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
