The DNL-5 has provisions for monitoring 2 types of fault inputs.

One type of fault is a contact closure fault input.  This is typically input from a fault relay from the amplifier (or any other device in the chain).

These fault inputs are fed into the controller through the rear chassis D-Sub type (Soc) connector J3.  Two pins are allocated for each amplifier.

FIG. 3

These fault inputs may be configured via a dip switch setting for either a “normally open” or “normally closed” fault input.

Dip switch 5 is used for this selection.

Dip switch 5 is a 3 position dip switch.

Set S5-1 to “On” for normally closed fault input.  (Open=fault)

Set S5-1 to “Off” for normally open fault inputs. (Closure =fault)

Set S5-2 to “On” in order to monitor the contact fault inputs.

Set S5-2 to “Off” in order to ignore the contact fault inputs.

Normally open fault defined:

A normally open fault input is defined by this document as a fault input that is “normally open” in a no fault condition.  When the “normally open” fault input closes, a fault is declared.  A closure causes a fault.

Normally closed fault defined:

A normally closed fault input is defined by this document as a fault input that is “normally closed” in a no fault condition.  When the “normally closed” fault input opens, a fault is declared.  These two fault pins being open (no contact with each other) constitutes a fault condition.

Priority leds and command:

IMPORTANT:  Priority leds / Priority command push button are only illuminated/active during an automatic mode of operation.

A priority command may only be entered while the unit is in automatic. 

Both Priority leds being lit identify the unit as a 1:1 controller.

In 1:2 automatic operation, either one or none of the priority status leds are on. 

Priority status is stored in EEPROM.

Current Monitoring Faults:

Setting Up Current Monitoring:

When the amplifier is ON, it should be drawing current from a supply inside the controller.  This current is monitored in such a way, that should it deviate from a specified window, a fault is declared.

See fig. 2 for PCB layout.

Setting Up the current monitoring feature:

Set Dip switch 5-3 to “ON”.  (Factory set to “On”)

This will instruct the DNL-5 to monitor the currents being drawn from the amplifiers.  This monitoring will affect automatic function.

When an amplifier operates outside its window for more than a few seconds, a fault is declared.  This fault will show up on the front panel by the associated fault led turning from green to a flashing red.

In order to set up an amplifier, a minimal amount of adjustments must be made.  These adjustments allow the DLN-5 to be used with just about any amplifier.  The adjustments are necessary because different amplifiers draw a different amount of current. 

For amplifiers that draw >325mA (More than 0.325 Amps), Go to Section 1.2.

(no need to move any jumpers if your amplifiers draw less than 325 mA. @ 24V.)

(The DNL-5 is shipped from the factory, assuming that all 3 amplifiers are going to draw less than 325 mA each.)

Section 1.1 (See fig. 2)

All that really needs to be done is, with an amplifier ON and drawing current, set it’s associated “V Adj” potentiometer to 2.5V.  This is done using potentiometers R3, R11, and R19, for amplifiers A,B,C respectively.  This voltage may be monitored on test points TP1,TP3,TP5 for amplifiers A,B,C respectively.

 Amplifier A:

With a volt meter set up between TP1 (SET 2.5V)  and GND (REF pin), measure the voltage being displayed with amplifier A drawing current.  Rotate potentiometer R3 so that the volt meter reads about 2.5V.

Setting Amplifier B:

With a volt meter set up between TP3 (SET 2.5V)  and GND (REF pin), measure the voltage being displayed with amplifier B drawing current.  Rotate potentiometer R11 so that the volt meter reads about 2.5V.

Setting Amplifier C:

With a volt meter set up between TP5 (SET 2.5V)  and GND (REF pin), measure the voltage being displayed with amplifier C drawing current.  Rotate potentiometer R19 so that the volt meter reads about 2.5V.

With an amplifier drawing current, and its V ADJ voltage set at 2.5V, the front panel led should be green.

The current being drawn by the amplifiers may be monitored using a Volt meter.  The current being drawn is transformed into a voltage that may be measured on TP2, TP4, TP6, for amplifiers A,B,C respectively.

Monitoring Amplifier A current with a volt meter:

With a volt meter set up between TP2 (CURRENT MONITOR VOLTAGE))  and GND (REF pin), measure the voltage being displayed with amplifier A drawing current.  Set the volt meter to measure VOLTS.   This allows a measurement of the current in terms of a voltage.   As an example, a measurement of  0.230 dcV may be interpreted as Amplifier A drawing 230 mA or (0.230 Amps). 

Monitoring Amplifier B current with a volt meter:

With a volt meter set up between TP4 (CURRENT MONITOR VOLTAGE))  and GND (REF pin), measure the voltage being displayed with amplifier B drawing current.  Set the volt meter to measure VOLTS.   This allows a measurement of the current in terms of a voltage.   As an example, a measurement of  0.230 dcV may be interpreted as Amplifier B drawing 190 mA or (0.190 Amps). 

Monitoring Amplifier C current  with a volt meter:

With a volt meter set up between TP6 (CURRENT MONITOR VOLTAGE))  and GND (REF pin), measure the voltage being displayed with amplifier C drawing current.  Set the volt meter to measure VOLTS.   This allows a measurement of the current in terms of a voltage.   As an example, a measurement of  0.230 dcV may be interpreted as Amplifier C drawing 270 mA or (0.270 Amps). 

Setting the DELTA voltage:

(IMPORTANT: Please note there should not be any need to adjust the potentiometer R25 (DELTA V). 

What is “DELTA V”?

The value of “DELTA V” is what sets up the window around the 2.5V.  This value set up by potentiometer R25 may be measured at TP7.   Typically, the value of this “DELT V” is around 0.5V.  It is set at the factory at 0.6.  The window may be expanded or contracted if desired.

A current monitored fault is declared when the current being monitored falls outside the “window”.  The “window” is between 2.5V - DELTA V and 2.5V + DELTA V.

Please Note that the amplifier currents are available on the computer port, but these measurements mustn’t be used for any fine measurement purposes.  The A/D converter used on the DNL-5 is an 8-bit device.  That means that each bit is worth 20 mV.  There is a 1:1 relationship between current and voltage with this application, so each bit is worth 20 mA of current.  Therefore, the measurements available on the computer interface port are to be viewed as somewhat coarse numbers only.

Current Monitoring Set up for Amplifiers that draw more than 325 mA.

Section  1.1 (See fig. 2)

For amplifiers that draw more than 325mA, it’s necessary to move the Jumpers at JP1,JP2 for amplifier A, JP3,JP4 for amplifier B, and JP5,JP6 for amplifier C. 

As you can see viewing FIG. 2, the Jumper locations have 3 pins.  The top two pins should be jumped for amplifiers drawing >300 mA (or 325mA), and for amplifiers that draw less than 300 mA (or 325mA), the bottom two pin should be jumped.

There is no need to use SW1 on A3.

 Fault operation:

When an amplifier is in a no fault condition, its associated led should be green on the front panel and the relay indicator on the remote STD port should be open.

In the event of a fault, the fault led will go red, and begin to flash on and off.  The audible alarm on the front panel will sound on and off (if the audible enable switch is placed to “ON”).  The relay fault indicator on the remote STD port will become a steady closure.

Pushing the “RESET” button on the front panel will extinguish the audible alarm, and cause the fault led to go steady state.  The fault light will always track the true status of the fault.  A blinking green led may signify that a fault had occurred, but then went away.

The response time to a closure type fault is immediate.  (keep in mind the time needed to switch a wave guide switch.)

The response time to a current fault is a few seconds.  This allows any minor variations that may occur in the amplifier current draw to take place without causing an alarm.

Switch Operation:

The DNL-5 contains two coax switches.  They have the designation of S2 and S4 on the front panel.

The two wave guide switches (not normally supplied) are external to the controller.

The S1 S2 combination of input and output switches are electrically ganged.  This means that the position commands are sent out to the 2 switches at the same time, from the same source.  Whenever the controller switches S1 to a position, the input coax switch that is internal to the controller will receive the same position command.  That is why it is necessary for the wave guide switches and the coax switches to have the same switching voltage and polarity. 

For most applications it is assumed that the operating voltage of the switches is between 20-30Vdc, with the switch common being “Negative”.  That means that the command voltage is “positive”.  The DNL-5 uses a 28Vdc supply for switch operation to reduce the effects of cable losses due to length and gauge of the switch cables being used.

Position Indicators are different.

Each of the 4 switches in the system have two position indicators (position 1 and position 2 indicators).  Each of these indicators are independently displayed on the front panel.  Under normal operation, both the input and output switches will always be in the same position.  It should be noted that for automatic switching purposes, the position indicators from the waveguide switch are used.

Should the input wave guide switch and output coax switches be in different positions, those positions will be displayed on the front panel.

All coax switches used are of the “Latching” type.  This means that the switches maintain their position in the event of the controller being turned off. 

All commands out to the switches are of a momentary nature.  A command only exists for about 0.5 seconds.   This facilitates the use of the mechanical override knobs that may be present on the switches.

All switches are 4 port devices.  When a switch has a position, then two diagonally opposite leds should be lit on the front panel at the same time.  A front panel switch display (the 4 leds), should always have 2 opposite leds lit.  Of course if the switch is not connected, then all leds should be “off”.

Also Note that there are 4 command relays on the main pcb.  Relays K1 (position 1) and K2 (position 2) are used to drive S1 (external wave guide switch) and S2 (internal coax switch).   Relays K3 (position 1) and K4 (position 2) are used to drive S3 (external wave guide switch) and S4 (internal coax switch).  There are leds mounted on the main pcb that are associated with each command relay.  A relay is receiving a command as long as the associated led is lit.

NOTE:

With all switches in Position 1, Amplifier A and Amplifier C are online.

Led Test Command:

Pressing the led test button on the front panel should illuminate all of the leds on the front panel. The Bi-colored leds will appear an orange color. (This is the led going from green to red to green very quickly).  The only Bi-colored leds on the front panel are the fault leds.  The rest of the front panel leds operate as a single color.

Note: The front panel led test command has no effect on leds mounted on the main pcb inside the controller.  Those leds indicate active commands going out to a particular relay.

Audible Alarm:

The audible alarm will sound whenever a new alarm occurs. It sounds whenever a fault led is flashing. It can be disabled by using the Audio on/off switch.  If an alarm occurs and the alarm sounds, pressing the fault reset button will turn off the alarm.

Fault Leds:

A fault led is associated with each LNB. See explanation of function earlier in this document.

Mode leds:

The mode leds  (when lit) represent the mode the controller is in at the time. Either auto or manual led should be lit at one time.  Also, only one of the remote or local leds should be lit at one time.

Front Panel Label:

The front panel area above the control area, where the local/remote, auto/manual switches are, is purposely left blank so the end user can place his own identification for the panels place in the over all system.  This can be done by using a simple label maker with an adhesive backing. 

If you don’t have a label maker, C&M Systems will make one free of charge if the exact text is supplied, and it is of reasonable physical length.

Factory Settings for pcb A1:

S1,S2,S3 are used for computer interface.

They have been set up at the factory as follows.

Address = “A”

BAUD =  9600

{} message delimiters

Check Sum check byte returned

No parity

RS485 mode

Ignore bad Checksum

No CR or LF returned

Termination resistor not engaged

Therefore, 7 bit words.

S4-1 “Off” for 1:2 operation.

S5-1: “Off” for normally open fault inputs. (closure for a fault)

S5-2: “Off” ignore closure fault inputs.

S5-3: “On” Monitor amplifier current levels for faults. 

Factory Settings for pcb A3:

The DNL-5 assumes that all amplifiers draw less than 325 mA.

Therefore all Jumpers on A3 (The top analog pcb above A1 (main pcb)) are positioned accordingly.

Delta V set at 0.6 volts.

The “2.5V” potentiometer settings were set with a current draw of 240 mA.

Appendix A

 Appendix B

Appendix C

Appendix D

Appendix E