pro bel Freeway User manual

I
.J
1
1 .1
1.2
1.3
1.4
1.5
r>.
2
) 2
.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10
3
3 .1
3.2
3.3
3.4
3.5
3.6
3.7
3.8
3.9
3.10
3
.11
3.12
3.13
6540T-00 Nov 97
Pro-Bel ltd
FreewayRange
Contents
Introduction 4
4
Control 4
Environmental 5
Problems?
5
Theright choice
5
General points
General information 6
Important safeguards and notices
6
I
nsta Ilation 8
EMC statement 8
Maintenance andwarranty 10
Telephone support
11
Customer support department 12
Repairs
12
Loans
12
Exchanges
13
Address information 13
Installation
16
Door removal
16
Power supply removal
16
Signal rear panel removal
18
Removal and replacement of modules
18
20
Cable connections
Control rear panel connections
21
23
Video references - BNC sockets (looping)
Setting the
AES reference - PL 17
Settingthe
level switch
Setting thedestination
assign switch
24
26
28
28
LED indications 30
Freewaycontrol
card
33
Setting the
reset switch

FreewayRange Pro-Bel
ltd
4 Hardware configuration
34
4 .1 Router details 34
4.2
Port definitions 36
4
.3
Controller configuration 38
4.4
Software controllable processes
40
5 Control system operation
42
5.1 Master and slave module details 42
5.2 Master router dual control and changeover
42
5.3
Operating modes
43
5.4
Salvos
45
r:
6
Routing 46
6 .1
Setting crosspoints
46
6.2
Salvo switching
47
6
.3
Handshaking and errorreporting 47
6.4 Defining
stereo analogue audio parameters
48
6.5 Configuring
general remote ports
50
6.6
Using PC based editors
50
6.7
Configuring the database
51
6.8
Understanding the database
57
7 Panel details
64
7.1
Summary of panel types
64
7
.2
General panel details 64
7
.3 Panel features
65
7.4
Panel types
74
7.5 Configuration via
panels
86
8 level types 92
8 .2
Normal Freeway(64x64) 92
8.3
YUV Freeway(5x5, 1 Ox1 0,15x15or 20x20)
92
8.4
Dual channel Freeway(8x8, 16x16,24x24 or32x32) 92
8
.5
Quad channel Freeway(4x4,8x8,12x12or16x16) 94
8.6
Machine control Freeway(17x16, 33x32,49x48,65x64) 94
8.7
YUV TM32 and TM16 (5x5, 1 Ox5 or lOx1 0) 94
8,8
Dual channel TM32andTM16(8x8or 16x16) 95
8.9
Quad channel TM32andTM16(4x4or8x8) 96
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Pro-Bel ltd
Technical manual
8.10
Normal TM24 (24x6, 24x12 or24x24) 97
8
.11 Dual channel TM24(12x6or12x12) 97
8.12
YUV TM24 (8x2 or8x8) 97
9 Terminal
command set 98
9.1
98
Command setdetails
9.2
Error responses 112
10 Configuring dial-up
keypads 114
10.1
Example keypad layouts
114
10.2 Example source keypad entry sequence us ing source keypad 34 115
10.3 Example destination keypad entry sequence using
destination keypad 34 116
11
PC support software 118
11.1
Software installation
118
11 .2
Running the program
118
12 Downloading Motorola S-record
HEX files 122
13 Theoryof operation 124
13.1 Switching duties 124
13.2
Freeway block diagrams 124
14 Problem solving 128
15 Specification 132
6540T-00 Nov 97 3

FreewayRange
1 Introduction
The Freeway series range of routing switchers addresses today's need for the
smaller installation whilst offering the high performance, cost effective, multi
signal-format, routing offered by Pro-Bel.
This guide describes the common features of Freeway (chassis, control card, PSU,
etc.). Part 1 of this User Guide details installation and configuration information
irrespective of specific signal type. The remaining parts cover each of the specific
signal types in turn .
• 1. 1 General points
A Freeway frame can accommodate a total of four signal cards ; each providing a
16x16 SWitching
module . These modules may be interconnected within the frame
(using the internal expansion bus) to produce router sizes of 16x16, 32x32, 48x48
and 64x64. By designing each signal-type module to require identical PSU and
support functions, any combination of signal type may be housed in the same 3U
chassis. So that, for instance, a 32x32 SOV and stereo audio switcher can be
housed within the same frame. And Freeway's modularity ensures that your
switcher can change as your requirements do. Switcher sizes below 64x64 may be
plug and play upgraded in the field. Similarly a predominantly analogue router
can gradually be transformed into a digital router (by swapping analogue sixteen
square modules for digital alternatives) as your installation requirements evolve.
In
Chapter 3 we'll tell you all you how to get your router up and running and, in
Chapter 4, how to configure the system for your present needs and future
expansion .
• 1.2 Control
Control for the router is provided by an internal daughter card. Optionally a
second control card can be fitted thereby providing a back-up controller should
the primary card fail. Freeway's control system offers extensive facilities,
supporting up to 32 panels or under monitor displays. Panel types may be XY,
button-per-crosspoint or multibus. Internal database editing functions provide
extensive system configuration options including; programmable salvos, source
and destination associations, marrying, route protects and inhibits, audio channel
configurations and overrides. Up to 8 levels of Freeway routing may be slaved to
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4

Pro-Bel Ltd Technical manual
the main frame by means of a parallel control link. A special version of this
parallel link is
also available to slave existing TMSeries routers. Extensive details
of the Freeway control system (and how to edit the internal database information)
are given in Chapters 4 and 5.
• 1.3 Environmental
By utilising advanced PSU circuit topology and the latest signal switching
technologies, Freeway offers a very compact router with low power dissipation,
ensuring fit and forget reliability. For extra security, each frame has provision for
two
PSU modules so that one may act as a backup in the event of a PSU fail. The
high-speed converter technology in the PSU is monitored by two on-board
microprocessors that assess the condition of the mains and of the supplies
leaving the power unit . Should any of the PSUs vital-signs show a warning
condition these are monitored and. if appropriate, an external warning alarm may
be activated. Freeway PSUs may be withdrawn from the unit from the front and a
replacement hot-plugged; thereby ensuring continuous service. For details, see
Chapter 3.
• 1.4 Problems?
We hope you won't have them! Perhaps it's finger -trouble or something more
serious? In Chapter 14 you'll find a problem solving guide to help you with
possible questions. You'll also find contact information for our Customer Service
department in Chapter 2.
Note: This product contains no user servicable parts; should this product require
servicing please
refer to Pro-Belor your local agent .
• 1.5 The right choice
Choosing a switcher is an important decision, no-one wants to get it wrong . With
all the
changes in television production today , you need a router that can evolve
and change. That's why we developed Freeway, the future-proofed modular
multi-format routing system that provides the smoothest ride to the future.
We re glad you
agree with us.
ee 7e
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FreewayRange Pro-Bel
ltd
2 General information
• 2.1 Important safeguards and notices
Before use
If this equipment is being used for the first time, is being installed in a new
location or
has not been used for a long time then the following checks should be
carried out.
Check that the equipment is not mechanically damaged ; if it is the unit should be
checked by a qualified engineer and, if necessary, returned to Pro-Bel Limited or to
its
agent.
Safety
All Pro-Bel equipment meets the requirements of specification : BS EN60950:1992
Safety of
Information Technology Equipment including Electrical Business
Equipment .
Pro-Bel
equipment is designed to be used in a rack mounted frame and all external
metal work should be earthed.
High temperatures
Under normal circumstances certain internal components, such as heat sinks and
mains transformers, may be too hot to touch ; also, if a fault develops one or more
components may become unusually hot. However no part that can be touched in
normal use should ever exceed 65°C; nevertheless always take care.
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Pro-Bel ltd
Technical manual
Disposal
None of the active devices or other components in this unit contains any
hazardous or dangerous chemicals or substances and therefore there are no
special
precautions that need to be observed if this equipment is disposed of.
High voltages
To prevent electrical shock when working on this equipment disconnect the a.c.
line cord from
the a.c. source before working on any internal components.
ESD warning
WARNING: All of the modules fitted contain static sensitive
components and full anti-static precautions should be taken when
handling them.
Warnings
• heed all warnings on the unit and in the operating instructions
• do not use this product in or near water
• disconnect a.c. power before installing any options
• route power cords and cables so that they are not easily damaged
• disconnect power before cleaning
• do
not use liquid or aerosol cleaners; use only a damp cloth
•
dangerous voltages exist at several points in this product -to avoid personal
injury, do not touch exposed connections and components while the power is
on
• do not
wear hand jewellery or watches when troubleshooting high current
circuits, such as the power supply
• to prevent damage to equipment when replacing fuses, locate and correct the
trouble that caused the fuse to blow before applying power
• to avoid fire hazard, replace fuses only with the specified type, voltage and
current rating -always refer fuse replacement to qualified service personnel
• to avoid explosion, do not operate this product in an explosive atmosphere
unless it has been specifically certified for such operation
• during installation, do not use the door handles or front panels to lift the
equipment because they may open abruptly and injure you
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FreewayRange Pro-Bel
ltd
• have qualified personnel perform safety checks after any completed service
Cautions
• use only specified replacement parts
• the front door of the cabinet is part of the fire enclosure and should be kept
closed
during normal operation.
• this product should be powered only as described in the user guide.
• 2.2 Installation
Any Pro-Bel equipment may be mounted next to other equipment provided it is
not subjected to excessive heat from that equipment. In order to maintain a cool,
internal temperature , make sure that the fans (if fitted) and vents on either side of
the equipment are unobstructed. Proper air circulation requires that both the fans
and vents have access to the ambient temperature room air mass .
• 2.3 EMC statement
General
Pro-Bel equipment has been tested against the European standards EN50081-1 and
-2. In all cases, the results depended heavily on the use of the correct cables and
connectors, and their correct assembly. Precautions applicable to each common
signal type are specified below. Installation provisions must be followed in order
that compliance is maintained in service. Normal practice as regards pushing
cards fully home and ensuring that connectors are well seated is essential to good
EMe performance .
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8

Pro-Bel Ltd
Technical manual
Digital audio connections
Cable should be of good lIOn design with a foil shield, such as Canford DST. This
shield must make contact all round at the entry to the mating connector body .
Pro-Bel
equipment with AES3 interfaces is fitted with '0' type connectors and the
shield is grounded to the chassis at the point of entry. The '0' type shield should
be of the tinned type fitted with screw-locks and with dimples on the male part.
Where a number of channels use the same connector, an overall shield is
preferred in addition to individual shields and this must also be firmly grounded
at both ends .
Serial digital video inputs and outputs
Cable should be good quality 75n design with double braided screens such as
PSFl/3 or Belden 8281. Pro-Bel equipment with Digital Video ('501' or SMPTE
259M) interfaces is fitted with BNC type connectors where the shield is grounded
to chassis at the point of entry. BNC plugs must be of the best quality as this type
is prone to EMC leakage if contact is not good all round the shell.
It is
possible to improve the emissions caused by this leakage by using cables with
ferrite collars. This
prevents leakage affecting adjacent cables in the installation
space.
Analogue audio (including time-code)
This causes the least problem as the signal spectrum is benign and the circuit
designs generally reject most unwanted signals. Some interference could occur if
the equipment contains processors, etc; so all screens are grounded at the point
of entry . Good quality cables with foil shields should be used with the shield
carried through from end to end, and connected to the chassis earth at the point
of entry using a very short tail.
Analogue video
As with analogue audio the risk lies with processors within the same equipment.
All output BNCs have the shield grounded at the fixing point and most inputs.
However, some inputs have floating connectors for maintenance of common-mode
rejection. Again, only good double-screened cable such as PSFl/3 should be used.
6540T-00 l'Jov 97
9

FreewayRange Pro-Bel
ltd
Other signal formats
MAD! and binary high-bit-rate telecom signals should be treated as digital video.
Other telecom signals, eg HDB3 signals at 34Mbit/s, 8448 and 2048kbit/s are
more akin to analogue video, but the presence of high frequency clock signals
inside the frame is more likely. The installation of telecom equipment may
require reference to telecom standards. These usually use unbalanced BNC
connections, but occasionally balanced 120Q circuits will be used, and should be
treated as AES3 .
Other balanced signals such as X21 (64,128,384,728 and 2048kbit/s) should be
treated as RS422/y11 control ports, and generally use 'D' type connectors.
Equipment with control ports
Cable should be of good quality with a foil shield. This shield must make contact
all round at the entry to the mating connector body at both ends of the cable. Pro-
Bel
equipment with control interfaces are fitted with '0' type connectors and the
shield is grounded to chassis at the point of entry. The 'D' type shield should be
of the tinned type fitted with screw-locks and with dimples on the male part.
Ribbon cables are NOT suitable under any circumstances outside of the
equipment frames .
• 2.4 Maintenance and warranty
Warranty statement
The warranty period covering Pro-Bel hardware is 5 years from the date of
shipment. During the first two months of this period, any defective product will
be
exchanged free of charge.
For the remainder of this period any defective product returned carriage paid will
be
repaired or replaced free of charge within our normal turnaround period of 21
days. Where
the defect is attributable to misuse or physical damage the warranty
will be deemed void with all costs associated with the repair or replacement
subject to charge .
Standard repair charges will apply to bought in items, power supplies, etc.
Repairs
required in less than the normal 21 day period will incur additional
charges.
6540T-00 Nov 97
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Pro-Bel ltd Technical manual
The warranty period covering software products is 90 day s. Beyond this
support/maintenance contracts are available and depending on the equipment
may be mandatory for a 3 year period .
WARNING: Ensure that any returned unit is adequately and appropriately packed;
for
example , do not pack static sensitive products in common polythene.
• 2.5 Telephone support
If technical help or advice is required, then in the first instance, Customers are
advised to contact their local sales office.
Customers with equipment directly supplied from Pro-Bel, are advised to contact
Customer Support, which has been set up to provide hardware, systems and
product support for all Pro-Bel supplied equipment.
To use this service please ensure you have the following information:
• order acknowledgement no./System product type no./Your order no.
Any
of these numbers will help us to quickly identify the equipment referred to.
Product type numbers - 4 digits
System type numbers - 4 digits beginning with 7 or 8 found on top of rear panel
of (custom equipment) frames or on system handbooks
• any module numbers relevant to the fault and their serial numbers
(e.g. 03/0017/05)
• a clear description of the fault
•
any relevant historical information
• any other information that might help diagnose the fault
• 2.6 Custom
Telephone number -
er support depa
44 (0)
118986-612 3
rtment
'.' . ,,~,'
Fax
number-
44 (0) 118975-5787
Internet addre ss -
support @pro-bel.co.uk
The
department is staffed from 9.00am to 5 .30pm Monday to Friday
Additional support is available outside these hours by purchasing a support
contract - det ails from the abo ve number.
6540T-00 Nov 97 11

FreewayRange Pro-Bel
ltd
• 2.7 Repairs
If the fault can be isolated to a single module, then the module can be sent for
repair in the following way :
•
please contact Customer Support for a repair number BEFORE sending your
repair to us
• supply, with the repair , the following information:
•
the repair number
• an order number (for out of warranty repairs)
• a
contact name and telephone number
• a description of the fault symptoms
• a list of modules supplied with their serial numbers
For correct address to send your repairs to, see 'Address Information'
• 2.8 Loans
If a loan module is required to cover a repair being sent:
•
please contact Customer Support, who will arrange the loan
• a
small charge is made to cover administration, so please have an order
number ready
• the loan will be sent to you in the normal way (urgent deliveries will be
charged at cost)
• when returning the loan please provide the following:
• the loan reference number, supplied with the loan
• a
contact name and telephone number
• a list of modules with their serial numbers
For correct address to send your loan returns to, see 'Address Information'
It is very important that you advise us if you need to keep the loan beyond the
'return by' date .
6540T-00 Nov 9712

Pro-Bel ltd
Technical manual
• 2.9 Exchanges
Exchanges are normally issued if a module has gone faulty within the first two
months of delivery.
When
returning your faulty module, which has been ex changed , please supply the
following information :
•
the exchange reference number
• a contact name and telephone numb er
• a description of the fault symptoms
• a list of module s supplied with their serial numbers
For correct address to send your exchange returns to, see 'Address Information'
• 2.10 Address information
The following addresses should be used when sending repairs, loan returns and
exchange returns to Pro-Bel.
UK customers
Customer Support
Telephone : [phone]
Pro-Bel Limited
Danehill
Lower Earley
Berkshire RG6 4
PB
England
6540T-00 Nov 97 13

Freeway Range
Pro-Bel Ltd
US customers
Customer Support Telephone: [phone]
Pro-Bel America
5
IIub Drive
Melville
NY 11747
Other customers
All other customers should contact their local agent , or UK Customer Support for
their correct return addr ess.
6540T-00 Nov 97 14

Pro-Bel ltd
Technical manual
6540T-00 Nov 97 15

FreewayRange Pro-Bel
ltd
3 Installation
During the installation process it is important to observe the following points :
• do
not obstruct the vents on the unit to allow cooling to take place
• remove shipping brackets
• 3.1 Door removal
The frame has a horizontally hinged front panel door that can be opened by
turning the knob anti-clockwise. The door can be removed from the frame by
opening it approximately 45 (, and lifting upwards. It will not disconnect from the
hinge at a greater angle.
For correct re-fitting of the door, ensure that it is centrally located on the hinge.
• 3.2 Power supply removal
There are two power suppl y modules used for main and backup . For EMC and
safety reasons the mains, chassis and signal earths are permanently connected
together with the module .
A
green LED on each PSU indicates the status of the power supply. PSU relay
alarms are also fitted.
The power supply modules are push fit into the frame and each secured by two
screws on the rear of the frame.
When replacing
the power supply the following recommendations must be
observed:
• always disconnect the mains from the unit before removal or during repair
• the securing screws should always be fitted before connecting the mains to
provide essential chassis earthing
Note: The Freeway PSU automatically adapts to the voltage range supplied. There
is no need to set a mains voltage selector position.
A WARNING: The screws form an essential chassis connection for
ili EMC compliance and must not be omitted
6540T-00 Nov 97
16

Pro-Bel ltd
Technical manual
o
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Power OK
Power OK
Green LED
Green LED
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Control panel
Po sitionof screws
onrearof panel
6540T -00 Nov 97 17

FreewayRange
Pro-Bel Ltd
• 3.3 Signal rear panel removal
Connections to the outside world are made through panels on the rear of the
frame. The control panel is common throughout the Freeway range and is fixed.
The signal rear panels are easily removed in the following manner:
• disconnect power from the frame
• remove the screws
• gently pull panel out
• replace panel and screws ensuring a good fit is made for EMC compliance
The connection details for the rear panels supplied are described in the second
part of the Freeway User Guide.
• 3.4 Removal and replacement of modules
The modules can be removed and replaced from the frame, powered or un-
powered, using the following procedure. For removal purposes it is advisable to
remove the ribbon cables first and then the cards.
• release the ribbon cables by pushing the catches up on either end of the
connector as shown
• lift up the card ejector on the module and gently pull the card out
Replacement is the reverse of above:
• slide
the card along the guide rail of the required slot, gently pushing it fully
home until it marries up with the connector on the motherboard
• if a card has a board reset pin (eg 4740 card), it is wise to exercise this when
plugging a board in with the power on
6540T-00 Nov 9718

Pro-Bel Ltd Technical manual
Signal rear panels
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o
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o
®®®®®®
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®®®®®® ®®
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Catches
Top view
Front view
6540T-00 Nov 97 19

FreewayRange
Pro-Bel Ltd
• 3.5 Cable connections
The standard cable connections diagram for a Freeway router is shown below.
Note: The
Freeway router can be controlled from multidropped panels (i.e. a
chain of panels on a common pin-to-pin cable bus, each set to a different address)
on ports RS485-1 and RS485-2 or from control systems on point to point links.
General Genera l
PC editorport remoteport
remote port
or
general
2/panel l /panel
remote port3 port port
11 11
625 PALori 1
525
NTSC i
TTL pulse I I
RS232 RS485 RS485
Inputs
...
r
utputs
~
... .. ... ... ..-... ........\ 9way
/...\ 9 way/...\ 9 way!..o...................°-...°--- .. -..........-....
°
Video ref1 Video ref2
(looping)
(looping)
I
Freeway Freeway
router router
modules modules
Master Master
2440 2440
control control
Inter processo r
subrnodule
submodu l
II
(Serial cornrns)
II
:
-Input
Outpu
...-
s
Rp
RP
ea ea
an an
e e
r
I I
s s
ts
- .
~
.. -. -. . .. . . - .. .. -_. ---....-.--.... -------... .....j .
... .. .... .. .... ........ .... .. ----.- . -- . ... ---- .. -..
\.
37 way
Contro l
1
o
6540T-00 Nov 97
Parallel xpt bus
(to slave routers)
20