GRASS VALLEY KayakDD-1 Technical manual

KayakDD-1™
DIGITAL PRODUCTION SWITCHER
Planning and Installation Manual
SOFTWARE VERSION 6.7.1
071826305
JUNE 2005

KayakDD-1 Digital Production Switcher
Contacting Grass Valley
Region Voice Fax Address Web Site
North America [phone]
Support: 530-478-4148
Sales: [phone]
Support: [phone]
Grass Valley
P.O. Box 599000
Nevada City,
CA 95959-7900
USA
www.thomsongrassvalley.com
Pacific Operations [phone]
Support: [phone]
[phone]
U.K., Asia, Middle East [phone] [phone]
France [phone]
Germany, Europe [phone] [phone]
Copyright © Thomson Broadcast and Media Solutions All rights reserved.
Grass Valley Web Site
The www.thomsongrassvalley.com web site offers the following:
Online User Documentation — Current versions of product catalogs, brochures, data sheets, ordering
guides, planning guides, manuals, and release notes in .pdf format can be downloaded.
FAQ Database — Solutions to problems and troubleshooting efforts can be found by searching our
Frequently Asked Questions (FAQ) database.
Software Downloads — Software updates, drivers, and patches can be downloaded.
2 Planning and Installation Manual

Number: 510057.001
The Quality System of:
Thomson Broadcast & Media Solutions
TBMS TBMS
400 Providence Mine Road 17 rue du Petit Albi-BP 8244
Nevada City, CA 95945 95801 Cergy Pontoise
Cergy, France
TBMS
Weiterstadt, Germany TBMS
Brunnenweg 9 10 Presidential Way, 3rd Floor, Suite 300
D-64331 Weiterstadt, Germany Woburn, MA 08101
TBMS TBMS
15655 SW Greystone Ct. 2300 South Decker Lake Blvd.
Beaverton, OR 97006 Salt Lake City, UT 84119
TBMS TBMS -PCB
Nederland B.V. Rennes, France
4800 RP BREDA Rue du Clos Courtel
The Nederlands Cesson-Sevigne, Cedex
France
TBMS/Nextream TBMS/Nextream
Rennes, France Technopole Brest Iroise
Rue du Clos Courtel CS 73808
Cesson-Sevigne, Cedex 29238 Brest Cedex 3
France France
Including its implementation, meets the requirements of the standard:
ISO 9001:2000
Scope: The design, manufacture and support of video hardware and software products
and related systems.
This Certificate is valid until: June 14, 2006
Revision Date: September 9, 2003
Renewal Date: June 14, 2003
Issued for the first time: June 14, 2000

KayakDD-1 Digital Production Switcher
Table of Contents
1PREFACE .........................................................................................................................................................9
1.1 ABOUT THIS MANUAL....................................................................................................................................9
1.2 STANDARD DOCUMENTATION SET .................................................................................................................9
1.3 OTHER DOCUMENTATION..............................................................................................................................9
2REGULATORY NOTICES ..............................................................................................................................11
2.1 CERTIFICATIONS AND COMPLIANCES ...........................................................................................................11
2.1.1 FCC EmissionControl ......................................................................................................................11
2.1.2 Canadian EMC Notice of Compliance ..............................................................................................11
2.1.3 FCC EmissionLimits ........................................................................................................................11
2.1.4 Certification and Compliance............................................................................................................12
3SAFETY SUMMARY.......................................................................................................................................15
3.1 SAFETY TERMSAND SYMBOLS ....................................................................................................................15
3.1.1 Terms in ThisManual .......................................................................................................................15
3.1.2 Terms on the Product .......................................................................................................................15
3.1.3 Symbols on the Product....................................................................................................................16
3.2 WARNINGS.................................................................................................................................................17
3.3 CAUTIONS..................................................................................................................................................18
4TECHNICAL SPECIFICATION.......................................................................................................................19
4.1 POWER SUPPLY FRAME..............................................................................................................................19
4.2 POWER SUPPLY PANEL ..............................................................................................................................19
4.3 ENVIRONMENTAL DATA...............................................................................................................................19
4.4 VIDEO SYSTEM DATA..................................................................................................................................20
4.5 SERIAL DIGITAL VIDEO INPUTS ....................................................................................................................20
4.6 SERIAL DIGITAL VIDEO OUTPUTS ................................................................................................................21
4.7 ANALOG REFERENCE INPUT ........................................................................................................................21
4.8 CONTROL PANEL CONNECTION ...................................................................................................................21
4.9 MECHANICAL DATA.....................................................................................................................................22
5SYSTEM OVERVIEW .....................................................................................................................................23
5.1 INTRODUCTION ...........................................................................................................................................23
5.1.1 Features............................................................................................................................................23
5.1.2 Supported Control Protocols.............................................................................................................24
5.1.3 KayakDD-1 Ordering Information .....................................................................................................25
5.2 SYSTEM COMPONENTS...............................................................................................................................26
5.3 CONTROL SURFACE...................................................................................................................................27
5.4 VIDEO PROCESSOR FRAME.........................................................................................................................28
5.4.1 System Components ........................................................................................................................29
5.4.2 Video Processor Frame Options.......................................................................................................29
5.5 FUNCTIONAL OVERVIEW .............................................................................................................................30
5.5.1 Video Signal Flow .............................................................................................................................30
5.5.2 System Control .................................................................................................................................31
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6INSTALLATION ............................................................................................................................................. 33
6.1 PRE-INSTALLATION PROCEDURES .............................................................................................................. 33
6.1.1 System Survey ................................................................................................................................. 33
6.1.2 Line Voltage ..................................................................................................................................... 33
6.1.3 Safety Requirements........................................................................................................................ 33
6.1.4 Installation Tasks............................................................................................................................. 34
6.2 MOUNTING THE PROCESSOR FRAME .......................................................................................................... 35
6.2.1 Video Processor Frame Measurements.......................................................................................... 35
6.2.2 General Rack Mounting Instructions................................................................................................ 36
6.2.3 Rack Mounting Procedure ............................................................................................................... 37
6.3 MOUNTING THE CONTROL PANEL ............................................................................................................... 38
6.3.1 Control Panel Measurements .......................................................................................................... 38
6.3.2 Table Top Mounting ......................................................................................................................... 40
6.3.3 Cut Out Dimensions for Surface Mounting...................................................................................... 40
6.3.4 Mounting Holes for Panel Fastening................................................................................................ 40
6.4 CONTROL PANEL CONNECTORS ................................................................................................................. 42
6.5 PROCESSOR FRAME CONNECTORS ............................................................................................................ 44
6.6 PIN ASSIGNMENTS ..................................................................................................................................... 46
6.6.1 RS 485 Port...................................................................................................................................... 46
6.6.2 RS 232 Port...................................................................................................................................... 46
6.6.3 Panel DC Power In........................................................................................................................... 47
6.6.4 Frame DC Power In ......................................................................................................................... 47
6.6.5 Frame DC Power Out....................................................................................................................... 47
6.6.6 Frame GPI/O – Tally ........................................................................................................................ 48
6.7 CABLING AND CONTROL ............................................................................................................................. 49
6.7.1 Cabling ............................................................................................................................................. 49
6.7.2 Control Cabling ................................................................................................................................50
6.7.3 Video ................................................................................................................................................ 52
6.7.4 Video Timing and Delay................................................................................................................... 53
6.7.5 GPI / Tally Outputs........................................................................................................................... 54
6.7.6 GPI Inputs ........................................................................................................................................ 54
6.7.7 Tally Adapter .................................................................................................................................... 54
7SERVICE INSTRUCTIONS............................................................................................................................ 55
7.1 RUNNING PANEL TESTS ............................................................................................................................. 55
7.1.1 Local Panel Test Mode 1 (Button Test) ........................................................................................... 56
7.1.2 Local Panel Test Mode 2 (LED Test)............................................................................................... 56
7.1.3 Local Panel Test Mode 3 (GroupTest / On Air Highlight Test): ...................................................... 56
7.1.4 Local Panel Test Mode 4 (Connect Mode) ...................................................................................... 56
7.1.5 Local Panel Test Mode 5 (Colour Test) ........................................................................................... 57
7.2 SOFTWARE-UPDATE .................................................................................................................................. 58
7.2.1 Recommended Memory Sticks ........................................................................................................ 58
7.2.2 Preparing the USB Memory Stick.................................................................................................... 58
7.2.3 Software Loading/Update ................................................................................................................ 62
7.2.4 Installation Procedure ...................................................................................................................... 63
7.2.5 Updating the CPLD Firmware .......................................................................................................... 66
7.3 DEVICE CONFIGURATION............................................................................................................................ 67
7.3.1 Configure Device Menu ................................................................................................................... 67
7.3.2 Reset / Check / Clear Device Menu................................................................................................ 68
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7.4 TROUBLE SHOOTING..................................................................................................................................69
7.4.1 How to Calibrate the TouchScreen...................................................................................................69
7.4.2 Lost LAN Connection........................................................................................................................69
7.4.3 Problems withNetwork Configuration..............................................................................................69
7.4.4 How to Connect a PC / Laptop to the KayakDD...............................................................................71
7.4.5 CPLD Update Trouble Shooting .......................................................................................................73
7.4.6 How to Install the Sidepanel Software to a PC / Laptop...................................................................74
7.4.7 Network Problems with Sidepanel....................................................................................................77
7.4.8 Lifetime of the Internal Battery..........................................................................................................79
7.4.9 Exchange the Battery .......................................................................................................................79
7.4.10 iButton Exchange for Spare Part Mainframe ....................................................................................84
7.5 CONTROL INTERFACES ...............................................................................................................................85
7.5.1 Supported GVG100 Commands.......................................................................................................85
7.5.2 Supported GVG200 Commands.......................................................................................................87
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KayakDD-1 Digital Production Switcher
Table of Figures
Figure 1 Video Processor Frame and Control Panel ..................................................................................... 26
Figure 2 Control Panel ................................................................................................................................... 26
Figure 3 KayakDD-1 Control Panel Surface .................................................................................................. 27
Figure 4 KayakDD-1 Video Processor Frame................................................................................................ 28
Figure 5 KayakDD Simplified Video Flow Diagram........................................................................................ 31
Figure 6 KayakDD-1 Video Processor Frame Dimensions............................................................................ 35
Figure 7 KayakDD-1 Video Processor Frame Rack Mounting....................................................................... 37
Figure 8 KayakDD-1 Control Panel Measurements 1 of 2............................................................................. 38
Figure 9 KayakDD-1 Control Panel Measurements 2 of 2............................................................................. 39
Figure 10 Bottom View, Position of the Mounting Points ................................................................................. 40
Figure 11 Bottom View, Measurements of the Mounting Points ...................................................................... 41
Figure 12 Panel Fastening Procedure ............................................................................................................. 41
Figure 13 Control Panel Connectors................................................................................................................ 42
Figure 14 Video Processor Frame Connectors................................................................................................ 44
Figure 15 KayakDD-1 Standard Cabling.......................................................................................................... 49
Figure 16 Timing and Delay ............................................................................................................................. 53
Figure 17 Tally Adapter Cable.......................................................................................................................... 54
Figure 18 KayakDD Control Panel Detail – Transition Panel........................................................................... 55
Figure 19 Device Control Menu........................................................................................................................ 61
Figure 20 Device Control Menu with Software Update Dialog......................................................................... 62
Figure 21 Start Installation Procedure.............................................................................................................. 63
Figure 22 Installation Procedure ...................................................................................................................... 63
Figure 23 Cancel Installation Procedure .......................................................................................................... 64
Figure 24 Device Control Installation Status .................................................................................................... 64
Figure 25 FinishInstallation ............................................................................................................................. 65
Figure 26 CPLD Update ................................................................................................................................... 66
Figure 27 Configure Devices............................................................................................................................ 67
Figure 28 Reset/Clear/Check Devices Menu ................................................................................................... 68
Figure 29 PC Connection................................................................................................................................. 71
Figure 30 Error Message during CPLDupdate................................................................................................ 73
Figure 31 Path to the NetCheck Software........................................................................................................ 77
Figure 32 NetCheck Window............................................................................................................................ 78
Figure 33 KayakDD-1 Frame Front.................................................................................................................. 79
Figure 34 KayakDD1-Frame Without Front Plate ............................................................................................ 79
Figure 35 KayakDD-1 Control Panel................................................................................................................ 80
Figure 36 Battery on the Board of the Control Panel ....................................................................................... 80
Figure 37 PS2 and VGA sockets on the KayakDD-1 Frame ........................................................................... 81
Figure 38 PS2 and VGA sockets on the KayakDD-1 Panel............................................................................. 82
Figure 39 Install – Config Device Menu........................................................................................................... 83
Figure 40 KayakDD-1 Frame Front View ......................................................................................................... 84
Figure 41 Position of the iButton ...................................................................................................................... 84
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8 Planning and Installation Manual

KayakDD-1 Digital Production Switcher
1 Preface
1.1 About This Manual
This KayakDD Planning and Installation Manual provides installation, configuration,
and service information for the Thomson Grass Valley KayakDD-1 Digital Production
Switcher. Thismanual isdesigned for technical personnel responsible for installing and
maintaining KayakDD systems.
1.2 Standard Documentation Set
The standard KayakDD-1 documentation set consists of a:
 Operating Instructions,
 Planning and Installation Manual, and
 Release Notes.
The Operating Instructions contains background information about the KayakDD
Digital Production switcher family and describes operating procedures. This manual
can be used while learningabout KayakDD and for enhancingyourbasic knowledge of
the system.
The Planning and Installation Manual contains information about installing, configuring,
and maintaining the system. The service part in this current manual is in preparation.
The Release Notes contain information about new featuresand system enhancements
for a specific software version, and also includes software installation procedures.
Always check the release notes for your current system software before you begin
operating yoursystem.
1.3 Other Documentation
Communication protocols of KayakDD are available upon request for developers and
software engineers to use to design editor and other external interfaces to the
KayakDD system.
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KayakDD-1 Digital Production Switcher
2 Regulatory Notices
2.1 Certifications and Compliances
2.1.1 FCC Emission Control
This equipment has been tested and found to comply with the limits for a Class A
(Control Panel) and Class B (Mainframe) digital device, pursuant toPart 15 of the FCC
Rules. These limits are designed to provide reasonable protection against harmful
interference whenthe equipment isoperatedin a commercial environment. This
equipment generates, uses, and can radiate radio frequency energy and, if not
installed and used in accordance with the instruction manual, may cause harmful
interference to radio communications. Operation of this equipment ina residential area
is likely to cause harmful interference inwhich case the user will be required to correct
the interference at his own expense.
Changes or modifications not expressly approvedby Thomson Grass Valley can affect
emission compliance and could void the user’s authority to operate this equipment.
2.1.2 Canadian EMC Notice of Compliance
This digital apparatus does not exceed the Class A (Control Panel) and Class B
(Mainframe) limits for radio noise emissions from digital apparatus set out in the Radio
Interference Regulations of the Canadian Department of Communications.
Le présent appareil numérique n’emet pas de bruits radioélectriques dépassant hors
des limitesapplicablesaux appareils numériques dela classe A pour des pupitre de
control et classe B pour le rack préscrites dans le Règlement sur lebrouillage
radioélectrique édicte par leministère des Communications duCanada.
2.1.3 FCC Emission Limits
This device complies with Part 15 of the FCC 47 Rules. Operation is subject to the
following two conditions: (1) This device may no cause harmful interference, and (2)
this device must accept any interference received, including interference that may
cause undesirable operation.
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KayakDD-1 Digital Production Switcher
2.1.4 Certification and Compliance
This product has been evaluated for Electromagnetic Compatibility under the EN
55103-1/2 standards for Emissions and Immunity and meets the requirements for
E1/E2 environment.
This product complies with Class A (Control Panel) and Class B (Mainframe). In a
domestic environment this product may cause radio interference in which case the
usermay be required to take adequate measures.
This product has been evaluated and meets the following Safety Certification
Standards:
Category Standard Designed/tested for compliance with
Safety ANSI / UL60950 Safety of Information Technology Equipment,
including Electrical Business Equipment.
IEC 60950 Safety of Information Technology Equipment,
including Electrical Business Equipment
CAN/CSA C22.2,
No. 60950-00
Safety of Information Technology Equipment,
including Electrical Business Equipment.
Europe:
EN 60950
Safety of Information Technology Equipment,
including Electrical Business Equipment.
73/23/EEC Low Voltage Directive
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KayakDD-1 Digital Production Switcher
Category Standard Designed/tested for compliance with
EMI EMC Directive
89/336/EEC via
EN 55103-1 and 2
Audio, Video and Entertainment Lighting
Control for the European Community.
EN 55103-1
standards
Electromagnetic compatibility.
Product family standard for audio, video, audio-
visual and entertainment lighting control
apparatus for professional use.
Part 1 Emissions, Environment E1/E2
EN 55022: Class A (ControlPanel) and Class B
(Mainframe) Radiated andConducted
Emissions
EN 61000-3-2: Power Line Harmonic
Emissions, Radiated Magnetic Field Emissions,
Peak Inrush Current
EN55103-2
standards
Electromagnetic compatibility--Product family
standard for audio, video, audio-visual and
entertainment lighting control apparatus for
professional use.
Part 2 Immunity, Environment E1/E2
EN 50082-1: Immunity
EN 61000-4-2:
Electrostatic Discharge “ESD” Immunity
EN 61000-4-3:
Radiated RF Electromagnetic Field Immunity
EN 61000-4-4:
Electrical Fast Transient/Burst “EFT” Immunity
EN 61000-4-5: Surge Immunity
EN 61000-4-6: ConductedRF Immunity
EN 61000-4-11: Voltage Dips, Short
Interruptions and Voltage Variations
Annex A - Radiated Magnetic Field Immunity
Note: This only applies to assemblies sensitive
to magnetic fields
US FCC Class A CISPR Pub. 22 (1985)
Canada FCC
Industry Canada
Australia &
New Zealand:
AS/NZS 3548
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3 Safety Summary
Readand follow the important safety information below, noting especially those
instructionsrelated to risk of fire, electric shock orinjury to persons. Additional specific
warningsnot listed here may be found throughout the manual.
WARNING!
Anyinstructions in this manual thatrequire opening the equipment cover or
enclosure are for use by qualified service personnel only.To reduce the
risk of electric shock, do not perform anyservicingother than thatcontained in
the operatinginstructionsunless you are qualified to do so.
3.1 Safety Terms and Symbols
3.1.1 Terms in This Manual
Safety-related statements may appear inthis manual in the following form:
WARNING!
Warning statements identify conditions or practices that may resultin personal injury or
loss of life.
CAUTION!
Caution statements identify conditions or practices that may result in damage to
equipment orother property, or which may cause equipment crucial to your business
environment to become temporarily non-operational.
3.1.2 Terms on the Product
The following terms may appear on the product:
DANGER!
A personal injuryhazard is immediately accessible as you read
the marking.
WARNING!
A personal injuryhazard exists but is not immediately accessible
as you read the marking.
CAUTION!
A hazard to property, product, and other equipment is present.
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KayakDD-1 Digital Production Switcher
3.1.3 Symbols on the Product
The following symbols may appear on the product:
Indicates that dangeroushigh voltage is present withinthe equipment enclosure that
may be of sufficient magnitude to
constitute a riskof electric shock.
Indicates that user, operator or service technician should
refer to product manual(s) for important operating, maintenance,
or service instructions.
This is a prompt to note fuse rating when replacing fuse(s).
The fuse referenced in the text must be replaced with one
having the ratings indicated.
Identifies a protective grounding terminalwhich must be
connected to earth ground prior to makingany other equipment
connections.
Identifies an external protective grounding terminal which
may be connected to earth ground as a supplement to an
internal grounding terminal.
Indicates that static sensitive components are present which
may be damaged by electrostatic discharge. Use anti-static
procedures, equipment and surfaces during servicing.
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KayakDD-1 Digital Production Switcher
3.2 Warnings
The following warning statements identify conditions or practices that can result in
personal injury or loss of life.
WARNING— To reduce the risk of electrical shock, do not remove cover or back. No
user-serviceable partsinside. Refer to qualified service personnel.
 Dangerous voltage or current maybe present— Disconnect power and remove
battery (if applicable) before removingprotective panels, soldering, or replacing
components.
 Do not service alone — Do not internally service this product unless another
person capable of renderingfirst aid and resuscitation is present.
 Removejewelry— Prior to servicing, remove jewelry such asrings, watches, and
other metallic objects.
 Avoid exposed circuitry — Do not touch exposed connections, components or
circuitry when poweris present.
 Use proper power cord — Use only the power cord supplied orspecified for this
product.
 Ground product — Connect the grounding conductor of the powercord to earth
ground.
 Operate only with covers and enclosure panels in place — Do not operate this
product when covers or enclosure panels are removed.
 Use correctfuse — Use only the fuse type and ratingspecified for this product.
 Use only in dryenvironment — Do not operate in wet or damp conditions.
 Use only in non-explosive environment — Do not operate thisproduct in an
explosive atmosphere.
 High leakage currentmay be present — Earth connectionof product is essential
before connecting power.
 Dual power supplies may be present — Be certain to plug each power supply
cord into a separate branch circuit employing a separate service ground.
Disconnect both power supply cords prior to servicing.
 Double pole neutral fusing— Disconnect mains power prior to servicing.
 Use proper lift points — Do not use door latches to lift or move equipment.
 Avoid mechanical hazards — Allow all rotating devices to come to a stop before
servicing.
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KayakDD-1 Digital Production Switcher
3.3 Cautions
The following caution statements identify conditions or practices that can result in
damage to equipment orother property:
 Use correct power source— Do not operate thisproduct from a power source
that applies more than the voltage specified for the product.
 Use correct voltage setting — If this product lacks auto-ranging power supplies,
before applying power ensure that each power supply is set to match the power
source.
 Provide proper ventilation — To prevent product overheating, provide equipment
ventilation in accordance with installation instructions.
 Use anti-static procedures — Static sensitive components are present which
may be damaged by electrostatic discharge. Use anti-static procedures, equipment
and surfaces during servicing.
 Do not operate with suspected equipment failure — If you suspect product
damage or equipment failure, have the equipment inspected by qualified service
personnel.
 Ensure mains disconnect — If mains switch isnot provided, the power cord(s) of
this equipment provide the means of disconnection. The socket outlet must be
installed near the equipment and must beeasily accessible. Verify that all mains
power is disconnected before installing or removing power supplies and/or options.
 Route cable properly — Route power cords and other cablesso that they are not
likely to be damaged. Properly support heavy cable bundlesto avoid connector
damage.
 Use correct power supply cords — Power cords for this equipment, if provided,
meet all North American electrical codes. Operation of this equipment at voltages
exceeding 130 VAC requires power supply cords which comply withNEMA
configurations. International power cords, if provided, have the approval of the
country of use.
 Use correct replacement battery— This product may contain batteries. To
reduce the risk of explosion, check polarity and replace only with the same or
equivalent type recommended by manufacturer. Dispose of used batteries
according to the manufacturer’s instructions.
 Troubleshoot only to board level — Circuit boards in this product are densely
populated withsurface mount technology (SMT) components and application
specific integrated circuits(ASICs). As a result, circuit board repair at the
component level is very difficult in the field, if not impossible. For warranty
compliance, do not troubleshoot systems beyond the board level.
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KayakDD-1 Digital Production Switcher
4 Technical Specification
4.1 Power Supply Frame
Line voltage 100V-240V AC+/-10% autorange,
power factor corrected
(48V / 5A DC Input for ext. redundancy)
Line frequency 50/60Hz +/- 5%
Power consumption max. 150W (max. 200W with 48V DC supply for panel)
Leakagecurrent < 2.5 mA
RAMRecorder buffer voltage: 6..8V DC approx. 150 mA.
DC-OUT for control panel 48V DC, max 1.6A
4.2 Power Supply Panel
DC-IN 48V DC In, max 1.3A
Power consumption max. 50W
4.3 Environmental Data
Storage temperature -20C to +70C (-4F to 158F)
Operating temperature +5C to +40C (41F to 104F)
Relative humidity 95% non-condensing
Electromagnetic
environment E2 (accordingto EN55103-1, -2)
Planning and Installation Manual 19