Embedded Diagnostic Unit EDU - sinesystems.com fileSection 1 — Safety Information The Embedded Diagnostic Unit (EDU) should be installed only by qualified technical personnel. Incorrect

Embedded Diagnostic Unit

EDU

— Instruction Book —

This instruction book containsdocumentation for version EDU-C1.01

Manufactured for

by

Table of Contents

Hardware Manual

Topic Page Number

Safety Information

Warnings 1.1

General Equipment Description

Equipment Overview 2.1System Components 2.2

Specific Equipment Description

Description 3.1System-Level Block Diagram 3.2Physical Location of Modules 3.3Inter-Module Cable Diagram 3.4System-Level Connector Documentation 3.5Telemetry-Sample Signal Levels 3.6User Programming 3.7.1Programming Address Table 3.7.2

Individual Module Documentation

AC Analog Buffer module AAB-5 AAB-5.1Battery Back-up module BBU-1 BBU-1.1DC Analog Buffer module DAB-16 DAB-16.1General purpose I/O module IO-54 IO-54.1Master control module MM-1.1Relay module RY-8.1

Version C1.01 EDU Hardware Manual i

Section 1 — Safety Information

The Embedded Diagnostic Unit (EDU) should be installed only by qualified technicalpersonnel. Incorrect or inappropriate installation could result in a hazardous condition.

When connected to the host device, EDU can contain potentially dangerous voltages.Trouble-diagnosis and repair should be attempted only after EDU is disconnected from thehost device.

EDU contains a lead-acid battery. Shorting the terminals to each other or to ground couldresult in a fire hazard. If this battery is replaced, recycle or dispose of the old battery in amanner that meets local regulations.

There are no conventional fuses in EDU but there are self-resetting current limiting devices. Ifthese devices become defective, they should be replaced with ones of the same type and rating.

Do not use EDU to directly control circuits greater than 28 volts AC or DC.

The Embedded Diagnostic Unit, as any electronics device, can fail in unexpected ways, andwithout warning. Do not use the Embedded Diagnostic Unit in applications were a life-threatening condition could result if it were to fail.

Version C1.01 EDU Hardware Manual 1.1

Section 2 — General Equipment Description

Equipment Overview

Function:

The Embedded Diagnostic Unit (EDU) is an autonomous device installed within a host device,typically a broadcast transmitter or other complex industrial device. It’s function is toautomatically monitor and record various key operating parameters of the host. This providesmaintenance personnel with data that can accomplish two important functions: failureprediction and failure analysis. EDU can assist with failure prediction by providing long-term parametric trends that can provide an opportunity to analyze and correct a slowlydeveloping problem before an outage occurs. EDU can also collect and store importantparametric data at the moment of a failure. This can provide important information thatmay assist maintenance personnel in determining the cause of failure, with the result ofquicker diagnosis and repair.

A secondary function of EDU is to provide a means to remotely control and monitor the hostdevice. This can be accomplished with an ordinary telephone line as the communicationslink.

Construction:

EDU is contained in a single metal enclosure and is normally located internally to the host-device it monitors. It is 16.75 inches wide, 12 inches deep, and 1.75 inches high. Optionalrack-ears allow mounting in a standard 19-inch rack.. The rear panel contains one or more37 pin “D” connectors that provide it with power (from the host) and interface the appropriatemonitoring and control circuits of the host-device. EDU has provisions for analog telemetryinputs, logic-level status inputs, and control outputs. EDU is designed to operate in a hostileenvironment with respect to RFI, voltage surges, and temperature extremes. All inputs,outputs and communications connections are RFI and voltage-surge protected. EDU isconstructed modularly so that the number and type of inputs and outputs can be scaled tothe requirements of the host.

Power Source:

EDU obtains its operating power from the host in the form of low-voltage DC. It also containsits own internal battery back-up supply and can continue to operate for up to 48 hourswithout power from the host. The internal battery is automatically recharged when power isavailable from the host.

Data Storage:

EDU can be instructed to autonomously store data (analog telemetry and logic-level status)using any (or all) of three techniques: trend recording, event recording, and manualrecording. In trend recording, EDU uses its internal clock/calendar to periodically (e.g., oncea day, three times a day, etc.) scan all analog telemetry and status inputs and store them withan electronic “time/date stamp.” With event recording, EDU continuously scans alltelemetry and status inputs. At the instant any designated channel reaches a user-defined


departure from normal, all available telemetry and status inputs are recorded with a notationof the date and time the event occurred. Manual recording is done at the instruction of anoperator. As in the above cases, this records a complete scan of all inputs along with anotation of the date and time. When the memory in the EDU is full, it begins over-writing theoldest data. Designation of alarm channels, scanning intervals and required data variance totrigger a recording are selected during initial set-up of EDU.

Communication:

EDU connects to an ordinary “dial-up” (POTS) telephone line and communicates with theoperator by means of an internal 2400 baud modem. Monitoring conditions can be modifiedand data can be downloaded using an “IBM compatible” computer, a modem, and a specialsoftware package (EDUchat). EDU also contains a standard RS-232 serial port that can beused for direct connection to a computer. The computer can be used to print or store (to disc)trend and/or event data as they are acquired.

EDU Software:

A key component of EDU is the software (EDU chat) used to access it. EDU Chat runs underWindows® on a regular IBM-compatible computer. EDU Chat can be used to download andprocess data stored in EDU, as well as monitor and operate the host device in real-time. Thisallows for permanent storage of the data collected and temporarily stored by EDU. WhenEDU Chat is used for real-time monitoring and operation, a graphicly generated controlpanel will be displayed on the computer screen that is similar to the actual control panel onthe host device. Using the computer's mouse, control buttons can be activated just like on thereal control panel.

A key feature of the system is that there are no calibration adjustments located in the EDUhardware. All calibration constants are stored in the computer running EDU Chat in asoftware "template" that is unique to each host device. When the host device is originallytested by the manufacturer, a calibration template is created and kept on file along with theoriginal factory test data. Later, (even years later) if a factory technician is called upon toassist in the diagnosis of a problem with the host device, the technician uses the originalfactory-calibration template to examine the current data. This insures that he is getting datathat has not been corrupted by adjustments that were made after the device left the factory.When the technician compares the current data to the original factory-test data, he knows hewill be comparing "apples to apples."

System Components

Enclosure:

Internally, EDU is a modular system that allows considerable flexibility in choosing andinterconnecting functional modules. The EDU modules have various lengths but are all 3inches wide. They snap into a track system inside the EDU enclosure and are interconnectedwith multiconductor flat cable. Flat cable also connects the modules with one or more 37 pinD connectors on the rear panel. In addition to configuration flexibility this hardwarearchitecture also has the benefit of easier troubleshooting and repair. Each module can beelectrically isolated and tested (and replaced, if necessary) as a sub-system. The only internalcomponent that does not mount in the track system is the back-up battery.


Battery Back-Up Module:

The BBU-1 module converts the incoming DC power supply voltage to 6.9 volts DC which isused to power the other modules and to keep the internal battery charged. An additional andimportant function of the BBU-1 is to provide voltage-surge protection for the DC power andexternal communications lines.

Master Module:

The MM-1 master module is the central control module for EDU. It contains the primarymicroprocessor and operating ROM, data storage RAM, a separate RAM for data processing,and a nonvolatile EEPROM for storing user-programmed set-ups. It also contains a modemand a dedicated RS-232 port for communication to an external computer. The MM-1 gatherstelemetry data from, and issues control commands to, other internal modules by means of ahigh-speed serial data buss. In addition to it’s function as system controller, the MM-1module has inputs for 6 external analog telemetry sources, 2 logic-level status sources, and itcan telemeter the EDU power supply voltage and internal case temperature.

Input/Output Module:

The IO-54 module is a general-purpose input/output module with 22 analog inputs, 16 logic-level status inputs and 16 control outputs (54 total channels). The IO-54 module has it’s ownmicroprocessor and nonvolatile EEPROM to store user-programmed information. Itcommunicates with the master module by means of a high-speed serial buss.

Buffer Modules:

The DAB-16 DC Analog Buffer Module provides a means to convert a wide range of analogsignals to a form (0-5 volts DC) that can be accepted by an EDU input module. Up to 16independent channels can be buffered. The DAB-16 can be configured to accept analogsignals of either polarity from a few millivolts to one hundred volts. It can also be configuredto accept analog signals that are offset from ground up to 100 volts.

The AAB-5 AC Analog Buffer Module provides a means to convert 5 AC analog signals from afew millivolts to a hundred volts to a form (0-5 volts DC) that can be accepted by an EDU inputmodule. The AAB-5 provides an output that is proportional to the RMS value of the inputsignal.

The RY-8 Relay Module contains 8 relays that can be used to convert open-collector outputsto isolated relay contacts.


Section 3.1 — Specific Equipment Description

Version EDU-C1

Mechanical:

This EDU version is contained in a 19 inch rack-mounted enclosure, 1.75 inches high and12.5 inches deep.

Electrical:

This EDU version contains one each of the following modules: BBU-1 Battery Back-UpModule, MM-1 Master Module, IO-54 General-Purpose Input/Out Module, DAB-16 DCAnalog Buffer Module, and AAB-5 AC Analog Buffer Module.

This EDU version can monitor 19 external analog telemetry sources, 24 external logic-levelstatus sources, and two internal telemetry sources (supply voltage and case temperature). Ithas 8 relay-isolated control outputs.

Connectors:

All interface to the EDU is accomplished with four 37 pin “D” connectors mounted on the rearpanel.


(connectors on rear

panel)

BBU-1

MM-10

IO-54

DAB-16

AAB-5

RY-8

Battery Back-Up/Surge & RFI Protection

Master Module (with 10 telemetry channels)

General Purpose Input/Output (54 total channels)

DC Analog Buffer (16 channels)

AC Analog Buffer (5 channels)

Relay Buffer (8 relays)

Modules:

Section 3.2 – System-Level Block

Diagram

For Version EDU-C1 Rev. 0

Modules:

BBU-1MM-10IO-54DAB-16AAB-5RY8

Battery Back-Up/Surge & RFI ProtectionMaster Module (with 10 telemetry channels)General Purpose Input/Output (54 total channels)DC Analog Buffer (16 channels)AC Analog Buffer (5 channels)Relay Buffer (8 relays)

Section 3.3 – Physical Locations of ModulesFor Version EDU-C1 Rev. 0

(connectors on rear

panel)

BBU-1

MM-10

IO-54

DAB-16

AAB-5

RY-8

Battery Back-Up/Surge & RFI Protection

Master Module (with 10 telemetry channels)

General Purpose Input/Output (54 total channels)

DC Analog Buffer (16 channels)

AC Analog Buffer (5 channels)

Relay Buffer (8 relays)

Modules:

Section 3.4 — Inter-Module Cable

Diagram


(front panel)

Section 3.5 — System-Level Connector


ModuleType

PinNumber

Module-LevelSignal Description

System-LevelSignal Description

PinNumber

ModuleConnector

( J # )

Rear PanelConnector

( J # )

BBU-1 1 1 Internal Battery "-" Internal Battery "-" 1 1

BBU-1 1 2 Internal Battery "-" Internal Battery "-" 1 20

BBU-1 1 3 DC Power "+" DC Power "+" 1 2

BBU-1 1 4 DC Power "+" DC Power "+" 1 21

BBU-1 1 5 RS-232 Transmit (from EDU) RS-232 Transmit 1 3

BBU-1 1 6 RS-232 Receive (to EDU) RS-232 Receive 1 22

BBU-1 1 7 System Ground System Ground 1 4




BBU-1 1 11 Telehone Line (tip) Telehone Line (tip) 1 6

BBU-1 1 12 Telehone Line (tip) Telehone Line (tip) 1 25

BBU-1 1 13 Telehone Line (ring) Telehone Line (ring) 1 7

BBU-1 1 14 Telehone Line (ring) Telehone Line (ring) 1 26



•

DAB-16 3 1 DC Analog Input 1 + Plate Current + 2 1

DAB-16 3 2 DC Analog Input 1 - Plate Current - 2 20

DAB-16 3 3 DC Analog Input 2 + Plate Voltage + 2 2

DAB-16 3 4 DC Analog Input 2 - Plate Voltage - 2 21

DAB-16 3 5 DC Analog Input 3 + Transmitter Output + 2 3

DAB-16 3 6 DC Analog Input 3 - Transmitter Output - 2 22

DAB-16 3 7 DC Analog Input 4 + Transmitter Reflected Power + 2 4

DAB-16 3 8 DC Analog Input 4 - Transmitter Reflected Power - 2 23

DAB-16 3 9 DC Analog Input 5 + PA Screen Voltage + 2 5

DAB-16 3 10 DC Analog Input 5 - PA Screen Voltage - 2 24

DAB-16 3 11 DC Analog Input 6 + PA Screen Current + 2 6

DAB-16 3 12 DC Analog Input 6 - PA Screen Current - 2 25

DAB-16 5 1 DC Analog Input 9 + IPA Forward Power + 2 7

DAB-16 5 2 DC Analog Input 9 - IPA Forward Power - 2 26

DAB-16 5 3 DC Analog Input 10 + IPA Reflected Power + 2 8

DAB-16 5 4 DC Analog Input 10 - IPA Reflected Power - 2 27

page 3.5.1

ModuleType

PinNumber



PinNumber

ModuleConnector

( J # )

Rear PanelConnector

( J # )

DAB-16 5 5 DC Analog Input 11 + IPA Collector Voltage + 2 9

DAB-16 5 6 DC Analog Input 11 - IPA Collector Voltage - 2 28

DAB-16 5 7 DC Analog Input 12 + IPA Collector Current + 2 10

DAB-16 5 8 DC Analog Input 12 - IPA Collector Current - 2 29

DAB-16 5 9 DC Analog Input 13 + PA Bias Voltage + 2 11

DAB-16 5 10 DC Analog Input 13 - PA Bias Voltage - 2 30

DAB-16 5 11 DC Analog Input 14 + PA Grid Current + 2 12

DAB-16 5 12 DC Analog Input 14 - PA Grid Current - 2 31

DAB-16 5 13 DC Analog Input 15 + Intake Temp + 2 13

DAB-16 5 14 DC Analog Input 15 - Intake Temp - 2 32

DAB-16 5 15 DC Analog Input 16 + Exhaust Temp + 2 14

DAB-16 5 16 DC Analog Input 16 - Exhaust Temp - 2 33

AAB-5 3 2 AC Analog Input 1 PA Filament Voltage 2 15

AAB-5 3 3 System Ground System Ground 2 34

AAB-5 3 4 AC Analog Input 1 PA Filament Current 2 16


AAB-5 3 6 AC Analog Input 1 AC Line Voltage A-B 2 17


AAB-5 3 8 AC Analog Input 1 AC Line Voltage B-C 2 18


AAB-5 3 10 AC Analog Input 1 AC Line Voltage C-A 2 19

•

IO-54 2 1 Analog Input 9 Phase Loss 3 1

IO-54 2 2 Analog Input 10 Card Cage 3 20

IO-54 2 3 Analog Input 11 Air Interlock 3 2

IO-54 2 4 Analog Input 12 Temperature Interlock 3 21

IO-54 2 5 Analog Input 13 Ready 3 3

IO-54 2 6 Analog Input 14 PA Door Interlock 3 22

IO-54 2 7 Analog Input 15 PA Grid Door Interlock 3 4

IO-54 2 8 Analog Input 16 Remote Plate Interlock 3 23

IO-54 2 9 Ground System Ground 3 5


IO-54 5 1 Status Input 3 Filament ON 3 6

IO-54 5 2 Status Input 4 Auto Power Control 3 25

IO-54 5 3 Status Input 5 VSWR Overload 3 7

IO-54 5 4 Status Input 6 PA Screen Overload 3 26

IO-54 5 5 Status Input 7 PA Plate Overload 3 8

IO-54 5 6 Status Input 8 IPA Fault 3 27

IO-54 5 7 Status Input 9 Exciter Fault 3 9

page 3.5.2

ModuleType

PinNumber



PinNumber

ModuleConnector

( J # )

Rear PanelConnector

( J # )

IO-54 5 8 Status Input 10 Spare Status 1 3 28



IO-54 6 1 Status Input 11 Local Control 3 11

IO-54 6 2 Status Input 12 Left Rear Door Interlock 3 30

IO-54 6 3 Status Input 13 Center Rear Door Interlock 3 12

IO-54 6 4 Status Input 14 Right Rear Door Interlock 3 31

IO-54 6 5 Status Input 15 Center Front Panel Interlock 3 13

IO-54 6 6 Status Input 16 Right Front Panel Interlock 3 32

IO-54 6 7 Status Input 17 Remote Interlock 3 14

IO-54 6 8 Status Input 18 Plate ON 3 33



•

RY-8 2 1 Relay Contact 1 Filament Start 4 1

RY-8 2 2 Relay Contact 1 4 20

RY-8 2 3 Relay Contact 2 Filament Stop 4 2


RY-8 2 5 Relay Contact 3 Plate Start 4 3


RY-8 2 7 Relay Contact 4 Plate Stop 4 4


RY-8 2 9 Relay Contact 5 Manual Power Control 4 5


RY-8 2 11 Relay Contact 6 Automatic Power Control 4 6


RY-8 2 13 Relay Contact 7 Power RAISE 4 7


RY-8 2 15 Relay Contact 8 Power LOWER 4 8


page 3.5.3

System-Level Signal: Raw Telemetry Sample Offset From Ground (volts):

Section 3.6 — Telemetry-Sample Signal Levels:

EDU Version C1 is set up for the following telemetry signal levels:

EDU System Voltage 28.0EDU Internal Case .01V/°FPlate Current + 9.7 1.0Plate Voltage + 2.69Transmitter Output + 6.54Transmitter Reflected Power 1.56PA Screen Voltage + 23.5PA Screen Current + .256IPA Forward Power + 2.42IPA Reflected Power + .35IPA Collector Voltage + 43IPA Collector Current + .4 43PA Bias Voltage + .29PA Grid Current + .02 .25Intake Temp + 2Exhaust Temp + 2PA Filament Voltage 1.4 ACPA Filament Current 1.79 ACAC Line Voltage A-B 5.4 ACAC Line Voltage B-C 5.4 ACAC Line Voltage C-A 5.4 AC

Section 3.7.1 — User Programming

Overview

The EDU has an internal clock/calendar that should be set by the user. It also has a numberof user-programmable options. All user-programmable options in the EDU (everything exceptthe current clock/calendar setting), are stored in non-volatile EEPROM. This means that thedata is stored indefinitely, without the need for either external DC power or even batteryback-up power. However, if the external DC power and the internal battery are disconnected,the clock/calendar reverts to 00:00:00 January 1, 1995 and will need to be reset.

The user-programmable options are pre-programmed at the factory with values that aresuitable for most field applications. In the vast majority of cases, additional user-programming is not necessary. All that will be required is to set the clock and calendar.

Use extreme care when programming memory addresses in the EDU. Becareful to enter the correct address and leave boxes blank that are not intendedfor programming. It is possible to actually disable the EDU from operating byinadvertently programming certain addresses.

Summary of Factory Programming for EDU Version C1

The EDU-C1 is factory programmed to trigger an event recording upon detection of any of thefollowing conditions:

Loss of plate currentLoss of power outputExcessive case temperatureExcessive exhaust temperatureVSWR overloadPA screen overloadPA plate overloadIPA faultExciter fault

The EDU-C1 is factory programmed to make a time-triggered recording at the followingtimes:

12:00 midnight6:00 AM12:00 noon6:00 PM

Version C1.01 EDU Hardware Manual 3.7.1.1

User-Programming Descriptions and Formats

For the more ambitious user, the information in this section describes everything that cancan be programmed in the EDU and how to program it. Two pieces of information arerequired to program data into the EDU. First, we need to know the module number andstarting address for the desired programming. This is found in the next section, Section3.7.2. Second, we need to know the description and format of the data to be programmed.This information is located in this section. To program the EDU, first open the EDUchatsoftware. From the main menu, click on the "Connect" button. From the "EDU:Terminal"screen, select whether this is a local or dial-up connection and then click the "Connect"button. After the EDU is on line, click on the word "Program" just below the top bar. Thefollowing screen will appear:


The module number and starting address information is located in the following section(Section 3.7.2). Note in the left half of the screen that there are two options for ProgrammingType: Event Programming and Data Programming. These options change the right half of thescreen. Here is the screen with Event Programming selected:

All programming should be done with the "Data Programming" option except theprogramming for the Telemetry Triggered Events or setting the Clock/Calendar.

The following paragraphs describe all the user-programmable functions available in the EDU.The programming formats are located in this section and the module numbers and addressesare located in the next section (Section 3.7.2).

Telemetry Trigger:

All telemetry channels, both analog and logic-level status channels, can be individuallyprogrammed to trigger an "event recording" when certain conditions are met. The requiredconditions are determined by the Trigger Rule, Lower Limit and Upper Limit for each channel.The four available Trigger Rules are defined below:

Trigger Rules:

1 Trigger an event recording when the telemetry crosses either the upper or lower limit.

2 Trigger an event recording if the telemetry moves from between the upper and lower limitsto above the upper limit.

3 Trigger an event recording if the telemetry moves from between the upper and lower limitsto below the lower limit.


4 Trigger an event recording if the telemetry moves from between the upper and lower limitsto either above the upper limit or below the lower limit.

The upper and lower limits for each channel should be based on the EDU's raw telemetryoutput. For example, a voltage reading may be 5.00 kilovolts in its final form but the rawtelemetry reading may be "179", the actual output of the EDU's A-D converter. Raw telemetrydata can be determined either of two ways:

Method 1: The raw data may be viewed directly on the EDU control screen by using aspecial test template called RAWDATA.MDB. This template performs no mathematicaladjustment of the data and lets the raw data be displayed directly on the control screen. If thenormal raw reading is 179 and it is desired that the upper and lower limits be at +20% and -20% respectively, use 215 for the upper limit (179 x 1.2) and 143 (179 x .8) for the lower limit.

Method 2: The raw data can be calculated by starting with the final telemetry data andapplying the formula in the calibration template "in reverse." For example, suppose that thefinal telemetry data is 5.00 kilovolts. Suppose the formula in the calibration template is "rawdata/35.8". To reverse the process, we take 5.00 and multiply it by 35.8 and get 179. If wewant an upper limit of 5.4 kilovolts, we would multiply 5.4 times 35.8 and get 193 for an upperlimit. If we want an lower limit of 3.5 kilovolts, we would multiply 3.5 times 35.8 and get 125for a lower limit.

The Trigger Rule, Lower Limit, and Upper Limit for each channel should be programmed asshown in the following example:

Function: Example:

trigger rule 4lower limit 125upper limit 179

The Module Number and Starting Address is located in Section 3.7.2. Program using the"Event Programming" format.

To prevent a channel from triggering an event recording, set the Trigger Rule to 4, the LowerLimit to 0 and the Upper Limit to 9999.

Logic-level "status" channels and analog channels that are configured to monitor logic-levelsignals can be considered to produce a raw data output of >128 for a logic-level "high" inputand <128 for a logic-level "low" input.


Time Trigger:

This programming determines the clock-triggered times when the EDU will record telemetrydata. There are 12 "Time Triggers" that can be programmed. For example, if the "hours" areset to "12" and the "minutes" are set to "00", the EDU will record a set of readings at noonevery day:

The Module Number and Starting Address is located in Section 3.7.2. Program using the"Data Programming" format.

Byte #: Description: Example:

byte 1 hours 12byte 2 minutes 00byte 3 digit 3 (leave blank)byte 4 digit 4 (leave blank)byte 5 digit 5 (leave blank)byte 6 digit 6 (leave blank)byte 7 digit 7 (leave blank)byte 8 digit 8 (leave blank)

A Time Trigger can be disabled by setting the "hours" to "100".

Setting a Time Triggered value (either hours or minutes) to "99" makes the trigger occur"every" unit of the value. For example. programming "99" hours and "03" minutes causesdata to be recorded every hour at three minutes past the hour.

Security Code:

In order to go on-line with the EDU, the EDUchat software must know the 8-digit securitycode for the EDU. This is factory programmed as "12345678". If the security code is changed,it must be changed in both the EDU and the EDUchat software. The following example showshow to change the security code to "76381724".


Byte #: Description: Example:

byte 1 digit 1 7byte 2 digit 2 6byte 3 digit 3 3byte 4 digit 4 8byte 5 digit 5 1byte 6 digit 6 7byte 7 digit 7 2byte 8 digit 8 4

After changing the security code in the EDU, be sure and change to the same code in theEDUchat software.

If it ever occurs that the security code in the EDU is accidentally changed to an unknownvalue, it will be impossible to access it with EDUchat. If this happens, disconnect J1 on the


back of the EDU and then reconnect it. The very next attempt (and only the very nextattempt) to go on-line with EDUchat will be successful regardless of the security code. Duringthe first session, read the security code in EDU (or change it) and set the same value inEDUchat. Also, don't forget to reset the EDU's clock/calendar.

Ring Number:

This programs how many rings occur before EDU answers the call.


Byte #: Ring Number: Example:

byte 1 digit 1 3byte 2 (leave blank)byte 3 (leave blank)byte 4 (leave blank)byte 5 (leave blank)byte 6 (leave blank)byte 7 (leave blank)byte 8 (leave blank)

Clock Speed Trim:

This function trims the speed of the clock. The clock-speed-trim value is factory set to "50000"and is equal to 256 times byte 1, plus byte 2. The factory setting for byte 1 is 195 and for byte2 is 80 [(256 x 195) + 80 = 50000]. Increasing the clock speed trim value decreases the clockspeed by 0.101 seconds per day per unit, and decreasing the clock speed trim value increasesthe clock speed by 0.101 seconds per day per unit. For example, if the clock is running 2.1seconds per day fast, we need to increase the clock-speed-trim value by 21. If the currentvalue is 50000, the new value needs to be 50021. 50021/256=195 for the first byte. 50021 -(195 x 256) = 101 for the second byte.


Byte #: Clock Speed Trim: Example:

byte 1 byte 1 195byte 2 byte 2 101byte 3 (leave blank)byte 4 (leave blank)byte 5 (leave blank)byte 6 (leave blank)byte 7 (leave blank)byte 8 (leave blank)


Lock-Out Time:

When EDU detects a change in telemetry or logic-level status that triggers an event recording,it is common for several telemetry sources to change in a "cluster" which are associated withthe same event. To prevent the EDU from making several duplicate recordings in thesecircumstances, the first telemetry source to trigger a recording also starts a "lock-out" periodduring which subsequent triggers are ignored. This lockout period is factory set to 2.0seconds. The lock-out period is programmed with a single byte. The lock-out time is equal to0.025 seconds times the value of the byte. For example, this value is set to 80 at the factoryand results in 80 x 0.025 or 2.0 seconds.


Byte #: Clock Speed Trim: Example: Notes:

byte 1 byte 1 80 80 x 0.025 = 2.0 secondsbyte 2 (leave blank)byte 3 (leave blank)byte 4 (leave blank)byte 5 (leave blank)byte 6 (leave blank)byte 7 (leave blank)byte 8 (leave blank)

Highest Module Polled:

This data byte is preset at the factory and should not be modified.

Module Address:

This data byte is preset at the factory and should not be modified.

Output On Time:

Some EDU modules have control outputs. When these outputs are operated in the"momentary" mode, the duration of the momentary output is controlled by this value, asingle byte. The momentary "on" time is equal to the value times 0.025 seconds. The factorysetting of "20" results in a momentary output time of 20 x 0.025 or 0.5 seconds.


Byte #: Output On Time: Example: Notes:

byte 1 byte 1 20 20 x 0.025 = 0.5 secondsbyte 2 (leave blank)byte 3 (leave blank)byte 4 (leave blank)byte 5 (leave blank)byte 6 (leave blank)byte 7 (leave blank)byte 8 (leave blank)


Firmware Version:

The firmware version of all modules is located at address 65468. The version is read as threebytes. For example, a read of 1, 0, and 0 means the firmware version is "1.00". Each modulewith a microprocessor has a firmware version so be sure to enter the appropriate moduleaddress number before the read. The firmware version is a read-only memory location andcan not be modified.

Module Type:

The "module type" of any module can be read at address 65468. The data is read as one byte.For example, a read of "54" means the module type is an "IO-54". Each module with amicroprocessor can be interrogated as to module type so be sure to enter the appropriatemodule address number before the read. The "module type" is a read-only memory locationand can not be modified.


System-Level Signal Description: Programming: Module #: Start Add.: Bytes: Factory Prog.:

Section 3.7.2—Programming Address Table:(For EDU Version C1)

Clock/Calendar 0 0 6

EDU System Voltage Telemetry Trigger 0 46592 5 04 0000 9999

Module Address 1 46592 1 1

IPA Forward Power + Telemetry Trigger 1 46593 5 04 0000 9999

EDU Internal Case Temperature Telemetry Trigger 0 46597 5 01 0000 0072

IPA Reflected Power + Telemetry Trigger 1 46598 5 04 0000 9999

Plate Current + Telemetry Trigger 0 46602 5 03 0080 9999

IPA Collector Voltage + Telemetry Trigger 1 46603 5 04 0000 9999

Plate Voltage + Telemetry Trigger 0 46607 5 04 0000 9999

IPA Collector Current + Telemetry Trigger 1 46608 5 04 0000 9999

Transmitter Output + Telemetry Trigger 0 46612 5 03 0152 9999

PA Bias Voltage + Telemetry Trigger 1 46613 5 04 0000 9999

Transmitter Reflected Power + Telemetry Trigger 0 46617 5 04 0000 9999

PA Grid Current + Telemetry Trigger 1 46618 5 04 0000 9999

PA Screen Voltage + Telemetry Trigger 0 46622 5 04 0000 9999

Intake Temp + Telemetry Trigger 1 46623 5 04 0000 9999

PA Screen Current + Telemetry Trigger 0 46627 5 04 0000 9999

Exhaust Temp + Telemetry Trigger 1 46628 5 01 0000 0225

Not used Telemetry Trigger 0 46632 5 04 0000 9999

Phase Loss Telemetry Trigger 1 46633 5 04 0000 9999


Card Cage Telemetry Trigger 1 46638 5 04 0000 9999

Time Trigger 1 0 46642 2 00 00

Air Interlock Telemetry Trigger 1 46643 5 04 0000 9999

Time Trigger 2 0 46644 2 06 00

Time Trigger 3 0 46646 2 12 00

Time Trigger 4 0 46648 2 18 00

Temperature Interlock Telemetry Trigger 1 46648 5 04 0000 9999

Time Trigger 5 0 46650 2 100 00

Time Trigger 6 0 46652 2 100 00

Ready Telemetry Trigger 1 46653 5 04 0000 9999

Time Trigger 7 0 46654 2 100 00

Time Trigger 8 0 46656 2 100 00

Time Trigger 9 0 46658 2 100 00

PA Door Interlock Telemetry Trigger 1 46658 5 04 0000 9999

Time Trigger 10 0 46660 2 100 00

Time Trigger 11 0 46662 2 100 00

PA Grid Door Interlock Telemetry Trigger 1 46663 5 04 0000 9999

Time Trigger 12 0 46664 2 100 00

page 3.7.2.1


Section 3.7.2—Programming Address Table:(For EDU Version C1)

Clock/Calendar 0 0 6

EDU System Voltage Telemetry Trigger 0 46592 5 04 0000 9999

EDU Internal Case Temperature Telemetry Trigger 0 46597 5 01 0000 0072

Plate Current + Telemetry Trigger 0 46602 5 03 0080 9999

Plate Voltage + Telemetry Trigger 0 46607 5 04 0000 9999

Transmitter Output + Telemetry Trigger 0 46612 5 03 0152 9999

Transmitter Reflected Power + Telemetry Trigger 0 46617 5 04 0000 9999

PA Screen Voltage + Telemetry Trigger 0 46622 5 04 0000 9999

PA Screen Current + Telemetry Trigger 0 46627 5 04 0000 9999



Time Trigger 1 0 46642 2 00 00

Time Trigger 2 0 46644 2 06 00

Time Trigger 3 0 46646 2 12 00

Time Trigger 4 0 46648 2 18 00

Time Trigger 5 0 46650 2 100 00

Time Trigger 6 0 46652 2 100 00

Time Trigger 7 0 46654 2 100 00

Time Trigger 8 0 46656 2 100 00

Time Trigger 9 0 46658 2 100 00

Time Trigger 10 0 46660 2 100 00

Time Trigger 11 0 46662 2 100 00

Time Trigger 12 0 46664 2 100 00

Security Code 0 46666 8 12345678

Ring Number 0 46674 1 4

Clock Speed Trim 0 46675 2 50000

Lock-Out Time 0 46677 1 80

Highest Module Polled 0 46678 1 2

Firmware Version 0 65468 3

Module Type 0 65471 1

Module Address 1 46592 1 1

IPA Forward Power + Telemetry Trigger 1 46593 5 04 0000 9999

IPA Reflected Power + Telemetry Trigger 1 46598 5 04 0000 9999

IPA Collector Voltage + Telemetry Trigger 1 46603 5 04 0000 9999

IPA Collector Current + Telemetry Trigger 1 46608 5 04 0000 9999

PA Bias Voltage + Telemetry Trigger 1 46613 5 04 0000 9999

PA Grid Current + Telemetry Trigger 1 46618 5 04 0000 9999

Intake Temp + Telemetry Trigger 1 46623 5 04 0000 9999

Exhaust Temp + Telemetry Trigger 1 46628 5 01 0000 0225

page 3.7.2.1


Programming Address Table:(For EDU Version C1)

Phase Loss Telemetry Trigger 1 46633 5 04 0000 9999

Card Cage Telemetry Trigger 1 46638 5 04 0000 9999

Air Interlock Telemetry Trigger 1 46643 5 04 0000 9999

Temperature Interlock Telemetry Trigger 1 46648 5 04 0000 9999

Ready Telemetry Trigger 1 46653 5 04 0000 9999

PA Door Interlock Telemetry Trigger 1 46658 5 04 0000 9999

PA Grid Door Interlock Telemetry Trigger 1 46663 5 04 0000 9999

Remote Plate Interlock Telemetry Trigger 1 46668 5 04 0000 9999

PA Filament Voltage Telemetry Trigger 1 46673 5 04 0000 9999

PA Filament Current Telemetry Trigger 1 46678 5 04 0000 9999

AC Line Voltage A-B Telemetry Trigger 1 46683 5 04 0000 9999

AC Line Voltage B-C Telemetry Trigger 1 46688 5 04 0000 9999

AC Line Voltage C-A Telemetry Trigger 1 46693 5 04 0000 9999


Filament ON Telemetry Trigger 1 46703 5 04 0000 9999

Auto Power Control Telemetry Trigger 1 46708 5 04 0000 9999

VSWR Overload Telemetry Trigger 1 46713 5 03 0150 9999

PA Screen Overload Telemetry Trigger 1 46718 5 03 0150 9999

PA Plate Overload Telemetry Trigger 1 46723 5 03 0150 9999

IPA Fault Telemetry Trigger 1 46728 5 03 0150 9999

Exciter Fault Telemetry Trigger 1 46733 5 03 0150 9999

Spare Status 1 Telemetry Trigger 1 46738 5 04 0000 9999

Local Control Telemetry Trigger 1 46743 5 04 0000 9999

Left Rear Door Interlock Telemetry Trigger 1 46748 5 04 0000 9999

Center Rear Door Interlock Telemetry Trigger 1 46753 5 04 0000 9999

Right Rear Door Interlock Telemetry Trigger 1 46758 5 04 0000 9999

Center Front Panel Interlock Telemetry Trigger 1 46763 5 04 0000 9999

Right Front Panel Interlock Telemetry Trigger 1 46768 5 04 0000 9999

Remote Interlock Telemetry Trigger 1 46773 5 04 0000 9999

Plate ON Telemetry Trigger 1 46778 5 04 0000 9999

Output On Time 1 46783 1

Firmware Version 1 65468 3

Module Type 1 65471 1

page 3.7.2.2

Individual Module Documentation

Module Description Section

AC Analog Buffer module AAB-5 AAB-5.1Battery Back-up module BBU-1 BBU-1.1DC Analog Buffer module DAB-16 DAB-16.1General purpose I/O module IO-54 IO-54.1Master control module MM-1.1Relay module RY-8.1


AAB-5 AC Buffer Module

General:

The AAB-5 AC Analog Buffer Module provides a means to convert 5 AC analog signals from afew millivolts to a hundred volts, to a form (0-5 volts DC) that can be accepted by the A-D(analog-to-digital) converter in an MM-1 or IO-54 module. The AAB-5 provides an outputthat is proportional to the RMS value of the input signal.

Additional attributes:

• True rms-to-DC conversion with a crest factor up to 5.• The gain of each of the 5 channels can be programmed with a plug-in resistor

Mechanical:

The AAB-5 is designed for installation in the standard 3 inch track of an EDU enclosure. Thesize of the module is 3.35 inches by 3 inches.

Electrical:

The AAB-5 module requires 6.9 volts DC at approximately 20 milliamperes.

Resistor Selection:

The gain-programming-resistors are 1/4 watt. 5%, carbon film resistors. These five resistorsare installed in a row near the bottom center of the board. The resistors are installed in asocket so they can be easily changed. Below each resistor is a number that corresponds tothe channel number:

The AC input impedance of each buffer channel is approximately equal to the value of theprogramming resistor plus 1000 ohms. The frequency response of the buffers is flat to within± 0.05 dB from 20 Hz to about 1250 Hz.

The following table shows the values of resistors that should be used for a wide range of inputsignals:

Version C1.01 EDU Hardware Manual AAB-5.1

Table 1: (based on the AAB-5 generating an output signal of 2.5 to 3.75 volts DC)

Input Range: Resistor Value:

75 to 112 volts AC rms 220K51 to 77 volts AC rms 150K34.2 to 51 volts AC rms 100K23.4 to 35 volts AC rms 68K16.3 to 24.4 volts AC rms 47K11.5 to 17.3 volts AC rms 33K7.8 to 11.7 volts AC rms 22K5.42 to 8.13 volts AC rms 15K3.73 to 5.59 volts AC rms 10K2.6 to 4.0 volts AC rms 6.8K1.9 to 2.9 volts AC rms 4.7K1.4 to 2.2 volts AC rms 3.3K1.35 to 2.0 volts AC rms 3.0K.95 to 1.4 volts AC rms 1.8K.68 to 1.0 volts AC rms 1.0K.45 to .68 volts AC rms 330.34 to .50 volts AC rms 0 (jumper)

Version C1.01 EDU Hardware Manual AAB-5.2

PA Filament VoltagePA Filament CurrentAC Line A-BAC Line B-CAC Line C-A

12345

Unless otherwise noted, all resistorvalues are in ohms and all capacitorvalues are in microfarads.


Module: AAB-5

Description: AC Buffer ModuleVersion: C1 Revision: 0

Parts List

AAB-5; Version 1.0

QuantityPart Description and Value

1board, PC, AAB-5, Rev. 0

5capacitor, aluminum, radial, 10 µF, 16v/short


5capacitor, aluminum, radial, 100 µF, 35v

5capacitor, monolythic ceramic, 0.01 µF, .1" spacing


3connector, pin-plug, female, 0.1", 10, IDC

15connector pins, pin-plug, male, 0.1", 40 x 2, 0.23 gold up/.015 tin dn

5integrated circuit, op amp, dual, OP97F, LT1097CN8/OP-27 compatible

1integrated circuit, voltage converter, DC-DC, LT1026CN8,

5integrated circuit, voltage converter, RMS-DC converter, AD736JN,

5resistor, carbon film, 1/4W, 1.0K, 5%

8resistor, carbon film, 1/4W, 10K, 5%




11socket, DIP, 8,

10socket, SIP, 32, gold, high

5varistor, metal oxide, 85 VDC, 60 VAC

BBU-1 Battery Back-Up Module

General:

The BBU-1 module converts the incoming DC power supply voltage to 6.9 volts DC which isused to power the other modules and to keep the internal battery charged. An additional andimportant function of the BBU-1 is to provide voltage-surge and RFI protection for the DCpower and external communications lines.


• Battery charge voltage is temperature compensated (+4.0 mV/°F) for optimum charging oflead-acid cells.

• Self-resetting "fuses" limit total input current to 0.9 amperes and battery current to 0.4amperes.

• Power supply line is protected from voltage surges and reverse-polarity.

• Current can not flow from the back-up battery to the host.

• Telephone line connection is surge-protected with self-resetting "fuses" and a dual gas-typesurge arrestor.

• RS-232 lines are voltage surge protected with varistors.

• All circuits (telephone line, RS-232 lines, and power supply line) are protected from RFI withbroadband filters.

Mechanical:

The BBU-1 is designed for installation in the standard 3 inch track of an EDU enclosure. Thesize of the module is 2.4 inches by 3 inches.

Electrical:

The BBU-1 module requires an input of +9.75 to +29.5 volts DC. It provides the necessarypower to the EDU modules plus up to 0.4 amperes to charge the back-up battery.

Version C1.01 EDU Hardware Manual BBU-1.1


Module: BBU-1

Description: Battery Back-Up Module

Version: C1 Revision: 1


* Note: Adjust R4 to produce 6.90 volts DC across terminals B+ and B- at room temperature (70° - 75°) with red wire disconnected from battery.

Parts List

BBU-1; Version 1.0


1board, PC, BBU-1, Rev. 0


1capacitor, aluminum, radial, 470 µF, 35v

4capacitor, ceramic disc, 0.001 µF/1000 pF, 1KV

4connector, D, female, 37, PCB, 0°

2connector, faston, female, 0.187", 1, crimp, insulated



110connector pins, D, 1, crimp


4connector shell, D, 37, gray

2diode, general purpose, 600 V/1 A, 1N4005

2fuse, polyswitch, resettable, 0.16 amp, 600 V



1hardware, ground lug, #6,

1hardware, nut, hex, 6-32,

2hardware, nut, locknut, hex, 4-40, stainless

3hardware, screw, pan head, 4-40 x 3/8", stainless


1hardware, standoff, round, F-F, 4-40 x 0.5", clear

1heatsink, TO-220, 1.0" x 0.85" x 0.75",

2inductor, 1.0 mH, 5 ohms/150 mA, radial

3inductor, EMI filter, 5 amp, 50 volt

2inductor, ferrite bead filter, ,

1integrated circuit, voltage regulator, LM317F, +adjustable/1.5 A

1resistor, carbon film, 1/4W, 470, 5%

1resistor, cermet trimmer, 200, 22 turn, vertical

1resistor, metal film, 1/4W, 121, 1%

1resistor, thermistor, 33K at 25°C, -5.1%/°C

1resistor, wire wound, 25W, 25, 1%

1surge protector, gas arrestor, 3 terminal, short leads

1surge protector, solid state supressor, 1.5KE33A,

1surge protector, solid state supressor, 1.5KE8.2A,


DAB-16 DC Analog Buffer Module

General:

The DAB-16 DC Analog Buffer Module provides a means to convert a wide range of analogsignals to a form (0-5 volts DC) that can be accepted by an EDU input module. Up to 16independent channels can be buffered. The DAB-16 can be configured to accept analogsignals of either polarity from a few millivolts to one hundred volts. It can also be configuredto accept analog signals that are offset from ground up to 100 volts.

Mechanical:

The DAB-16 is designed for installation in the standard 3 inch track of an EDU enclosure.The size of the module is 7.3 inches by 3 inches.

Electrical:

The DAB-16 module requires 6.9 volts DC at approximately 40 milliamperes.

Function of the DAB-16 Board:

The EDU telemetry inputs are are connected to telemetry-sample-signals that correspondwith actual parameters to be monitored in the host device. In some cases the telemetrysample and and the monitored parameter are identical. However, in many cases thetelemetry sample is a voltage that is proportional to a monitored parameter. For example,the telemetry sample could be 0.927 volts DC per 1 ampere plate current, or 10 millivolts DCper degree Fahrenheit exhaust temperature. The sample voltages are produced by circuits ordevices that perform the conversion and deliver the sample signal to the EDU.

It is the job of the A-D (analog-to-digital) converters on the MM-1 and IO-54 boards to convertthe sample voltages to a numerical value for further processing. These A-D converters requirean input signal in the range of 0 to +5 volts DC, referenced to chassis ground. This voltagerange causes the A-D converter to produce a corresponding numerical output of 0 to 255.Feeding 3.0 volts into the A-D converter, for example, would produce a numerical output of3/5 times 255 or 153. In actual use, output of the A-D converter is scaled to the desiredreading by an automatic mathematical computation performed by the EDU.

The goal of the 16 Channel DC Analog Buffer (DAB-16) board is to act as a buffer between theraw sample signals and the A-D converters on the MM-1 and IO-54 modules. The DAB-16serves to adjust the amplitude (which can range from a few millivolts to a hundred volts ormore), DC offset (which can range from -100 volts to +100 volts), and polarity of the telemetrysample signals to the 0 to +5 volt range required by the A-D converters. It also serves to blockvoltage surges and RFI (radio frequency interference).

Each of the 16 buffer amplifiers on the DAB-16 board has a pair of sockets which containplug-in resistor networks, or, in some cases, individual resistors. The values and position ofthese resistors determine the electrical characteristics of the amplifier. In this way, it isrelatively easy to tailor the characteristics of each amplifier to accommodate a wide range oftelemetry sample signals.

Version C1.01 EDU Hardware Manual DAB-16.1

Choosing Amplifier Gain (and resulting signal output level):

In most cases, the DAB-16 will convert the sample signal from a normally operating host toabout 2.5 to 3.75 volts DC. If the “normal condition” signal significantly exceeds 3.75 volts,the converter has limited ability to report accurate data when the host device is in an overloadcondition. When the “normal condition” signal is adjusted to significantly less than 2.5 volts,the resolution of the signal starts to become less than optimum.

A good analogy for this concept is a simple analog panel meter. If a transmitter has a“normal” plate voltage of 950 volts, one would not want to monitor this with a 0-to-1000 voltpanel meter. If the meter was pegged at full-scale, the operator could not tell whether thevoltage was 1001 volts or 2000 volts, an important difference. Conversely, in the samesituation, one would not want to use a panel meter that has a range of 0-to-10,000 volts. The“normal” reading of 950 volts would not even reach 10% of the full scale and an accuratereading would be impossible.

By adjusting the “highest normal” sampled voltage to 50% to 75% of the full-scale reading ofthe A-D converter, this assures plenty of resolution yet allows 33% to 50% headroom to allowfor “overload” conditions.

In some host devices more than one power setting is used. In these cases, the “normalcondition” signal from the highest power setting should be set to the 50% to 75% of full-scale.

There are some exceptions to the “normal = 50% to 75%” rule. For example, a transmittermight have a “normal” VSWR of 1% yet it might reach 35% during some conditions. In thiscase, the DAB-16 should be configured so that the sample signal from the highest expectedreading is converted to 5 volts DC (full scale). The result might be that the “normal” reading isonly 3% of full scale but this is acceptable in this case.

To summarize, the DAB-16 should take the telemetry sample signals of a normally operatinghost device at its highest normal power setting and convert them to somewhere in the rangeof 2.5 to 3.75 volts DC —unless the ratio of “normal” to “overload” conditions is quite large,in which case the sample voltage resulting from the greatest likely overload condition shouldbe converted to a full-scale voltage (5 volts).

Explanation of the Differential Amplifier:

There are 16 separate differential amplifiers on the DAB-16 board. Each differential amplifierhas a "-" (inverting) and a "+" (noninverting) input. The output of a differential amplifierresponds to the voltage difference between the two input terminals. Consider, for example, adifferential amplifier with a gain of 1 (unity). If the "-" input were connected to ground andthe "+" input were connected to +1.5 volts, the output would be +1.5 volts. If the "+" inputwere connected to ground and the "-" input were connected to -1.5 volts, the output would stillbe +1.5 volts. This is because the "+" terminal is still 1.5 volts more positive than the "-"terminal. Because of this characteristic, the differential amplifier is a very useful method ofinterfacing "real world" telemetry-sample-signals. For example, suppose in a host device asample voltage is developed by the current flowing through a 100 ohm resistor. One end ofthe resistor is 0.5 volts above ground and the other is 4.5 volts above ground. The differentialamplifier will "see" only the 4.0 volts across the resistor.


One important specification of a differential amplifier is its common mode range. This is thevoltage range that both input terminals must stay within if it is to operate properly. If eitheror both input terminals go outside this range, the amplifier will not necessarily be damagedbut the output signal will be inaccurate.

Here is the schematic diagram for one of the differential amplifiers on the DAB-16 board:

Here is the same schematic re-drawn for clarity:

Choosing Resistor Values:

R3 is a four element SIP (single in-line package) resistor network and R4 is a three elementSIP network. For the purposes of identification, we will call R3 the "input" SIP and R4 the"feedback" SIP. Both SIPs are mounted in plug-in sockets to make changing them easier. Allelements of R3 are the same value and the same is true for R4. The gain of the differentialamplifier is R4b divided by the sum of R3a and R3b. In order to produce an output range of2.5 volts to 3.75 volts, the following table shows the input and feedback resistor selections fora wide range of input signals:


Table 1: (based on the DAB-16 generating an output signal of 2.5 to 3.75 volts DC)

Input Range: Input SIP: Feedback SIP: Common Mode Range:

50 to 75 volts 150K x4 15K x3 ±189 volts33.3 to 50 volts 100K x4 15K x3 ±129 volts27.4 to 41 volts 82K x4 15K x3 ±107 volts22.7 to 34 volts 68K x4 15K x3 ±90 volts15.7 to 23.5 volts 47K x4 15K x3 ±65 volts11 to 16.5 volts 33K x4 15K x3 ±48 volts7.4 to 11 volts 22K x4 15K x3 ±35 volts5.0 to 7.5 volts 15K x4 15K x3 ±27 volts3.4 to 5.1 volts 15K x4 22K x3 ±21 volts2.27 to 3.4 volts 15K x4 33K x3 ±17 volts1.6 to 2.4 volts 15K x4 47K x3 ±14 volts1.34 to 2.0 volts 15K x4 56K x3 ±13 volts.915 to 1.37 volts 15K x4 82K x3 ±12 volts.75 to 1.12 volts 15K x4 100K x3 ±11 volts500 to 750 millivolts 15k x4 150K x3 ±10 volts340 to 510 millivolts 15K x4 220K x3 ±10 volts220 to 340 millivolts 15K x4 330K x3 ±9 volts160 to 240 millivolts 15K x4 470K x3 ±9 volts110 to 165 millivolts 15K x4 680K x3 ±9 volts73 to 110 millivolts 10K x4 680K x3 ±9 volts50 to 75 millivolts 6.8K x4 680K x3 ±9 volts34 to 51 millivolts 4.7K x4 680K x3 ±9 volts24 to 36 millivolts 3.3K x4 680K x3 ±9 volts

16 to 24 millivolts 2.2K x4 680K x3 ±9 volts

Note the "common mode range" for each input voltage range. This is the range that bothinput terminals must fall between. Later, we will see how to extend this range.

The typical common-mode-rejection-ratio for the circuit and components shown above isabout 40 dB. This means that any common-mode signal (a signal common to both inputs)will be rejected about 99%. For situations where the differential input is at least as large asthe common mode input, this circuit is entirely satisfactory. In some cases, however, this willnot be the case. As a modification of the example used earlier, suppose we wanted to measurethe voltage across a resistor that was normally 0.5 volts DC but the resistor was elevatedabove ground by 4 volts. In other words, one terminal will be at +4.0 volts and the other willbe at +4.5 volts. We want the output to respond only to the differential signal (0.5 volts), notthe common mode signal (4.0 volts). In cases where the common mode signal is significant(as large or larger that the differential signal) we need to improve the common-mode-rejectionof our differential amplifier. We do this by adding a fixed resistor and a trimmer resistor tothe input circuit. The resulting schematic is shown below:


Mounting locations for these two resistors are included on the DAB-16 board but they arenormally jumpered out with traces. When the components are installed, the appropriatetraces should be cut. The fixed resistor is a 1/8 watt 5% carbon film and the variable resistoris a vertically adjusted 22 turn cermet trimmer. The combination of these resistors allows thetotal resistance in each of horizontal rows to be exactly matched. The table below shows therequired values for the added resistors:

Table 2:

Common-Mode-Rejection Adjustment Trimmers:

Input Range: Input SIP: Input Trimmer: Input Fixed:

50 to 75 volts 150K x4 20K 10K ±5%33.3 to 50 volts 100K x4 10K 5.1K ±5%27.4 to 41 volts 82K x4 10K 5.1K ±5%22.7 to 34 volts 68K x4 10K 5.1K ±5%15.7 to 23.5 volts 47K x4 5K 2.4K ±5%11 to 16.5 volts 33K x4 5K 2.4K ±5%7.4 to 11 volts 22K x4 2K 1.0K ±5%5.0 to 7.5 volts 15K x4 2K 1.0K ±5%3.4 to 5.1 volts 15K x4 2K 1.0K ±5%2.27 to 3.4 volts 15K x4 2K 1.0K ±5%1.6 to 2.4 volts 15K x4 2K 1.0K ±5%1.34 to 2.0 volts 15K x4 2K 1.0K ±5%.915 to 1.37 volts 15K x4 2K 1.0K ±5%.75 to 1.12 volts 15K x4 2K 1.0K ±5%500 to 750 millivolts 15k x4 2K 1.0K ±5%340 to 510 millivolts 15K x4 2K 1.0K ±5%220 to 340 millivolts 15K x4 2K 1.0K ±5%160 to 240 millivolts 15K x4 2K 1.0K ±5%110 to 165 millivolts 15K x4 2K 1.0K ±5%73 to 110 millivolts 10K x4 1K 510 ±5%50 to 75 millivolts 6.8K x4 1K 510 ±5%34 to 51 millivolts 4.7K x4 500 240 ±5%24 to 36 millivolts 3.3K x4 500 240 ±5%

16 to 24 millivolts 2.2K x4 200 100 ±5%


The adjustment procedure for the trimmer is simple: place both input terminals at thecommon mode offset voltage and adjust the trimmer until the output is exactly 0.0 volts DC.In the above example, both terminals should be connected to a source of +4 volts DC in orderto make the adjustment.

In unusual cases, the common-mode signal is very large —so large, in fact, that it fallsoutside the common mode range of the values listed in Table 1. Suppose, for example that wewanted to measure a 250 millivolt signal that is offset from ground by 50 volts. In otherwords, one terminal will be at 50.00 volts and the other will be at 50.25 volts. If we look atTable 1 we can see that the maximum common mode range for this combination of resistorsis only ±9 volts. In order to expand this range, as slight modification of the original circuitneeds to be made:

The change is the addition of jumper JP1 and resistor R4a. R4a, R4b and R4c are threedifferent values so a SIP network cannot be used. Individual 1/4 watt, 1%, metal film resistorsare recommended. Here are the values for the three resistors with the extended commonmode range shown in the right column:

Table 3: (based on a signal output of 2.5 to 3.75 volts DC)

Input Range: Trimmer: Fixed (5%): Input SIP: Ra: (1%) Rb: (1%) Rc: (1%) Common Mode:

22.7 to 34 volts 10K 5.1K 68K x4 158K 15.0K 13.7K ±98 volts15.7 to 23.5 volts 5K 2.4K 47K x4 24.3K 15.0K 9.31K ±98 volts11 to 16.5 volts 5K 2.4K 33K x4 11.8K 15.0K 6.65K ±98 volts7.4 to 11 volts 2K 1.0K 22K x4 6.19K 15.0K 4.42K ±98 volts5.0 to 7.5 volts 2K 1.0K 15K x4 3.74K 15.0K 3.01K ±98 volts3.4 to 5.1 volts 2K 1.0K 15K x4 3.47K 22.1K 3.01K ±98 volts2.27 to 3.4 volts 2K 1.0K 15K x4 3.32K 33.2K 3.01K ±98 volts1.6 to 2.4 volts 2K 1.0K 15K x4 3.24K 47.5K 3.01K ±98 volts1.34 to 2.0 volts 2K 1.0K 15K x4 3.16K 56.2K 3.01K ±98 volts.915 to 1.37 volts 2K 1.0K 15K x4 3.09K 82.5K 3.01K ±98 volts.75 to 1.12 volts 2K 1.0K 15K x4 3.09K 100K 3.01K ±98 volts500 to 750 millivolts 2K 1.0K 15k x4 3.09K 150K 3.01K ±98 volts340 to 510 millivolts 2K 1.0K 15K x4 3.01K 221K 3.01K ±98 volts220 to 340 millivolts 2K 1.0K 15K x4 3.01K 332K 3.01K ±98 volts

The values for the fixed and adjustable input resistors should be chosen from Table 2.


Individual resistors can easily be installed in the socket for the SIP resistors by folding one ofthe leads around the body of the resistor and installing it vertically as shown below:

Ra is always the resistor nearest the end of the associated IC and Rc is the one nearest thecenter of the IC as shown in the example below:

The adjustment procedure for the trimmer is the same as before. Put both input terminals atthe common mode voltage (+50 volts, in the example) and set the output for 0.0 volts.

In Summary:

1. For normal situations where the differential signal exceeds the common mode signal,choose and install two SIP networks from the values in Table 1.

2. If the common mode signal exceeds the differential signal, add the fixed and trimmerresistors listed in Table 2.

3. If the common mode voltage is beyond the range of Table 1, use the individual feedbackresistors and trimming resistors listed in Table 3.


Plate CurrentPlate VoltageTransmitter OutputTransmitter Reflected PowerPA Screen VoltagePA Screen CurrentNot UsedNot UsedIPA Forward PowerIPA Reflected PowerIPA Collector VoltageIPA Collector CurrentPA Bias VoltagePA Grid CurrentIntake TempExhaust Temp

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10111213141516


Revision: 0Embedded Diagnostic Unit

Module: DAB-16

Description: DC Buffer

Module

Version: C1

Parts List

DAB-16; Version 1.0


1board, PC, DAB-16, Rev. 0






4integrated circuit, op amp, quad, LT1114CN, low power, DC



1resistor, carbon film, 1/8W, 100, 5%

1resistor, cermet trimmer, 200, 22 turn, vertical

1resistor, cermet trimmer, 2K, 22 turn, vertical

1resistor, metal film, 1/4W, 221K, 1%

2resistor, metal film, 1/4W, 3.01K, 1%

5resistor, SIP, 3 x 15K, isolated








1resistor, SIP, 4 x 2.2K, isolated



4socket, DIP, 14,

1socket, DIP, 8,

196socket, SIP, 32, gold, high


IO-54 Input/Output Module

General:

The IO-54 General Purpose Input/Output Module is designed for use with the EmbeddedDiagnostic Unit—EDU. It supplements the data-gathering capabilities of the Master Moduleby adding 22 analog telemetry channels, 16 logic-level status channels, and 16 control-outputchannels. The IO-54 communicates with the Master Module by means of a high-speed serialdata buss.


• Each of the 38 data channels can be tested for "events" with a user-programmable lowerlimit, upper limit and trigger rule.

• All 38 data channels are scanned for "event" conditions about 100 times each second.

• All user programming stored in a nonvolatile EEROM.

• Provides latched or momentary control outputs.

Mechanical:

The IO-54 is designed for installation in the standard 3 inch track of an EDU enclosure. Thesize of the module is 5.3 inches by 3 inches.

Electrical:

The IO-54 module requires 6.9 volts DC at approximately 10 milliamperes.

Version C1.01 EDU Hardware Manual IO-54.1

Note: Unless otherwise specified, all resistor values are in ohms and all capacitor values are in microfarads.


Module: IO-54

Description: General Purpose Input/Output ModuleVersion: C1 Revision: 0

Parts List

IO-54; Version 1.0


1board, PC, IO-54, Rev. 0




2capacitor, monolythic ceramic, 27 pF, .1" spacing



1crystal, 8.000 MHz, 20 pF series, HC-49/U

1hardware, nut, locknut, hex, 4-40, stainless


1heatsink, TO-220, 0.52" x 0.375" x 0.75", vert, solder

2integrated circuit, analog switch 1 of 8, MAX358CPE,

2integrated circuit, driver, octal sink, ULN2803A,

4integrated circuit, latch, octal parallel, tri-state, 74HC373,

1integrated circuit, low voltage interrupt, MN1381-S, CMOS output

1integrated circuit, microprocessor, MC68HC711E9CFN2,

1integrated circuit, transistor, N channel, MOSFET, avalanche, TO-92 flat


1integrated circuit, voltage regulator, low drop, LM2937ET-5.0, +5V DC/0.5 A


1resistor, carbon film, 1/4W, 1M, 5%


1resistor, SIP, 3 x 22, isolated





2resistor, SIP, 9 x 220K, common

1resistor, SIP, 9 x 22K, common

2socket, DIP, 16,

2socket, DIP, 18,

4socket, DIP, 20,

1socket, DIP, 8,

1socket, PLCC, 52,

2surge protector, solid state supressor, 1.5KE33A,

MM-1 Master Module

General:

The MM-1 Master Module is designed for use with the Embedded Diagnostic Unit—EDU. Itacts as the central control for the system. It contains the primary microprocessor andoperating ROM, data storage RAM, a separate RAM for data processing, and a nonvolatileEEPROM for storing user-programmed set-ups. It also contains a modem and a dedicatedRS-232 port for communication to an external computer. The MM-1 gathers telemetry datafrom, and issues control commands to, other internal modules by means of a high-speedserial data buss.

In addition to its function as system controller, the MM-1 module has , 2 logic-level statussources, and it can telemeter the EDU power supply voltage and internal case temperature.


• Inputs provided for 6 external analog telemetry sources.

• Inputs provided for 2 external logic-level status sources.

• Telemeters power supply voltage and case temperature.

• Modem powers-down when not in use.

Data Memory:

In addition to RAM, EPROM and EEROM located in the microprocessor, the MM-1 has a262,144 bit static RAM. This is sufficient to store over 18,000 individual telemetry readingwith a resolution of 11 bits. In a system with 48 telemetry and status channels, this equatesto 376 recordings of all data. In typical applications, this is sufficient to record the datahistory of the host for about two to four months.

Battery Operation:

EDU contains a 7.2 amperehour sealed lead-acid battery. This is sufficient to allow full-specification operation of the system for about 40 hours without external power. During thisperiod, data continues to be collected, previously collected data is retained, the internalclock/calendar continues to run, and the unit may be operated either by local RS-232connection or modem. After this period, EDU enters a "sleep" mode that preserves data for anadditional 24 hours or so. EDU can not be operated during this period but the data can berecovered after external power is restored.

Mechanical:

The MM-1 is designed for installation in the standard 3 inch track of an EDU enclosure. Thesize of the module is 3.9 inches by 3 inches.

Electrical:

The MM-1 module requires 6.9 volts DC at approximately 110 milliamperes.

Version C1.01 EDU Hardware Manual MM-1.1

Note: Unless otherwise specified, all resistor values are in ohms and all capacitor values are in microfarads.


Module: MM-1

Description: Master Module

Version: C1 Revision: 0

Parts List

MM-1; Version 1.0


1board, PC, MM-10, Rev. 0



2capacitor, monolythic ceramic, 27 pF, .1" spacing



1crystal, 8.000 MHz, 20 pF series, HC-49/U

2diode, general purpose, 600 V/1 A, 1N4005

1integrated circuit, latch, octal parallel, tri-state, 74HC373,

1integrated circuit, low voltage interrupt, MN1381-S, CMOS output

1integrated circuit, microprocessor, MC68HC711E9CFN2,

1integrated circuit, modem module, 2400 baud, CH1785

1integrated circuit, RS-232, +5V, MAX202CPE,

1integrated circuit, SRAM, 256K (32K x 8), HY62256ALP-10, 28 pin DIP

1integrated circuit, temperature sensor, analog, LM34DZ,

1integrated circuit, transistor, N channel, MOSFET, avalanche, TO-92 flat

1integrated circuit, voltage regulator, low drop, LM2940CT-5.0, +5V DC/1 A


1resistor, carbon film, 1/4W, 1M, 5%

1resistor, metal film, 1/4W, 59.0K, 1%




1socket, DIP, 16,

1socket, DIP, 20,

1socket, DIP, 28,

1socket, PLCC, 52,

RY-8 Relay Module

General:

The RY-8 Relay Module contains 8 relays that can be used to the convert open-collectoroutputs of other EDU modules to isolated relay contacts.


• Each relay contact is rated at 1 ampere at 24 volts AC/DC.

Mechanical:

The RY-8 is designed for installation in the standard 3 inch track of an EDU enclosure. Thesize of the module is 1.5 inches by 3 inches.

Electrical:

The relay coils in the RY-8 are rated at 5 volts DC. Each relay draws about 89 milliampereswhen turned on.

Version C1.01 EDU Hardware Manual RY-8.1


Module: RY-8

Description: Relay ModuleVersion: G Revision: 0

Parts List

RY-8; Version 1.0


1board, PC, RY-8, Rev. 1




8relay, part 68, sealed, 5 volt DC, form 1C

Documents

Embedded Diagnostic Unit EDU - sinesystems.com fileSection 1 — Safety Information The Embedded Diagnostic Unit (EDU) should be installed only by qualified technical personnel. Incorrect