Dansk Radio AS TU 4015 Service manual

c OPERATING AND SERVICE MANUAL
TU4015
,.
ANTENNA TUNER
c
c
DOCUMENT NO. 210641-001 ISSUE 90-07
c·

All RIGHTS RESERVED.
NO PART OF THIS MANUAL MAY BE REPRODUCED BY ANY
METHOD OR MANNER, NOR TRANSMITTED, NOR TRANSLA-
TED INTO A MACHINE LANGUAGE WITHOUT THE SPECIFIC
WRITTEN AUTHORIZATION OF DANSK RADIO AS.
THIS MANUAL, OR PARTS HEREIN, MUST NOT BE SHOWN
TO COMPETITORS OR OTHER PARTIES NOT HAVING LEGITI-
MATE CLAIM OF ACCESS TO SAME.
The information given in this manual at the time of publication is valid. However, the products
ore, as a consequence of DANSK RADIO's continuous research and development, subject to
alteration without obligation of prior notice.
I. -
DK-2630 Taastrup,
Dansk Ra. dio AS . ~:x~dariosdk.
· ~ Telefax [phone]
-

c
SAFETY SUMMARY
The following general safety precautions must be observed during all
phases of operation, service, and repair of this equipment. Failure
to comply with these precautions or with specific warnings elsewhere
in
this manual violates safety standards of design, manufacture, and
intended use of the equipment. Oansk Radio AS assumes no liability
for the customer's failure to comply with these requirements.
GROUND THE EQUIPMENT
To minimize shock hazard, the equipment chassis and cabinet must be
connected to an electrical ground. The equipment is equipped with a
three-conductor ac
power socket. The power cable must either be plug-
ged into an approved three-contact electrical outlet or used with a
three-contact to two-contact adapter with the grounding wire {green)
firmly connected
to an electrical ground (safety ground) at the po-
wer outlet.
DO NOT OPERATE IN AN EXPLOSIVE ATMOSPHERE
Do not operate the equipment in the presence of flammable gases or fu-
mes. Operation of any electrical equipment in such an environment con-
stitutes a definite safety hazard.
KEEP AWAY FROM LIVE CIRCUITS
Operating personnel must not remove equipment covers. Component repla-
cement and internal adjustments must be made by qualified maintenance
personnel.
Do not replace components with power cable connected. Under
certain conditions, dangerous voltages may exist even with the power
cable removed. To avoid injuries, always disconnect power and dischar-
ge circuits before touching them.
i

i i
SAFETY SUMMARY (continued)
DO NOT SERVICE OR ADJUST ALONE
Do not attempt internal service or adjustment unless another person,
capable
of rendering first aid and resuscitation, is present.
DO NOT SUBSTITUTE PARTS OR MODIFY EQUIPMENT
Because of the danger of introducing additional hazards, do not in-
stall substitute parts or perform any unauthorized modification to
the equipment.
DANGEROUS PROCEDURE WARNINGS
Warnings, such as the example below, precede potentially dangerous
procedures throughout
this manual. Instructions contained in the warn-
ings must
be follm'led.
WARNING I
Dangerous voltages, capable of causing death, are present in
this equipment. Use extreme caution when handling, testing,
and adjusting.
0

c
TABLE OF CONTENTS
Section
Page
1 GENERAL INFORMATION ....................................... 1-1
1.1
Introduction ......................................... 1-1
1.2 Safety Considerations
................................ 1-1
1.3 Description .......................................... 1-1
1.4 Accessories Supplied
................................. 1-2
1.5 Accessories Available
................................ 1-2
1.6
Specifications ....................................... 1-3
2
INSTALLATION .............................................. 2-1
2.1
Introduction ......................................... 2-1
2.2
Initial Inspection ................................... 2-1
2.3 Storage
.............................................. 2-1
2.4 Repacking
for shipment ............................... 2-2
2.5 Mounting information
................................. 2-2
2.6 Power Requirements ................................... 2-2
2.7 Fuses
................................................ 2-5
2.8 Control Cable ........................................ 2-5
2. 9 Contro1 Socket
Jl. ................................... 2-5
2.9. 1
Mains 1ines ................................... 2-5
2.9.2 Data lines .....................•.............. 2-6
2.9.3
Assemb 1i ng the Contro1 p1 ug ................... 2-6
2.9.4 Final protection of Control Connector ......... 2-6
2.9. 5
Tx Connector .................................. 2-6
2.9.6 Assembling the Tx connector ................... 2-6
2.9.7 Final protection of Tx connector .............. 2-6
.<(''·
I
2.9.8 Antenna Stud .................................. 2-7
2.10 Installation Check-out ............................... 2-7
3
OPERATION ................................................. 3-1
3.1
Introduction ......................................... 3-1
3.2
The ATU control system ............................... 3-1
3.3 Front Panel Features ................................. 3-1
3.4
Power/Warm-up ........................................ 3-1
3.5
Initial Conditions SE4010 ............................ 3-1
3.6 System Initial Conditions ............................ 3-1
3.7
Self Test ............................................ 3-2
3.8 Switch meter
......................................... 3-4
3.9
Tx on ................................................ 3-4
3.10 Introduction to tuning ............................... 3-4
3.10.1 The tuning strategy ........................... 3-4
c
TU4015/Doc. no. 210641-001
iii

3.10.2 Example of manual tuning with a Type 1
configuration ................................. 3-5
3.10.3 Example of manual tuning with a Type 2
configuration ................................. 3-6
3.10.4 Elements available ............................ 3-7
3.10.5 Automatic Narrow Band tuning .................. 3-7
3.11 Operational
Status/error messages .................... 3-8
3.12 Introduction
to the Program Function ................. 3-8
3.12.1 Self Test ..................................... 3-10
3.12.2 Antenna Tuner memory programming .............. 3-10
3.12.3 Antenna Tuner memory clearing ................. 3-12
3.12.4 Broad Band select ............................. 3-12
3.12.5 Dummy Load ON/OFF ............................. 3-13
3.12.6 Supervision of tuner power condition .......... 3-14
3.12.7
Battle ON/OFF ................................. 3-15
3.12.8
Manu a1 tuning, Narrow Band .................... 3-15
3.12.9 Manual Silent tuning .......................... 3-17
4
OPTIONS ................................................... 4-1
6
REPLACEABLE PARTS ......................................... 6-1
6.1 Introduction
......................................... 6-1
6.2 Replaceable
Parts List ............................... 6-1
6.3 Ordering Information
................................. 6-1
7
MANUAL CHANGES ............................................ 7-1
8
SERVICE ................................................... 8-1
8.1
Introduction ......................................... 8-1
8.2 Theory of Operation .................................. 8-1
8.3 Trouble Shooting
..................................... 8-1
8.4
Self-Test Program .................................... 8-1
8.4.1 Fatal Errors ................................... 8-3
8.5 Operational
Status/error messages .................... 8-3
8.5.1 Communication/Controller Status ................ 8-3
8.5.2 Current/temperature Status ..................... 8-3
8.6 Preventive Maintenance ............................... 8-4
8.7 Front
Ooorl Removal .................................. 8-4
8.8 PC-Board Assembly Removal ............................ 8-5
8.8.1 Flat cable removal ............................. 8-5
8.8.2 Removal of PC-Board Assemblies A1 and A3 ....... 8-5
8.8.3 Removal of PC-Board Assemblies A4, A5, A6
and A7 ......................................... 8-5
8.8.4 Removal of PC-Board Assembly A2 ................ 8-6
8.8.5 Removal of PC-Board Assemblies A8 and A9 ....... 8-6
8.8.6 Removal of PC-Board Assembly A10 ............... 8-7
iv
TU4015/0oc. no. 210641-001

c
8.9
8.10
8.11
8.12
8.13
8.8.7 Removal of PC-Board Assembly A13 ............... 8-7
Servicing PC-Boards .................................. 8-7
MOS Handling Precautions ............................. 8-7
Logic Devices
........................................ 8-8
Test and Measuring access to assemblies .............. 8-9
Rep 1acement of Re 1ays ................................ 8-9
8.13.1 Replacement of relay, vacuum .................. 8-10
8.13.2 Replacement of relay, reed 12 Amp ............. 8-10
8.13.3 Replacement of relay, reed 6 Amp .............. 8-10
Table
8.4
Table 8.5
Fatal Self Test error messages ................ 8-11
Self Test error messages ...................... 8-12
APPENDIX 1
Assembling
of cable connectors
TU4015/Doc. no. 210641-001
v

0

c
1.1 Introduction
SECTION 1
GENERAL INFORMATION
This Operating and Service Manual contains information required
to install, operate, test, adjust and service the TU4015.
Specifications are listed in paragraph 1.6.
These specifications are the performance standards or limits
against which the TU4015 is tested.
Due to experience obtained from the production and operation of
the equipment, minor differences between the TU4015 and the
manual may occur.
Wherever
possible such differences are dealt with in Section 7
11
MANUAL CHANGES ...
The electrical modules of the TU4015 are listed in Section 6.
1.2 Safety Considerations
This
manual contains information,
must
be followed to ensure safe
TU4015 in a safe condition.
1.3 Description
cautions and warnings which
operation and to maintain the
The TU4015 is a fast antenna tuner for shipboard use. The control
of the tuner is carried out by means of a serial data bus from a
SE4010, an exciter located in the transmitter.
The serial data bus is compatibel with RS485, strappable between
1200, 2400, 4800 and 9600 bps, with a maximum distance between
the
exciter and the antenna tuner of 150 meters.
The TU4015 is configured as a L matching circuit with a lowpass
characteristic. The inductors and capacitors are discrete binary
weighted elements switched
by high speed reed relays.
The TU4015 incorporates a dummy load used for transmitter tests
as well as tuning.
The housing of the tuner is especially designed for a low thermal
resistance which combined with the temperature controlled forced
air circulation and temperature supervisors ensures a low stress-
ing of the components in the tuner.
TU4015/0oc. no. 210641-001
1-1

1.4 Accessories Supplied.
The following accessories are supplied with the TU4015.
One Operating and Service Manual, ORA part no. 210641
One Connector Kit, ORA part no. 210634-001
Standard Spare Parts Kit, ORA part no. 210690
1.5 Accessories Available
The following items are available for use with the TU4015.
Depot Spares Kit. Consult factory.
Special Tools Kit, ORA part no. 210638-001
1-2
TU4015/Doc. no. 210641-001
0
0

c
1.6 Specifications
FREQUENCY RANGE
1. 5 - 30 MHz
RF POWER CAPABILITY
1000 WPEP/average
INPUT IMPEDANCE
50 ohms, VSWR < 1.5 (Narrow Bandwidth), N-connector
ANTENNA TYPE
Danish Navy KUF1200 (12 m. whip antenna)
BANDWIDTH
Narrow band: Depending upon antenna impedance
Broad band +/-5%, max. +/-500 kHz
TUNING MODES
Automatic
Manual
Silent/memory with 99 channels
Silent/manual
TUNING TIME
Automatic < 1 sec. Narrow band
Silent/memory: < 20 msec.
DUMMY LOAD
500 W/50 ohms/1 minute built-in
HEATING ELEMENT
Built-in, activated below 5°C
COOLING
Natural convection. Internal air circulation ensured by
controlled blower. Overheat alarm (75°C) provided.
REMOTE CONTROL
Fully remotely controlled by exciter SE4010
9600 Baud, RS485.
Cable length between SE4010 and ATU up to 150 m.
SELF-TEST PROGRAM (BITE)
Automatic self-test program enabling test of all functions
down to relay level.
MTBF
5000 hrs.
INPUT POWER
115/220 Vac +/-10%, 47-63 Hz
TU4015/0oc. no. 210641-001
1-3

POWER COMSUMPTION
With heating element off: 170 Wmax.(220 Vac)
With heating element on : 530 Wmax.(220 Vac)
OPERATING ENVIRONMENT
Temperature
Relative humidity
Vibration
Shock
Wind load
Enclosure
protection
WEIGHT
96 kg approx.
DIMENSIONS
-40°C to +55°C operating
-40°C to +75°C storage
95% at 40°C
3-10 Hz +/-2 mm
10-150 Hz +/- 1g
20 g pp, 17-20 Hz sine decaying to
half amplitude in 5 cycles.
250 kpm load on tuner tap.
I EC529, I P46
See drawings on the following pages.
1-4
TU4015/Doc. no. 210641-001
0

DIMENSIONS
c
f/!50
D
( \
••
•I
r-,
I
1411
••
o I
' I
·~
' '
'
'
' I
' '
L.J
••
•1
••
--<
1-- --- _•J ~
-
t------~
\~
;
••o
'
VI
'
, ______ J
Note: Six holes for mounting: Diam.: 14 mm
TU4015/Doc. no. Z10641-001 1-5

DIMENSIONS continued
Antenna Stud.
0
1-6
TU4015/0oc. no. 210641-001

-
'
c
c
2.1 Introduction
SECTION 2
INSTALLATION
This section of the manual provides installation instructions for
the TU4015. It also includes information about initial inspection
and damage claims, preparation for use and information on
repacking for shipment.
2.2
Initial Inspection
II WARNING
II
To avoid hazardous electrical shock, do not perform
electrical tests when there are signs of shipping damage to
any portion of the outer cover. Read the safety summary at
the front of this manual before installing or operating the
TU4015.
Inspect the shipping container for damage. If the shipping
container or cushioning material is damaged, it should be kept
until the contents of the shipment have been checked for
completeness and the TU4015 has been checked mechanically and
electrically. If the contents are incomplete, if there is a
mechanical
damage or defect, or if the TU4015 does not pass the
performance tests, notify the nearest Dansk Radio agent. If the
shipping container is damaged, or if the cushioning material
shows signs of stress, notify the carrier as well as the Dansk
Radio agent.
A
full report of the damage should also be forwarded to Dansk
Radio.
Include
the following:
Order number
Model and serial number
Name of forwarding agency
2.3 Storage
The TU4015 may be stored or shipped at temperatures within the
limits -40°C to +75°C. It is advisable to protect the TU4015
from extreme temperature variation which can cause excessive
condensation.
TU4015/Doc. no. 210641-001
2-1

2.4 Repacking for shipment
The shipping container for the TU4015 has been carefully
designed to protect the TU4015 and its accessories during
shipment. This
container and its associated packing material
should
be used when repacking for shipment. If shipping to Dansk
Radio for service is planned, attach a tag indicating the type of
service required, return address, model number and full serial
number. Mark the container FRAGILE to ensure careful handling.
2.5 Mounting information
The TU4015 is designed for mounting on a ship deck or bridge
wing.
The tuner is secured with six 12 mm bolts. Please refer to
Section 1, Specifications, Dimensions for position of the bolts.
To reach the full performance of TU4015 it is vital to establish
a heavy grounding between the tuner housing and the metal surface
of the ship. Failure to follow the mounting installation can
result in degraded performance.
When placing the tuner it can be convenient first to mount one
bolt and use this as a fixing aid. The mounting holes are the non
threaded holes. Locating the rest of the mounting holes is done
by rotating the tuner around the first bolt.
The housing of TU4015 shall be grounded via a heavy copper strap
between the base and the ground plane in the installation. The
distance between the tuner and the grounding point shall be as
short as possible.
The copper strap shal have a minimum width of 50 mm and a minimum
thickness of 1 mm.
On both sides of the base are two threaded holes which accept 8
mm bolts.
2.6 Power Requirements
115/220V, +/-10%, 47-63 Hz.
CAUTION
The TU4015 is normally set at the factory for 220 Vac.
The selection of 115 volt nominal mains voltage is made by moving
a codeplug on the power supply assembly A10A1 and inserting a
short circuit on the blower controller A13. To change the mains
voltage
setting, proceed as follows:
(refer to Fig. 2.1 and Fig. 2.2 ).
a. Disconnect the control plug from the TU4015.
b. Remove the door assy by unscrewing the twenty screws holding
2-2
TU4015/0oc. no. 210641-001
0

c
c
c
the door. The screws are captive and will therefore not need
to be fully unscrewed.
Tools
are aviable in Special Tool Kit 210638.
c. Disconnect the flatcable located in the right side of the
rack by operating the ejectors on the connectors starting
from the top. Bend the flatcable out of the door opening.
Disconnect the
flatcable located in the left side of the
rack by operating the ejectors on the connectors, starting
from the A9 module.
Disconnect the
two coax cables from the A9 module.
d.
Loosen the screws holding the frames of the A3, A4, A7, A9,
A8 modules with an - umbraco key. Starting from the A3 module,
undo the screws with a umbraco screw driver and remove the
module. The screws are captive and will therefore not need to
be fully unscrewed.
Tools
are avilable in Special Tool Kit 210638.
When removing the A3 module remember
to disconnect the flat cable located
on the assembly.
e. Remove the top cover from the power supply assembly by
unscrewing the six screws holding the cover.
f. Remove the codeplug P1
from J7 (220 Vac) and
reinsert the plug
in J6 (115 Vac). Refer
to fig. 2 .1.
g.
Change the fuses
F1 and F2 according
to
tab 1e 2 .1.
h. Reposition the top cover on the power supply assembly
and
fasten the
six
screws.
i. Loosen the six screws holding the A13 module. The module
is located between the left rack side and the outer tuner
housing.
j.
k.
1.
k.
After loosening the screws carefully remove the module and
disconnect Pl.
Install a strap
as shown in figure 2.2.
( 115 Vac:
Strap mounted;
220 Vac: No strap
mounted)
Reconnect
P1 and reinstall the A13 module. Fasten
the six
screws.
Reinstall
the modules starting from A8.
Reconnect
the two flatcabels starting
from the bottom.
Reconnect the
two
coax cabels.
TU4015/0oc. no. 210641-001
2-3

m. Mount the door assembly and fasten the twenty screws.
n. Reconnect
the control plug.
rm12
~
r1ffi1
~14
~
~ TP1 TP2
: . .
m
J3
a
~4 STEO£A
I .................
~.
18
Figure 2.1. Code plug on AlOAl
0
Figure 2.2. Strap on A13
2-4
TU4015/0oc. no. 210641-001

c
c
2.7 Fuses
Table 2.1 Fuse Ratings
Fuse
Fuse Rating
F1
1A T (220 V)
II
2A T (
115 v)
F2
2A T (220 V)
II
4A T (115
V)
2.8 Control cable
The control cable contains both mains power and data lines. The
control plug accepts four lines with 1.2 mm
2
and eight lines with
0.5 mm
2.
The cable must be with twisted pairs and must be
screened.
The cable may have a maximum outer diameter of 12.5 mm.
2.9 Control Socket J1
The Control socket contains both the data and the mains power
lines. The Control socket connections are as follows:
pin
circuit
description
A
RS485B RS485 data line
B
RS485A
RS485 data line
c
ATU SENSE
D GND
Signal ground
E
uP STOP Microprosessor halt
F POWER ON
Tuner power supply control
G
TUNER READY
H MUTE
Muting
of transmitter
J
MAINS PHASE
J
K MAINS PHASE
Common
L
MAINS COMMON J
M
MAINS COMMON Common
Figure 2. Control socket
The appropriate cable connector may be ordered from Dansk Radio
Part no. 235055-002.
2.9.1 Mains lines
To allow the greatest distance between the antenna tuner and the
mains supplier, both the mains phase and the mains common can be
supplied via two pins on the control socket. Via the appropriate
cable connector this allows a square of 1 mm
2, using a standard
twisted cable.
If using two wires for the mains phase and two for the mains
TU4015/0oc. no. 210641-001
2-5

two wires twisted for the phase and two wires
common it must be
twisted for common.
During installation it
present in the TU4015
power supply is within
2.9.2 Data lines
is advisable to measure the mains voltage
to ensure that the mains voltage at the
limits.
To allow the greatest distance between TU4015 and SE4010, it is
advisable to use a cable with a square of 0.25 mm
2•
The wires must be twisted pairs. The only lines demanded to be
twisted together, except for the phase and common, are the lines
marked RS485B and RS485A. These are the data lines.
2.9.3 Assembling the Control plug
To ensure proper operation of the TU4015 it is important to
follow the assembling instructions carefully. Appendix 1 of this
manual contains assembling instructions.
2.9.4 Final protection of control connector
For final protection of the connector against corrosion, wrap
self-vulcanizing rubber around the connector. The rubber must
cover the
gab between the socket and the plug. It is advisable
to cover all of the plug and the gap between the plug and the
cab1e as we 11 .
2.9.5 Tx connector
The Tx connector is a special water tight type meant for cable
types
RG 8/U, RG 8A/U and RG 213/U.
The appropriate cable connector may be ordered from Dansk Radio
Part no. 206139-001.
2.9.6 Assembling the Tx connector
To ensure proper operation of the TU4015 it is important to
follow the assembling instructions carefully. Appendix 1 of this
manual contains assembling instructions.
2.9.7 Final protection of TX connector
For
final protection of the connector against corrosion, wrap
self-vulcanizing rubber around the connector. The rubber must
cover
the gab between the socket and the plug. It is advisable
to cover all of the connector and the gap between the connector
and the cable as well.
2-6
TU4015/Doc. no. 210641-001
0