Platinum Z5 CD™: FM Transmitter Manual
Platinum Z5 CD™: FM Transmitter Manual
Platinum Z5 CD™: FM Transmitter Manual
FM Transmitter Manual
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Platinum Z5 CD™
FM Transmitter Manual
Unpacking
Carefully unpack the equipment and preform a visual inspection to determine that no
apparent damage was incurred during shipment. Retain the shipping materials until it has
been determined that all received equipment is not damaged. Locate and retain all
PACKING CHECK LISTs. Use the PACKING CHECK LIST to help locate and identify
any components or assemblies which are removed for shipping and must be reinstalled.
Also remove any shipping supports, straps, and packing materials prior to initial turn on.
Technical Assistance
HARRIS Technical and Troubleshooting assistance is available from HARRIS Field
Service during normal business hours (8:00 AM - 5:00 PM Central Time). Emergency
service is available 24 hours a day. Telephone 217/222-8200 to contact the Field Service
Department or address correspondence to Field Service Department, HARRIS CORPO-
RATION, Broadcast Systems Division, P.O. Box 4290, Quincy, Illinois 62305-4290,
USA. The HARRIS factory may also be contacted through a FAX facility (217/222-7041)
or a TELEX service (650/372-2976).
NOTE
The # symbol used in the parts list means used with (e.g. #C001 =
used with C001)
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MANUAL REVISION HISTORY
Platinum Z5 CD™
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Rev. Date ECN Pages Affected
B 12-17-01 47926 Title page, added MRH1/MRH2, sections 2 and 4.
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Guide to Using Harris Parts List Information
The Harris Replaceable Parts List Index portrays a tree structure with the major items being leftmost in the index.
The example below shows the Transmitter as the highest item in the tree structure. If you were to look at the bill of
materials table for the Transmitter you would find the Control Cabinet, the PA Cabinet, and the Output Cabinet. In
the Replaceable Parts List Index the Control Cabinet, PA Cabinet, and Output Cabinet show up one indentation level
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below the Transmitter and implies that they are used in the Transmitter. The Controller Board is indented one level
below the Control Cabinet so it will show up in the bill of material for the Control Cabinet. The tree structure of this
same index is shown to the right of the table and shows indentation level versus tree structure level.
Example of Replaceable Parts List Index and equivalent tree structure:
The part number of the item is shown to the right of the description as is the page in the manual where the bill for
that part number starts.
Inside the actual tables, four main headings are used:
Table #-#. ITEM NAME - HARRIS PART NUMBER - this line gives the information that corresponds to the
Replaceable Parts List Index entry;
HARRIS P/N column gives the ten digit Harris part number (usually in ascending order);
DESCRIPTION column gives a 25 character or less description of the part number;
REF. SYMBOLS/EXPLANATIONS column 1) gives the reference designators for the item (i.e., C001, R102,
etc.) that corresponds to the number found in the schematics (C001 in a bill of material is equivalent to C1 on the
schematic) or 2) gives added information or further explanation (i.e., “Used for 208V operation only,” or “Used
for HT 10LS only,” etc.).
Inside the individual tables some standard conventions are used:
A # symbol in front of a component such as #C001 under the REF. SYMBOLS/EXPLANATIONS column means
that this item is used on or with C001 and is not the actual part number for C001.
In the ten digit part numbers, if the last three numbers are 000, the item is a part that Harris has purchased and
has not manufactured or modified. If the last three numbers are other than 000, the item is either manufactured by
Harris or is purchased from a vendor and modified for use in the Harris product.
The first three digits of the ten digit part number tell which family the part number belongs to - for example, all
electrolytic (can) capacitors will be in the same family (524 xxxx 000). If an electrolytic (can) capacitor is found
to have a 9xx xxxx xxx part number (a number outside of the normal family of numbers), it has probably been
modified in some manner at the Harris factory and will therefore show up farther down into the individual parts
list (because each table is normally sorted in ascending order). Most Harris made or modified assemblies will
have 9xx xxxx xxx numbers associated with them.
The term “SEE HIGHER LEVEL BILL” in the description column implies that the reference designated part
number will show up in a bill that is higher in the tree structure. This is often the case for components that may
be frequency determinant or voltage determinant and are called out in a higher level bill structure that is more
customer dependent than the bill at a lower level.
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WARNING
The currents and voltages in this equipment are dangerous. Person-
nel must at all times observe safety warnings, instructions and regu-
lations.
This manual is intended as a general guide for trained and qualified personnel who are
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The installation, operation, maintenance and service of this equipment involves risks both
to personnel and equipment, and must be performed only by qualified personnel exercising
due care. HARRIS CORPORATION shall not be responsible for injury or damage
resulting from improper procedures or from the use of improperly trained or inexperienced
personnel performing such tasks.
During installation and operation of this equipment, local building codes and fire protec-
tion standards must be observed. The following National Fire Protection Association
(NFPA) standards are recommended as reference:
• Automatic Fire Detectors, No. 72E
• Installation, Maintenance, and Use of Portable Fire Extinguishers, No. 10
• Halogenated Fire Extinguishing Agent Systems, No. 12A
WARNING
Always disconnect power before opening covers, doors, enclosures,
gates, panels or shields. Always use grounding sticks and short out
high voltage points before servicing. Never make internal adjust-
ments, perform maintenance or service when alone or when fa-
tigued.
Do not remove, short-circuit or tamper with interlock switches on access covers, doors,
enclosures, gates, panels or shields. Keep away from live circuits, know your equipment
and don’t take chances.
WARNING
In case of emergency ensure that power has been disconnected.
If oil filled or electrolytic capacitors are utilized in your equipment, and if a leak or bulge
is apparent on the capacitor case when the unit is opened for service or maintenance, allow
the unit to cool down before attempting to remove the defective capacitor. Do not attempt
to service a defective capacitor while it is hot due to the possibility of a case rupture and
subsequent injury.
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FIRST-AID
Personnel engaged in the installation, operation, maintenance or servicing of this
equipment are urged to become familiar with first-aid theory and practices. The following
information is not intended to be complete first-aid procedures, it is a brief and is only to
be used as a reference. It is the duty of all personnel using the equipment to be prepared to
give adequate Emergency First Aid and thereby prevent avoidable loss of life.
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NOTE
If medical help will not be available within an hour and the victim
is conscious and not vomiting, give him a weak solution of salt and
soda: 1 level teaspoonful of salt and 1/2 level teaspoonful of baking
soda to each quart of water (neither hot or cold). Allow victim to sip
slowly about 4 ounces (a half of glass) over a period of 15 minutes.
Discontinue fluid if vomiting occurs. (Do not give alcohol.)
REFERENCE
ILLINOIS HEART ASSOCIATION
AMERICAN RED CROSS STANDARD FIRST AID AND PERSONAL SAFETY
MANUAL (SECOND EDITION)
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Table of Contents
1 Introduction/Specifications Control Inputs . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Status Ouputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 UPS IN/Remote Exciter Select,
Features/Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2 Configurable Input TB1-9 . . . . . . . . . . . . . . . . . . . . 2-24
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Using an Uninterruptable Power Supply or UPS . . 2-25
Harris DIGIT Digital FM Exciter . . . . . . . . . . . . . . . 1-3 Setting The UPS Power Level . . . . . . . . . . . . . . . 2-25
Harris SuperCiter Analog Exciter . . . . . . . . . . . . . . . 1-3 Optimizing Efficiency . . . . . . . . . . . . . . . . . . . . . . . . 2-26
Redundant Exciters . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Setting the Low Power Alarm. . . . . . . . . . . . . . . . . . 2-27
PA/IPA Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4 Jumper Settings for Installation of a Harris Exciter . 2-27
RF Combining. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Power Distribution for Optimum Transmitter
Control System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
Directional RF Sample Port . . . . . . . . . . . . . . . . . . . 1-5
Overheating from Line Unbalance . . . . . . . . . . . . . 2-31
Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Transmitter Noise Performance . . . . . . . . . . . . . . . 2-31
Air System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
The Causes of Line Unbalance. . . . . . . . . . . . . . . . 2-31
Performance Specifications . . . . . . . . . . . . . . . . . . . . . 1-5 Three Phase Delta Distribution Transformers . . . . 2-32
Three Phase Wye Distribution Transformers . . . . . 2-33
2 Installation & Initial Turn-On
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 3 Operator Guide
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Returns and Exchanges . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Transmitter Controls . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Air Cooling Requirements. . . . . . . . . . . . . . . . . . . . . . 2-2 Transmitter Metering. . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Z5 Transmitter Installation . . . . . . . . . . . . . . . . . . . . . 2-2 Forward Power (FWD PWR) Units of Measure . . . 3-3
Transmitter Placement . . . . . . . . . . . . . . . . . . . . . . . 2-3 Reflected Power (RFL PWR) Units of Measure . . . 3-3
Removal of Pallet Bolts . . . . . . . . . . . . . . . . . . . . . 2-3 Using the Diagnostic Display . . . . . . . . . . . . . . . . . . . 3-4
Visual Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3 HOME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Exciter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4 BACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
3-Phase Power Supply Installation . . . . . . . . . . . . . . 2-5 MORE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Power Transformer Tapping. . . . . . . . . . . . . . . . . . 2-5 Diagnostic Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Power Supply Connections . . . . . . . . . . . . . . . . . . 2-6 Asterisk and Pound Signs(*, #) . . . . . . . . . . . . . . . . 3-8
Single Phase Power Supply Installation . . . . . . . . . . 2-8 Fault Logging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Power Transformer Tapping. . . . . . . . . . . . . . . . . . 2-8 Emergency Operating Procedures. . . . . . . . . . . . . . . . 3-9
Single Phase Power Supply Connections. . . . . . . . 2-9 Multiple PA Failures in a Foursome. . . . . . . . . . . . . 3-9
Transmitter AC Connections. . . . . . . . . . . . . . . . . . 2-11
Manual Exciter Switching. . . . . . . . . . . . . . . . . . . . . 3-10
Information concerning some 360 to 416 volt
Manual IPA Switching . . . . . . . . . . . . . . . . . . . . . . . 3-10
systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
AC Input Connection . . . . . . . . . . . . . . . . . . . . . . 2-12 Optimizing Efficiency . . . . . . . . . . . . . . . . . . . . . . . . 3-11
Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13 Fan Speed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Low Voltage Power Supply and Blower . . . . . . . 2-14
Exciter AC Voltage Selection. . . . . . . . . . . . . . . . 2-14
RF Output Connection . . . . . . . . . . . . . . . . . . . . . . 2-14 4 Overall System Theory
Audio Input Connections . . . . . . . . . . . . . . . . . . . . 2-14 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
External and Failsafe Interlock Connections . . . . . 2-15 RF Flow Block Diagram Description . . . . . . . . . . . . . 4-1
External Interlock Connection . . . . . . . . . . . . . . . 2-15 Exciters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Failsafe Interlock Connection . . . . . . . . . . . . . . . 2-15 IPAs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Initial Turn-on . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16 PA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Remote Control Connections . . . . . . . . . . . . . . . . . 2-21 Z-Plane Divider Board. . . . . . . . . . . . . . . . . . . . . . 4-3
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Table of Contents
Z-Plane Combiner Board . . . . . . . . . . . . . . . . . . . . 4-3 MAX HIGH, MAX LOW and UPS Power Levels4-37
5kW Hybrid Combiner . . . . . . . . . . . . . . . . . . . . . . . 4-4 EXC Factor and IPA Factor . . . . . . . . . . . . . . . . . 4-39
Detailed RF Theory of Operation . . . . . . . . . . . . . . . . 4-4 Reflect Factor and A/D_RFL_PWR . . . . . . . . . . 4-39
Exciter Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 VSWR Foldback. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-40
Automatic Exciter Switching . . . . . . . . . . . . . . . . . 4-4 Master Controller Faults . . . . . . . . . . . . . . . . . . . 4-41
Manual Exciter Switching . . . . . . . . . . . . . . . . . . . 4-4 PA Controller Boards . . . . . . . . . . . . . . . . . . . . . . . 4-42
IPA. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 PA Turn On/Turn Off . . . . . . . . . . . . . . . . . . . . . . 4-42
IPA Power Output. . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Metering. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43
IPA Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . 4-5 Crossover (XOVER) Protection . . . . . . . . . . . . . 4-44
IPA Backplane Board . . . . . . . . . . . . . . . . . . . . . . . . 4-5 PA Controller Faults . . . . . . . . . . . . . . . . . . . . . . 4-44
Main/Alternate Exciter Switching . . . . . . . . . . . . . 4-6 Power Supply Controller . . . . . . . . . . . . . . . . . . . . 4-44
Main/Alternate IPA Switching . . . . . . . . . . . . . . . . 4-7 Power Supply Turn On . . . . . . . . . . . . . . . . . . . . 4-45
IPA Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7 PA Power Supply Discharge . . . . . . . . . . . . . . . . 4-46
Air Flow Sensing. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 Power Supply Standby Mode . . . . . . . . . . . . . . . 4-46
IPA_AB1 and IPA_AB2 interlocking. . . . . . . . . . . 4-8 Discharge Protection Circuit . . . . . . . . . . . . . . . . 4-46
IPA Power Divider (3dB Hybrid) . . . . . . . . . . . . . . 4-8 RESET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-46
Z-Plane Combiner/Divider Boards . . . . . . . . . . . . . . 4-8 Watchdog Timer. . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
8-Way Divider . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 Analog Inputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-47
8-Way Combiner. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9 PS Controller Faults. . . . . . . . . . . . . . . . . . . . . . . 4-47
PA Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10 Life Support Board . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
Power Amplifier (PA). . . . . . . . . . . . . . . . . . . . . . 4-10 Normal Operational Mode . . . . . . . . . . . . . . . . . . 4-48
3 dB Hybrid Combiner . . . . . . . . . . . . . . . . . . . . . 4-13 Life Support Mode. . . . . . . . . . . . . . . . . . . . . . . . 4-55
Harmonic Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Directional Coupler Assembly . . . . . . . . . . . . . . . . 4-14
Power Supply Block Diagram Description . . . . . . . . 4-15 5 Maintenance and Alignment
PA Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
3-Phase Power Supply . . . . . . . . . . . . . . . . . . . . . 4-15 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Single Phase Power Supply . . . . . . . . . . . . . . . . . 4-18 Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Low Voltage Power Supply. . . . . . . . . . . . . . . . . . . 4-20 Record Keeping . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Detailed Power Supply Descriptions . . . . . . . . . . . . . 4-20 Recommended Log Readings . . . . . . . . . . . . . . . . 5-1
3-Phase PA Power Supply. . . . . . . . . . . . . . . . . . . . 4-20 Transmitter Logbook . . . . . . . . . . . . . . . . . . . . . . . 5-2
Rectifier Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22 Maintenance Logbook . . . . . . . . . . . . . . . . . . . . . . 5-2
Rectifier Board Circuit Description . . . . . . . . . . . 4-22 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Single Phase PA Power Supply . . . . . . . . . . . . . . . . 4-25 Module cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Rectifier Board . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25 Cleaning the Air Filter . . . . . . . . . . . . . . . . . . . . . . 5-3
Rectifier Board Circuit Description . . . . . . . . . . . 4-26 Cleaning the Power Supply . . . . . . . . . . . . . . . . . . 5-3
Power Supply ID Jumpers. . . . . . . . . . . . . . . . . . . . 4-28 Blower Motor Maintenance . . . . . . . . . . . . . . . . . . . . 5-3
Low Voltage Power Supply Board . . . . . . . . . . . . . 4-28
Routine Annual Tests . . . . . . . . . . . . . . . . . . . . . . . . . 5-4
Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29
System Level ISO/Reject Load Ohmmeter Test . . . 5-4
Cooling System Description . . . . . . . . . . . . . . . . . . . 4-29 System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
Control System Description. . . . . . . . . . . . . . . . . . . . 4-30 Isolation Board Maintenance . . . . . . . . . . . . . . . . . . . 5-6
Master Controller . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 Isolation Board Replacement . . . . . . . . . . . . . . . . . . 5-6
EEPROM U39 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-31 Isolation Board Removal . . . . . . . . . . . . . . . . . . . . 5-6
APC, Automatic Power Control . . . . . . . . . . . . . . 4-32 Inspection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Calibration Factors and A/D Values . . . . . . . . . . . . 4-34 Installation of Isolation Assembly . . . . . . . . . . . . . 5-7
DAC_APC_REF. . . . . . . . . . . . . . . . . . . . . . . . . . 4-35
PA Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Forward Factor and A/D_FWD_PWR . . . . . . . . . 4-36
Directional Coupler Removal and Replacement. . . . . 5-8
APC Factor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-37
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Table of Contents
Typical Coupling Ratios . . . . . . . . . . . . . . . . . . . . . . 5-8 THERMISTOR, Fault . . . . . . . . . . . . . . . . . . . . . . 6-14
Setting Maximum Power Limits . . . . . . . . . . . . . . . . . 5-9 EEPROM_DEF, EEPROM U39 Default Load . . . 6-15
Setting FWD PWR to Display 100% . . . . . . . . . . . . 5-10 REF_WARNING, +5V Reference Warning. . . . . . 6-15
Setting Life Support Power Level . . . . . . . . . . . . . . . 5-10 MSTR_REF, +5V Reference Fault. . . . . . . . . . . . . 6-15
Forward Power Calibration . . . . . . . . . . . . . . . . . . . . 5-11 RFL_PWR, Reflected Power Fault . . . . . . . . . . . . 6-16
Reflected Power Calibration . . . . . . . . . . . . . . . . . . . 5-14 INTLK, External Interlock Fault . . . . . . . . . . . . . . 6-16
FAILSAFE, Interlock Fault . . . . . . . . . . . . . . . . . . 6-17
PC Board Replacement Procedures. . . . . . . . . . . . . . 5-16
POWER_FAIL, Fault . . . . . . . . . . . . . . . . . . . . . . . 6-17
Replacement of the Life Support Board . . . . . . . . . 5-16
LOW_AIR, Fault . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17
Replacing the Power Supply Controller Board. . . . 5-18
UPS, Uninterruptable Power Supply Fault. . . . . . . 6-18
Replacing a PA Controller Board . . . . . . . . . . . . . . 5-18
CPLR_NC, Forward Directional Coupler Cable Not
Replacing the Master Controller Board . . . . . . . . . 5-19
Connected . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Replacement Using EEPROM U39 From
IPA_AB#_MUTE, Fault. . . . . . . . . . . . . . . . . . . . . 6-18
Old Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19
IPA_AB#_LOW, (Power) Fault . . . . . . . . . . . . . . . 6-18
Replacing EEPROM U39 . . . . . . . . . . . . . . . . . . . . 5-20
IPA_AB#_OC, Fault. . . . . . . . . . . . . . . . . . . . . . . . 6-18
System Configuration and Calibration . . . . . . . . . . . 5-22
IPA_TW, IPA Temperature Warning . . . . . . . . . . . 6-18
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
IPA_OT, Fault. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-18
Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
IPA_AB#_OUT, Fault . . . . . . . . . . . . . . . . . . . . . . 6-19
Removing/Replacing Firmware ICs . . . . . . . . . . . . . 5-24 IPA_LOAD, Fault. . . . . . . . . . . . . . . . . . . . . . . . . . 6-19
PSC#_COMM, Fault . . . . . . . . . . . . . . . . . . . . . . . 6-19
PAC#_COMM, Fault . . . . . . . . . . . . . . . . . . . . . . . 6-19
6 Troubleshooting AMB_WARNING, Ambient Temperature Warning6-19
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 AMB_TEMP, Ambient Temperature Fault . . . . . . 6-19
Power Amplifier Repair. . . . . . . . . . . . . . . . . . . . . . . . 6-2 ISO_##_OT, Over-Temperature . . . . . . . . . . . . . . . 6-20
Transmitter Power vs. Module Failures . . . . . . . . . . 6-2 System ISO Foldback . . . . . . . . . . . . . . . . . . . . . 6-20
Multiple PA Failures in a Foursome . . . . . . . . . . . . . 6-3 System ISO Overload (Fault) . . . . . . . . . . . . . . . 6-20
Software Revision . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 EXC#_FAULT, Fault . . . . . . . . . . . . . . . . . . . . . . . 6-21
System Reset - TX_RESTART . . . . . . . . . . . . . . . . . . 6-4 EXC#_LOW, Fault . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
3 Strike Routine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4 EXC#_AFC Fault . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Diagnostics Display Menu Tree . . . . . . . . . . . . . . . . . 6-6 PA Signal Tracing . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21
Fault Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 PA Controller Faults . . . . . . . . . . . . . . . . . . . . . . . . . 6-22
Front Panel Fault LED . . . . . . . . . . . . . . . . . . . . . . . 6-7 General PA Troubleshooting . . . . . . . . . . . . . . . . . 6-22
Fault Reset . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7 A or B#_OC, PA Over-Current Fault . . . . . . . . . . . 6-22
Abbreviations Used In Fault Reporting . . . . . . . . . . 6-7 PA Current Foldback . . . . . . . . . . . . . . . . . . . . . . . 6-23
Fault Listing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8 A or B#_UC, PA Under-Current . . . . . . . . . . . . . . 6-23
Self Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 A or B#_MUTE_FLT, PA Mute Fault . . . . . . . . . . 6-23
System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-9 A or B#_OT, PA Over-Temperature . . . . . . . . . . . . 6-24
PA Muting Test. . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 A or B#_OUT, PA Out Fault . . . . . . . . . . . . . . . . . 6-24
PA_ISO Resistor and Thermistor Test . . . . . . . . . 6-10 A or B#_ISO, PA ISO Temperature Fault . . . . . . . 6-24
PA RF Switch Test . . . . . . . . . . . . . . . . . . . . . . . . 6-11 PA_ISO_OT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
Hardware Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12 PA_ISO_LOW, Fault . . . . . . . . . . . . . . . . . . . . . . . 6-25
PA_ISO_SW, Fault . . . . . . . . . . . . . . . . . . . . . . . . . 6-25
General Troubleshooting Tips . . . . . . . . . . . . . . . . . . 6-13
Combiner ISO Faults . . . . . . . . . . . . . . . . . . . . . . . 6-26
Foldback Conditions . . . . . . . . . . . . . . . . . . . . . . . . 6-13
PAC#_REF, +5V Reference Fault . . . . . . . . . . . . . 6-26
Turning the Transmitter ON with No Power
PAC#_VOLTS, Power Supply Fault . . . . . . . . . . . 6-26
Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
PAC#_-15V, PA Controller PS Fault . . . . . . . . . . . 6-27
Asterisk and Pound Signs(*, #). . . . . . . . . . . . . . . . 6-13
PAC#_J#, Cable Fault. . . . . . . . . . . . . . . . . . . . . . . 6-27
Master Controller Related Faults. . . . . . . . . . . . . . . . 6-14
Power Supply Controller Faults . . . . . . . . . . . . . . . . 6-28
888-2408-002 3
WARNING: Disconnect primary power prior to servicing.
Table of Contents
General Power Supply Troubleshooting . . . . . . . . . 6-28
Critical Power Supply Faults. . . . . . . . . . . . . . . . . . 6-28
PS#_START, Soft Start Circuit Fault . . . . . . . . . . 6-29
PS#_HS_TEMP, Rectifier Heatsink Temperature 6-29
PS#_DSCHG, Discharge circuit fault. . . . . . . . . . 6-29
PS#_PHS_LS, Phase Loss (100-120 Hz ripple). . 6-30
PSC#+20V, Fault . . . . . . . . . . . . . . . . . . . . . . . . . 6-30
PS#_CONFIG, Configuration Fault . . . . . . . . . . . 6-30
PS#_JUMP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-31
Non Critical Power Supply Faults. . . . . . . . . . . . . . 6-31
PS#_TAP#, Power Supply Tap Fault . . . . . . . . . . 6-31
7 Parts List
Part List Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
4 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Introduction/
Specifications
1.1 Introduction
This technical manual describes the Harris Platinum Z5 solid-state FM radio
transmitter. This manual contains all the information needed to install, operate and
service these transmitters.
888-2408-002 1-1
WARNING: Disconnect primary power prior to servicing.
Introduction/Specifications
1.2 Features/Benefits
• Includes the field-proven Harris DIGIT Digital FM Exciter with built in DSP ste-
reo generator. As the world’s first all-digital FM exciter the Harris DIGIT accepts
AES/EBU digital audio and generates the fully modulated RF carrier totally in
the digital domain for the lowest noise and distortion available in any FM trans-
mitter (16 bit digital audio quality).
• Power output range: 1.25 - 5kW for Z5CD; up to 5.5kW into a 1.1 or less VSWR.
• Redundant, autoswitching, IPA amplifiers to eliminate a single point of failure.
• Microprocessor based controller for advanced control, diagnostics and display
capability. Includes built-in logic and commands for switching between main/
alternate DIGIT exciters and IPAs.
• Redundant RF amplifier modules that allow maintenance while the transmitter
remains on the air at reduced power (“Hot-Pluggable” modules).
• Redundant power supplies to keep the transmitter on the air.
• Broadband design to eliminate tuning adjustments from 87 through 108MHz
(N+1 capable). Frequency change can be done manually in less than five minutes
using simple switch settings, and in less than 0.5 seconds using an optional,
external controller.
• Quick start design provides full output power meeting all specifications within
five seconds of an “On” Command.
• Versatile air cooling design uses either an internal blower or an external air sys-
tem.
• Dual output power settings, standard, along with a third available power setting
for use with UPS or generator backup systems.
• Directional RF sample port provided for customer use.
• Available for single or three phase mains power, 50/60Hz.
1-2 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Introduction/Specifications
888-2408-002 1-3
WARNING: Disconnect primary power prior to servicing.
Introduction/Specifications
The IPA consists of a standard PA Module with only one side active at a time to
provide the required drive to the 5kW PA. The transmitter contains sensing, logic
and switching circuitry which will automatically switch from a failed IPA to the
remaining one. For even further redundancy, any PA module can also be used as an
IPA module, without modification.
1.3.5 RF Combining
Each PA (one half of a PA module) is combined first in groups of eight in a
compact, “Z plane” isolated combiner. True isolation means that each module will
continue to work into a nominal 50 ohm load regardless of the number of active
amplifiers, for almost zero stress to the amplifiers during fault conditions. The
outputs of the 8 way combiners are then combined in a compact 3dB hybrid. The
3dB hybrid provides improved load conditions for the RF modules and tends to
absorb power received by the antenna. This can reduce the amount of RF
intermodulation generated by the transmitter when co-sited with other FM
transmitters.
The Controller also includes built-in logic and controls for automatically switching
to the reserve IPA section, and a backup exciter if installed. The main controller
provides automatic power control, VSWR overload protection, automatic VSWR
foldback, RF power soft start, AC restart and diagnostics. Basic control functions
available even without the main controller are VSWR protection, IPA protection,
transmitter on/off, failsafe and interlock.
The control system for the transmitter is modular and is centered on the backplane
which is also the control panel for the transmitter. Various control printed circuit
1-4 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Introduction/Specifications
boards are plugged into the backplane to fit the transmitter for the configuration
being supplied.
The control system front panel includes an output metering LCD display which can
be used to view power output, VSWR, PA voltage and PA current. A second LCD
window , the Diagnostics Display, permits extensive viewing of internal voltages,
temperatures and a detailed Fault Log to easily pin-point problems. Long-life LED
fault and status indicators and reliable membrane switches provide all needed local
control and selection for the transmitter.
NOTE:
Specifications subject to change without notice.
888-2408-002 1-5
WARNING: Disconnect primary power prior to servicing.
Introduction/Specifications
1-6 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Installation &
Initial Turn-On
2.1 Introduction
This section contains information for the installation of the Platinum Z5 solid state
FM Broadcast Transmitter and for performing the pre-operational checks.
NOTE:
For Dual transmitter installations refer to the Systems Manual before
proceeding with this procedure.
2.2 Unpacking
Carefully unpack the transmitter and perform a visual inspection to ensure that no
apparent damage was incurred during shipment. Retain the shipping materials until
it has been determined that the unit is not damaged. The contents of the shipment
should be as indicated on the packing list. If the contents are incomplete or if the
unit is damaged electrically or mechanically, notify the carrier and HARRIS
CORPORATION, Broadcast Systems
888-2408-002 2-1
WARNING: Disconnect primary power prior to servicing.
Installation & Initial Turn-On
NOTE:
“Clean” air is required. No salt air, polluted air, or sulphur air can be tol-
erated. A closed air system is recommended in these environments;
that is, an air conditioned room that recirculates, and properly filters,
the room air. No outside air is brought into the transmitter room.
! CAUTION:
ALL CONNECTIONS REFERRED TO IN THIS INSTALLATION PROCEDURE
SHOULD BE VERIFIED USING THE SCHEMATICS SUPPLIED WITH THE
TRANSMITTER. THE SCHEMATICS SHOULD BE CONSIDERED THE MOST
ACCURATE IN CASE OF A DISCREPANCY.
1. Transmitter placement
2. Visual Inspection
3. Exciter Installation
4. Power Supply Installation
5. Transmitter wiring
6. Initial checkout
7. Remote Control Connections
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WARNING: Disconnect primary power prior to servicing.
Installation & Initial Turn-On
After the transmitter is off the pallet, it is also a good idea to remove the shipping
screws holding the rear of the power supply tray. This will allow the power supply
to be rolled out the front of the transmitter at a later date without having to take off
the fan assembly.
888-2408-002 2-3
WARNING: Disconnect primary power prior to servicing.
Installation & Initial Turn-On
b. Controller Connections
1. Check the Ribbon cables connected to the back of the controller boards
and to the exciter(s).
2. Make sure that all of the boards in the controller are properly seated in
the backplane (motherboard) connector.
2.5.3 Exciter Installation
The exciter may or may not be removed from the transmitter depending on the
shipping considerations. If the exciter was not removed for shipping, then all
transmitter connections will already be hooked up. The audio input connections and
level adjustments can be found in the exciter manual accompanying the transmitter.
Install the exciter input cables in a metal conduit which is separate from the AC
supply. Remote control cabling may be included in the same conduit with the
exciter cabling. AC power wiring and small signal lines should never be put in the
same conduit.
If the exciter was removed for shipping, there are three cables which will need to be
hooked up (not counting the audio inputs).
a. A ribbon cable which will hook to the remote control connector on the back
of the exciter. This is A10-J2 on the SuperCiter and J2 on the ‘DIGIT.
b. A coaxial cable with a male BNC connector which connects to the exciter rf
output. This is A10-J11 on the SuperCiter and J1 on the DIGIT.
c. AC Power Cable. Verify that the exciter is set for the correct operating volt-
age. For more information refer to the Exciter Manual, Section II, Installation.
NOTE:
For Digit Exciters, the VCO shipping screws must be removed as out-
lined in the exciter manual in Section II.
2-4 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Installation & Initial Turn-On
! WARNING:
DISCONNECT AND LOCKOUT STATION PRIMARY POWER AT THE WALL
BREAKER BEFORE MAKING ANY CONNECTIONS.
888-2408-002 2-5
WARNING: Disconnect primary power prior to servicing.
Installation & Initial Turn-On
a. There are two ribbon cables W11 and W12 (blue) and one control voltage
cable W21 (gray with orange connector) hanging on the right side of the
power supply compartment.
1. First connect W12 to J4 on the PS2 Rectifier Board. See Figure 2-1.
2. Now the supply can be rolled into the cabinet. Be sure to get the orange
AC input cables, #1, #2 and #3 and wires #40 and #41 out of the way
before rolling the power supply all of the way in. These are bundled on
the left side of the power supply compartment.
3. Connect W11 to J4 on the PS1 Rectifier Board.
4. Connect W21 (flat gray cable with orange connector) to J6 on the PS1
Rectifier Board.
b. The cable labeled A1P2 (gray multi-conductor cable with 12 pin gray connector)
plugs into its mating connector on the left wall of the power supply compartment.
c. Roll the power supply the rest of the way into the cabinet.
d. Wires 45 and 52 (large orange cables tied up with the transformers) connect to
the feed-thru terminals, C3 and C4 at the top of the power supply compart-
ment. These are the 52Vdc outputs from the two supplies. See Figure 2-2. The
wires connect as follows:
• Wire #52 connects to C4 (on the left along with wire #81)
• Wire #45 connects to C3 (on the right along with wire #80)
e. Wires #1, #2, and #3 (orange cables tied up on the left side of the power sup-
ply compartment) and two smaller gray wires #40 and #41* plug into the gray
Wego block connector, A17TB1 on the front of the power supply tray (A17
designates a component on the power supply tray). See Figure 2-1. The Wego
block has 8 terminals labeled terminal #1 on the left and #8 on the right. The
connections are as follows:
• Wire #1 connects to terminal #1
• Wire #2 connects to terminal #3
• Wire #3 connects to terminal #5
• Wire #40 connects to terminal #7
• Wire #41* connects to terminal #8
(*Wire #41 is not used on 3 phase 4-wire system)
NOTE:
If these wires are not connected to the appropriate terminal on the
Wego block, as designated on the Overall System Block Diagram, the
blower may not operate.
f. To insert the wires into the Wego block, insert a screwdriver into the rectan-
gular slot above the wire hole then carefully lift. This will open the contact
inside the Wego block and the wire can be inserted. Be very careful not to let
the wire ends fray as the connectors are very close together and could cause a
short. The wire insulation should actually extend just inside the Wego block
hole.
g. The large orange ground wires, #46 and 60, coming from the top of each rec-
tifier assembly attach to ground studs at the top-front edge of the power sup-
ply compartment. It is located under the shelf which separates the power
supply from the PA compartment just above C3 and C4. See Figure 2-2.
h. Connect the safety ground wire to the stud on the front of the power supply
tray, just in front of A17TB1, See Figure 2-1.
i. Tighten the two hold down nuts located on the bottom front corners of the
power supply compartment. Re-install the front cover panel for the power
supply compartment.
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WARNING: Disconnect primary power prior to servicing.
Installation & Initial Turn-On
a. There are two ribbon cables and one power connector hanging on the right
side of the power supply compartment inside the transmitter. The ribbon
cables connect to J4 on the Rectifier Boards. The longer ribbon cable, W12
connects to the Rectifier Board on PS2 (nearest the back of the transmitter)
and should be connected first. Be sure to route this cable so it does not touch
the resistor standing up on top of the Rectifier heatsink. See Figure 2-3.
b. The shorter blue ribbon cable, W21 connects to the front Rectifier Board on
PS1. The power cable, W11 (the gray cable with the orange connector) con-
nects to J6, on the Rectifier Board nearest the front of the transmitter.
c. The cable labeled A1P2 (gray and yellow multi-conductor cable with gray
connector) plugs into its mating connector on the left wall of the power sup-
ply compartment. Roll the power supply all the way into the cabinet.
d. Wires 80 and 81 (large orange cables tied up with the transformers) connect to
the feed-thru terminals at the top of the power supply compartment. See Fig-
ure 2-4. The cables are dressed such that the shorter cable, 81 connects to the
left hand terminal and the longer cable, 80 connects to the right hand terminal.
e. Wires #1 and #2 (orange cables tied up on the left side of the power supply
compartment) plug into the gray Wego block connector on the front of the
power supply tray. See Figure 2-3. Wire #1 goes to the left and #2 in the 3rd
hole from the left. Wires #40 and #41 are inserted into the 5th and 6th holes
respectively from the left. To insert the wires into the Wego block, insert a
screwdriver into the rectangular slot behind the wire hole and then carefully
push toward the rear of the transmitter. This will open the contact inside the
Wego block and the wire can be inserted. Be very careful not to let the wire
ends fray as the connectors are very close together and could cause a short.
The wire insulation should actually extend just inside the Wego block hole.
f. The large orange ground wires, #52 and 152, coming from the power supply
attach to the ground stud at the top-front edge of the power supply compart-
ment. It is located under the shelf which separates the power supply from the
PA compartment, see Figure 2-4.
g. Connect the safety ground wire to the stud on the front of the power supply
tray, just in front of A17TB1, See Figure 2-3.
h. Tighten the two hold down nuts located on the bottom front corners of the
power supply compartment.
Re-install the front cover panel for the power supply compartment.
Figure 2-4 DC and Ground Connections for Single Phase Power Supply
2-10 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Installation & Initial Turn-On
NOTE:
Harris does not recommend using circuit breakers for the main trans-
mitter disconnect due to the inrush current during turn-on.
The recommended fuse type is class RK5, a dual element time delay fuse. Examples
are the Bussmann FRN-R (250V), FRS-R (600V), Littelfuse FLNR (250V), FLSR
(600V), and Ferraz gG fuses. If you prefer to use a circuit breaker in your
installation, select one with a motor-starting trip curve, similar to the RK5 curve for
fuses. This type of delayed response is needed in order to accommodate the
momentary in-rush current. This can be 300 to 600 amps, depending on the
transmitter model and AC configuration.
! WARNING:
DISCONNECT AND LOCK OUT PRIMARY POWER TO THE TRANSMITTER
BEFORE PROCEEDING.
In a typical 380 volt system that has a connection to earth ground, each AC phase
will measure about 220 volts to ground. The phase-to-phase, and phase-to-ground
voltages should be balanced within a few percent.
MOV protection may need to be modified. Please consult with an electrician if this
applies to your installation. If applicable, the phase-to-earth 275 volt MOVs in the
RV7 through RV13 and RV20 positions may be replaced with 510 volt MOVs
(Harris part number 560-0042-000, quantity 8).
For safety reasons, you also must install a 4 pole disconnect device if your neutral
line is not connected to earth ground.
! CAUTION:
THE NEUTRAL CONNECTION IS EXTREMELY IMPORTANT IN 380VAC 4
WIRE APPLICATIONS. BY VIRTUE OF THE SINGLE PHASE LOADS
WITHIN THE TRANSMITTER, THE SYSTEM IS NOT ENTIRELY
BALANCED, REQUIRING NEUTRAL CURRENT TO MAINTAIN PROPER
PHASE TO NEUTRAL VOLTAGES. A POOR NEUTRAL CONNECTION
COULD CAUSE DAMAGE TO THE SINGLE PHASE ELEMENTS IN THE
TRANSMITTER.
NOTE:
The NEUTRAL connection is NOT required for 208/220VAC 4-wire
WYE source voltage and should not be run to the transmitter.
There is no connection in the transmitter for the neutral connection (for
this application) and it should not be connected to chassis ground. The
power supply transformers in the transmitter will be configured as
delta for this application.
2-12 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Installation & Initial Turn-On
2.5.6.3 Grounding
The importance of a good grounding system and lightning protection can hardly be
overemphasized for reasons of personnel safety, protection of the equipment, and
equipment performance. The following is only a brief overview.
Lightning and transient energy via the power line or tower connections can impose
serious threats to your personal safety as well as damage the equipment. For these
reasons you should have a good protective earthing system to divert these forms of
energy to earth ground. Proper grounding of the equipment also guards against
electrical shock hazards that would exist if the equipment failed in a way which put
a hazardous voltage on the chassis.
A good grounding system should include substantial grounding at the tower base
using copper ground rods and/or a buried copper ground screen, with copper strap
used to connect the tower base to earth ground. A low impedance will help carry
lightning current directly into the ground instead of into your building. Additionally,
coax shield(s) should be electrically connected to and exit the tower as near to the
bottom as practical to minimize the lightning voltage potential carried by the coax
into your building.
For coaxes, a single point of entry into the building is best, with all connected to a
common grounding plate (or bulkhead panel) having a low impedance connection
to the building perimeter ground. Wide copper straps should be used for making the
connection from the common grounding plate to earth ground.
A common grounding plate is also the best location for coaxial surge protectors for
sensitive equipment such as an STL receiver. Ideally, this plate should also be the
entry point for all signal lines, and serve as a single point ground for AC power
surge protection.
Good grounding and shielding will help keep stray RF current to a minimum. RF
interference usually shows up in one of several ways, intermittent problems with
digital or remote control circuits, audio feedback or high pitched noise. Even a
small amount of non-shielded wire makes a very efficient antenna for RF and
transient energy. If RF is allowed into the audio equipment, it can be rectified and
may show up as noise or feedback. Wire and cable shields should normally be
connected at both ends to the equipment chassis.
888-2408-002 2-13
WARNING: Disconnect primary power prior to servicing.
Installation & Initial Turn-On
A ground strap attachment point is located on the top, right rear, of the cabinet (use
four 1/4-20 brass screws with brass washers). Use this connection when utilizing a
single point grounding system, attaching your ground strap to the common
grounding plate. An alternate ground connection is a short copper strap on the back
of the Platinum Z transmitter, on the bottom right side. Unfold this strap and
securely bolt or silver solder it to the building ground. This strap can be removed
from the bottom and used at the top.
A grounding stud is also provided near the AC input connections in the upper
portion of the Platinum Z transmitter. Use this connection for the power line ground.
It is located above the low voltage power supply board.
2-14 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Installation & Initial Turn-On
! CAUTION:
TO CONNECT TO THE WAGO BLOCK, J4 ON THE LIFE SUPPORT BOARD
REQUIRES PRESSING A SCREWDRIVER INTO THE RECTANGULAR
SLOT ON THE FRONT SIDE OF THE BLOCK SO THE WIRE CAN BE
INSERTED FROM THE REAR. BE SURE TO PROPERLY SUPPORT THE
BOARD SO THAT IT IS NOT BENT OR STRESSED IN ANY WAY WHILE
INSERTING THE WIRES.
888-2408-002 2-15
WARNING: Disconnect primary power prior to servicing.
Installation & Initial Turn-On
STEP 2 Turn on the low voltage power supply breaker, CB1, located in the
rear of the transmitter cabinet in the upper right-hand corner. There
are 6 green LEDs on the Low Voltage Supply board which should be
illuminated. Close and secure the rear door.
STEP 3 Verify that the two LCD displays on the front of the controller are
active. The Diagnostics display should look like Figure 2-5. The
Fault LED on the front panel will be lit, since the modules are not
installed yet, and should be ignored at this point.
STEP 5 Press the LOW power ON button on the front of the controller, but
be ready to quickly press the off button if necessary. The PA VOLTS
reading on the front panel should be above 40Vdc and the blower
should come on at HIGH Speed.
2-16 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Installation & Initial Turn-On
NOTE:
If the blower does not run, check the position of wires #1, #2 and #3
for 3-phase or wires #1 and #2 for a single phase, at A17TB1. If these
are connected in the wrong position, the fan may not operate (this is
also true for the single phase transmitter due to switching on the Low
Voltage Supply Board). Also check blower fuses F1 and F2 located in
the bottom deck of the front PA compartment (F2 not used in 3 phase
4-wire systems).
STEP 6 If the PA VOLTS reading appears okay then shut the transmitter off
and insert the PA and IPA Modules as directed below. See Figure 2-6
and Figure 2-7.
! WARNING:
THE PA MODULES ARE DESIGNED TO HANDLE VERY HIGH TEMPERATURES
AND MAY BE EXTREMELY HOT. DO NOT TOUCH THE MODULES WITH BARE
HANDS AFTER THE TRANSMITTER HAS BEEN RUNNING, ESPECIALLY IN HIGH
AMBIENT TEMPERATURE ENVIRONMENTS.
STEP 8 Optimization - The Factory Test Data Sheet contains the serial
numbers of each of the PA and IPA modules. The data sheet also tells
which slot each of the PA modules were connected into during
factory testing. While it is Not Critical to operation, the transmitter
readings may be closer to the data sheet if the PA and IPA modules
are placed in the same positions as during factory testing. The
module serial number tag should be on top of the module when
inserted into the transmitter.
! CAUTION:
EACH MODULE HAS TWO CAPTIVE THUMBSCREWS WHICH MUST BE
TIGHTENED TO ASSURE PROPER MODULE OPERATION. THEY SHOULD
BE FINGER TIGHT. IF A SMALL SCREWDRIVER IS USED, BE SURE NOT
TO OVERTIGHTEN.
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Installation & Initial Turn-On
B1 A1
B2
B3 A2
A3
A4
IPA_AB2
IPA_AB1 B4
Figure 2-6 PA Compartment Front View
B5
A5
B6
A6
B7
A7
A8 B8
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Installation & Initial Turn-On
STEP 9 For the dual IPA configuration, the IPA will be identical to any of the
PA modules and may be plugged in with either side up in the IPA
slot. To see which IPA is active press [HOME, STATUS D,B]. This
should bring up the screen shown in Figure 2-8. If the transmitter is
configured with only a single IPA, then one half of the module will
be empty. It is recommended that the IPA module be inserted with
the amplifier on the right side of the heatsink. This places the
amplifier in the IPA_AB1 position (the default for the controller). If
the IPA is on the left side of the heatsink when inserted, then
IPA_AB2 will have to be selected before operating the transmitter.
To select IPA_AB2 press the [D] or switch key to toggle from
IPA_AB1 to IPA_AB2 and back.
STEP 10 With all of the modules installed, the Fault LED on the controller
front panel should be flashing at this point. This indicates that there
are inactive faults in the fault log which need to be cleared at this
time. To reset the Fault Log press [FAULT, C, and then D for YES].
This will erase all inactive faults in the Fault Log and the front panel
Fault LED should be off. If the “FAULT” LED on the front panel of
the controller is not lit, then proceed to the next step.
If the “FAULT” LED, on the front panel of the controller, is
illuminated (not flashing), use the Fault Log to find the active
fault(s) and refer to Section VI, Troubleshooting for information on
how to track down the problem.
STEP 11 Turn the transmitter back ON at LOW power. Verify that the exciter
power is the same as the factory test data sheet. This can affect
performance.
The fan will run at high speed for 1 minute then will automatically
switch to low speed provided there are no faults. Any fault will
cause the fan to automatically switch to high speed. There is also an
option to force the fan speed to HIGH in the Configuration menus of
the Diagnostics Display. See Table 2-14 on page 2-24.
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Installation & Initial Turn-On
STEP 12 At this point, if there are no faults, verify that the transmitter display
readings closely resemble those on the factory test data sheet for
LOW power. If the “FAULT” LED comes on, go to the Fault Log in
the Diagnostics Display to find out which fault has been activated
and refer to Section VI, Troubleshooting. If everything looks okay,
proceed to the next step.
STEP 13 Press the HIGH power ON button on the front panel of the controller.
If there are no faults, again verify all of the transmitter display
readings against those in the factory test data sheet.
STEP 14 This step is optional, as it simply makes the transmitter FWD PWR
% meter read 100% at the customer specified Transmitter Power
Output (TPO), which should already be factory set. This will not
change the kW reading on the FWD PWR display.
a. Set the power to the desired TPO using the raise and lower but-
tons.
b. Go to the 100% TPO SET screen [HOME,MORE,CONFIGU-
RATION B,A] and set the power level to your TPO. Press
[BACK] to update and store the new information.
c. The front panel FWD PWR reading should be 100%. You may
also want change the MAX HIGH and MAX LOW power set-
tings to something more in line with your new TPO as well.
MAX HIGH sets the maximum power level when the HIGH ON
button is pressed, while MAX LOW sets the maximum power
level when the LOW ON button is pressed. The procedure for
changing power limits is given in Section V, Maintenance and
Alignments.
The initial turn on is now complete.
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Installation & Initial Turn-On
Use shielded cable for the remote control lines and/or install it in a metal conduit. It
is acceptable to install it in the same conduit as the exciter input cables.
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Installation & Initial Turn-On
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Installation & Initial Turn-On
A series resistor and LED can also be used for extended status indications.
Maximum external supply voltage should not exceed +28Vdc.
NOTE:
Maximum status line current is 25 mA. If the output is used to drive a
small printed circuit board type relay, check current requirements for
relay coil and be sure to install a circuit protection diode across the
coil. A 1N4004 or equivalent will work.
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Installation & Initial Turn-On
Extended metering can also be connected to TB1 terminals. See Figure 2-13 for an
example of extended metering connections.
NOTE:
This input is simply a switch command and does not care which
exciter was on the air to begin with. For example, if the Main exciter is
on the air, then it will switch to the alternate, but if the alternate is on
the air it will switch to the main exciter.
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Installation & Initial Turn-On
When the UPS is activated, TB1-9, the remote control interface terminal strip, must
be pulled low. This will take the transmitter to the preset UPS power level which is
factory set for 2.5kW, via software in the Diagnostics Display System. However, if
the transmitter is operating in LOW power when the UPS mode is activated, then the
transmitter will stay at the LOW power level unless the UPS level is set lower. For
example, if LOW power is set for 2kW and UPS is set for 2.5kW, the transmitter will
stay at the LOW power level of 2kW. If the transmitter is operating at HIGH power
when the UPS mode is activated then it will drop to the UPS power setting.
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Installation & Initial Turn-On
NOTE:
The REF VOLTAGE in Figure 2-17 is merely an internal reference
point the controller uses to reduce the supply voltage in optimized
mode. This reading is usually in the low 40’s when the transmitter is
optimized (well below the actual supply voltage).
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Installation & Initial Turn-On
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Installation & Initial Turn-On
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Installation & Initial Turn-On
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Installation & Initial Turn-On
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Installation & Initial Turn-On
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Installation & Initial Turn-On
Another likely source of this problem can come from unbalanced impedances in the
power distribution system. Unbalanced impedance will always be seen when an
“open” delta three phase distribution system is used. Transformer design textbooks
clearly show that the voltage regulation of an unbalanced system is poor.
The only advantage of the open delta is lower initial cost, and this is partially offset
by the fact that when only two transformers are used, they must be larger than the
three transformers in a closed delta system.
Difficulties have often been experienced with open delta systems; but when a third
transformer was added to close the delta, the problems disappeared.
There is another problem which can occur with an open delta system, and that is
caused by lightning and switching transients. When lightning strikes or heavy loads
are switched on a power distribution system, high voltage transients are propagated
throughout the system. Unbalanced impedances will enhance these transients and
can cause transmitter damage, particularly to solid state rectifiers.
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Installation & Initial Turn-On
Many transmitters are located at the end of a long transmission line which is highly
susceptible to transient phenomena. Devices such as Metal Oxide Varistors are
inexpensive and very effective in reducing over voltage spikes. These units are
limited in the amount of energy that can be dissipated, but will handle, if designed
properly, very large currents. You can’t take a direct lightning hit and still operate,
but not many things will. It has been reported by engineers that installation of a third
transformer and transient protection devices, have eliminated the difficulty.
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Installation & Initial Turn-On
Today, many transformers are supplied with all of the primary terminals available so
that either a delta or WYE connection can be made. Table 2-3 shows the different
line-to-line voltages that are available with this configuration.
220* 380*
230 400
240* 415*
250 433
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Operator Guide
3.1 Introduction
This section contains normal operational procedures and information pertaining to
the function of the Platinum Z5 Transmitter. Most important, is the information
regarding use of the Diagnostic System. All of the information in this section
assumes the the transmitter and controller are in proper working order.
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Operator Guide
ON - LOW - Turns the transmitter on to the previous LOW setting. If the transmitter
has folded back power automatically, due for instance to high VSWR, pressing the
LOW button will return the transmitter to the normal low power level provided the
cause of the foldback is gone.
POWER (up/down arrows) - used to raise and lower the transmitter power.
REMOTE DISABLE - (Located on the left side of the controller) used to disable
any remote control system which is connected to the transmitter. When the LED is
lit, the remote control inputs are disabled.
NOTE:
Some of the less often used transmitter controls, such as calibration and con-
figuration, are located in the menu screens of the Diagnostics system. These
are covered as part of the Diagnostics system later in this section.
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Operator Guide
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Operator Guide
The diagnostic system consists of the LCD Diagnostic display and 6 function keys,
HOME, BACK and the four selection keys on the right side of the LCD screen.
IMPORTANT: For all discussions pertaining to the Diagnostic system, the four
function keys to the right side of the Diagnostic LCD display will be called A, B, C
and D from top to bottom as in Figure 3-2. This figure also shows the default screen
which will show up when the controller is first turned on or after being idle for 15
minutes.
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Operator Guide
3.4.1 HOME
HOME takes you to the home layer or root menu. This menu should look like the
one in Figure 3-3, which is the first of two screens in this layer. The second screen
in the HOME layer is accessed by pressing the “D” function key to the right of the
display which is labelled “MORE -” on the display. The screen should now look like
Figure 3-4. These two screens give access to all six HOME menus:
• Status
• Metering
• Fault
• Configuration
• Test
• Software Revision
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Operator Guide
3.4.2 BACK
BACK takes you to the previous layer in the menu tree, not necessarily to the
previous screen. As an example, if you were to press HOME and then choose
STATUS you would now be in layer 2 of the STATUS menu. You should see the
screen shown in Figure 3-5. If you press MORE, you go the the second screen in
layer 2. Now press the BACK key. Notice that it did not take you to the previous
screen but back to Layer 1, the HOME layer, shown in Figure 3-3. However, if
instead of pressing BACK, you pressed more again, this would have taken you to
the first screen in layer 2 (since there are only two screens).
3.4.3 MORE
MORE is a menu item which is used when there are more menu items on a layer
than will fit on one screen. It will take you to the next screen in the same layer.
When you have reached the last screen in that layer, pressing MORE again will take
you back to the first screen in that layer. This is shown on the Diagnostics Display
Menu Tree drawings.
NOTE:
It will be assumed that you always press the HOME key first before entering
the key sequences in the brackets.
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Operator Guide
Example 1
After entering this key sequence the screen should look like Figure 3-6. This is
equivalent to pressing the following menu items as they appear on each successive
screen: METERING, TEMPERATURE, PA, Z PLANE A.
Example 2
You want to check or possibly change the Maximum High Power Setting. This falls
under the category of CONFIGURATION, but this menu item only shows up on the
second screen of the HOME layer. Therefore, press the following keys:
This should have taken you to the screen shown in Figure 3-7. This screen now
allows the operator to change the Maximum High Power setting using the A,B,C
and D function keys. Pressing the BACK key updates the change, while pressing
HOME would cancel any changes.
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Operator Guide
! WARNING:
THE PA MODULES ARE DESIGNED TO HANDLE VERY HIGH TEMPERATURES
AND MAY BE EXTREMELY HOT. DO NOT TOUCH THE MODULES WITH BARE
HANDS AFTER THE TRANSMITTER HAS BEEN RUNNING, ESPECIALLY IN HIGH
AMBIENT TEMPERATURE ENVIRONMENTS.
If two PAs were to fail in a single group of four or Foursome, the resulting system
imbalance could result in a power foldback to approximately 84% of nominal power
output. Since a single PA failure in a foursome does not create an imbalance severe
enough to cause foldback, one of the PA modules with a bad PA should be taken
out, turned over and re-inserted, placing the bad PA in a different foursome. For
example, if PA amplifiers B1 and B2 have failed, pull out the A2/B2 PA module,
turn it over and plug it back in so that the bad PA is in position A2 instead of B2.
There are still 2 failed PAs, B1 and A2, but now each one is in a different foursome.
This will restore balance to the system and the transmitter will still be able to
operate at or near full power output by automatically increasing the drive to the
remaining PAs (via the APC voltage). For more information on Foursomes refer to
Section IV, Overall System Theory, under the heading “8-Way Combiner”.
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Operator Guide
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Operator Guide
• Automatic Mode - When AUTO mode is selected, the transmitter will automati-
cally optimize the efficiency every 12 hours if there are not faults present. This is
the recommended mode of operation and is the default mode from the factory.
• Manual Mode - In the Diagnostics Display there is a menu screen which can be
used to optimize the transmitter efficiency. To optimize efficiency press [HOME,
METERING D,C then D for Maximization]. The Efficiency Status/Manual Opti-
mize screen is shown in Figure 3-13.
NOTE:
The REF VOLTAGE in Figure 3-13 is merely an internal reference point the
controller uses to reduce the supply voltage in optimized mode. This reading
is usually in the low 40’s when the transmitter is optimized (well below the
actual supply voltage).
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Operator Guide
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Overall System
Theory
4.1 Introduction
This section contains theory of operation and circuit descriptions of the Platinum
Z5™ FM Broadcast Transmitter.
4.2.1 Exciters
It starts with the built in dual exciter option (in other words the switching
components are present but the exciter is optional). The RF output of both exciters
(if present) connect in to the Exciter/IPA Backplane board. The exciter RF switch
shown on this board is activated by the controller if Exciter A were to fail, placing
Exciter B on the air automatically. This fault and all other transmitter faults are
stored in the Fault Log in the Diagnostics Display System. The active exciter output
is selected by the first RF switch and directed to the active IPA by the second RF
switch. Both RF switches are controlled by the Master Controller.
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Overall System Theory
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Overall System Theory
4.2.2 IPAs
The Z5 has 1 IPA Module, which is made up of 2 power amplifiers or PAs. The IPA
Module is identical to, and interchangeable with, the PA Modules. The 2 IPAs per
IPA Module operate in Main/Alternate mode, meaning that only one of them is
active at a time. The block diagram shows that IPA_AB1 is the normally active
amplifier. RF switching on the input and output of the IPA is activated by the
controller if a fault is sensed in the active IPA. The IPA output is split using a 3dB
hybrid built onto the IPA Backplane Board. This provides 2 equal amplitude outputs
90 degrees out of phase to drive the Power Amplifiers.
4.2.3 PA
The Z5 contains two Z-Planes which could be considered 2.5kW Power Blocks. For
simplicity in Figure 4-1, Z-Plane A is the only one which shows the actual
component assemblies located on each Z-Plane. Z-Plane B is identical. Next, each
Z-Plane can also be broken down into 2 parts, a Divider Board and a Combiner
Board.
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Overall System Theory
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Overall System Theory
4.3.2 IPA
The IPA amplifier and/or module is identical to any one of the PA modules. This
allows a PA module to be used in place of a failed IPA. The standard IPA
configuration includes dual IPA amplifiers, used in a main/alternate configuration
(in other words only one is used at a time).In this configuration the IPA Module is
identical to a PA module. If one of the IPA amplifiers fails, the controller will
automatically switch to the second IPA with a minimal interruption of service. For a
detailed explanation of the RF amplifier operation refer to the paragraph “Power
Amplifier” later in this section.
• Main/Alternate exciter switching (only active with optional dual exciter configu-
ration).
• Main/Alternate IPA switching (active with standard, dual IPA configuration).
• Monitoring of IPA temperature, voltage, current and forward power.
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Overall System Theory
• Splitting of the IPA output into 2 equal amplitude signals 90 degrees out of phase,
by way of a 3dB hybrid, to drive the Z Plane dividers.
• Air flow sensing
• Ambient temperature sensing
• IPA 1 and IPA 2 interlocking
4.3.3.1 Main/Alternate Exciter Switching
Exciter selection is done via relay K1 and the EXCITER SELECT control signal
from the Life Support Board. The EXCITER SELECT signal is normally low which
places K1 in the position shown on the schematic, sending the Exciter 1 RF output
to the IPA input relay K2. If EXCITER SELECT goes high, K1 will be energized
and switches to the Exciter 2 RF output. This switching will take place
automatically if an exciter fault is detected by the Master Controller board. Exciter
switching can also be done manually using the Diagnostics display. Press [HOME,
STATUS D,C] (this code is explained in Section III, Operation). This should bring
up the screen in Figure 4-2. Pressing the D function key will now toggle K1,
switching from exciter 1 to exciter 2 or vise versa.
NOTE:
For easy navigation through the Diagnostic menus, refer to “Using the Diag-
nostic Display” in Section III, Operation and to the “Diagnostics Display
Menu Tree”, in the schematic package, which gives a complete overview of
the Diagnostics menu structure.
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Overall System Theory
NOTE:
The term “AB” is used to associate a component with Z-Plane A and Z-Plane B.
K2 switches the input RF drive from the exciter to IPA_AB1 or IPA_AB2 while K3
selects the active IPA RF output. The control signal, IPA DRIVER SELECT, is
normally low which places K2 and K3 in the IPA_AB1 position as shown on the
schematic. If IPA DRIVER SELECT goes high, K2 and K3 will be energized and
switch to the IPA_AB2 position. If the Master Controller detects a loss of RF output
from the active IPA it will automatically switch to the second IPA.
IPA switching can also be done manually using the Diagnostics display. Press
[HOME, STATUS, D,B] This should bring up the screen in Figure 4-3. Pressing the
D function key will now toggle K2 and K3, switching from IPA_AB1 to IPA_AB2
or vise versa.
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Overall System Theory
• Edge connectors for 8 PA amplifier boards (4 in front and 4 in the rear). These
connectors are labeled J1-J8.
• An 8 way Wilkinson Divider, driven by the IPA, which feeds RF drive to each of
the 8 PA amplifiers.
• An 8 way Wilkinson Combiner which combines the output of the same 8 PA
amplifiers.
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Overall System Theory
The RF output of the Z-Plane board connects directly to the 3dB hybrid where it is
combined with the output of the second Z-Plane Combiner/Divider board. The Z
plane boards are identical, but the outputs connect to opposite ends of the 3dB
hybrid (one at the top and one at the bottom). This requires that one of the Z Planes
be physically inverted.
The input to the divider is first divided into two equal outputs at approximately 35
ohms by a two-way Wilkinson divider with a 70.7 ohm isolation resistor, R9. Each
of these outputs (each end of R9) is then divided into 4 outputs in a 4-way
Wilkinson divider.
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Overall System Theory
4.3.4.3 PA Modules
Each of the 8 PA Modules contain two PA Amplifier boards mounted on opposite
sides of the PA Module heat sink. The modules are numbered 1 through 8 with the
top module in the front being #1 and counting to #4 at the bottom. The top rear
module is #5 counting down to #8 at the bottom rear, see Figure 4-5 for the front
view and Figure 4-6 for the rear view. The PAs are numbered as 1A, 1B, 8A, 8B
etc... with the “A” side PAs being plugged into the “A” Z Plane, and the “B” PAs
plugged into the “B” Z Plane. From the front of the transmitter, the “A” Z Plane is
on the right and the “B” Z Plane is on the left. Keep in mind this is reversed when
viewing from the rear of the transmitter. All DC, signal and RF connections to a PA
board are through one edge connector.
The control voltage input called VG can be thought of as a bias voltage which can
be used to vary the amplifier output. Normally for the PAs it is simply used to turn
the amplifiers on and off. If VG is -18V the amplifier is off or muted. If VG is 0V
the amplifier is fully turned on and drive level from the IPA determines the
amplifier power output.
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Overall System Theory
When the amplifier is used as the IPA, VG is used to linearly vary the IPA output
which then controls the transmitter power output. For an IPA, VG comes from the
Life Support Board and is controlled by the APC loop on the Master Controller
Board. Pressing the RAISE and LOWER controls on the front of the transmitter will
vary the APC voltage which in turn will vary VG to the IPAs. This will vary the IPA
RF output, which will raise or lower transmitter power.
The MOSFET outputs are combined in T2, a 1:4 transformer. C19 and C20 fine-
match the 50 ohm load impedance at the PA output to the output impedance of T2.
The +52Vdc or VD (Drain Voltage) from the main power supply enters at location
C-1 and is decoupled and filtered by C11, C12, C13, C14, C16, C24, L1 and L2.
The DC voltage reaches the drain of MOSFETs Q1 and Q2 through the center tap of
T2’s primary winding. The advantage of this method is to allow direct DC
connection to the MOSFETs and have an AC RF output through the coax without
the need for a blocking capacitor.
Maximum RF output is 425 watts. Typical output level is 300 to 340 watts. The
power module is designed for single amplifier field replacement. In the event an RF
power MOSFET fails, field replacement is not practical due to the cost of
components, time and test equipment involved in repair and alignment of phase,
gain and response. This is a highly critical area, and if not done correctly, improper
module and transmitter operation will occur.
! WARNING:
PRODUCT AND ENVIRONMENTAL SAFETY-TOXIC MATERIALS. THIS PRODUCT
CONTAINS BERYLLIUM OXIDE. THE PRODUCT IS ENTIRELY SAFE PROVIDED
THAT THE BEO DISC IS NOT DAMAGED. ALL PERSONS WHO HANDLE, USE OR
DISPOSE OF THIS PRODUCT SHOULD BE AWARE OF ITS NATURE AND OF
THE NECESSARY SAFETY PRECAUTIONS. AFTER USE, DISPOSE OF AS
CHEMICAL OR SPECIAL WASTE ACCORDING TO THE REGULATIONS APPLY-
ING AT THE LOCATION OF THE USER. IT MUST NEVER BE THROWN OUT WITH
THE GENERAL OR DOMESTIC WASTE.
Failed PA boards should be sent in for repair or exchanged mainly due to the
minimal cost involved. Refer to the Maintenance section of this manual for the RF
amplifier replacement procedure.
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Overall System Theory
B1 A1
B2
B3 A2
A3
A4
IPA_AB2
IPA_AB1 B4
Figure 4-5 PA Compartment Front View
B5
A5
B6
A6
B7
A7
A8 B8
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Overall System Theory
If the two Z Plane outputs are not equal, or are not exactly 90 degrees apart in phase,
a portion of the power appears to the reject load, however the 3dB hybrid is a very
stable device which sends most of the input power to the combined output over a
fairly wide range of input power ratios and input phase differences. The reject load
is a 50 ohm 800 watt resistor mounted on a heatsink which is located on the upper
end of the hybrid, just above the Z-Planes. The output of the 3dB hybrid is on the
lower end of the hybrid and is connected to the transmission line Harmonic Filter in
the rear of the cabinet, via the aluminum enclosure just above the power supply.
There is a static drain choke located inside this box.
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Overall System Theory
NOTE:
Note that the reflected coupler cannot be interchanged with the other 2 cou-
plers due to the different coupling ratio for the forward and reflected samples.
The typical coupling ratio for each of the couplers is given below:
(Typical tolerance is +/- 0.1dB but this is not guaranteed since any minor variation
can be factored out using the calibration procedures).
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Overall System Theory
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Overall System Theory
PS1 and PAC1 connect to A1, A2, A5, A6, B3, B4, B7 and B8.
PS2 and PAC2 connect to A3, A4, A7, A8, B1, B2, B5 and B6.
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Overall System Theory
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Overall System Theory
Each of the secondary windings has 4 output taps, each of which are connected
through an SCR to ground. The SCRs act as both tap switches, activating the tap
which gives the appropriate DC voltage output, and as rectifiers. This gives a total
of 8 SCRs per secondary, only 2 of which will be activated at any one time
providing the ability to regulate the output DC voltage by changing the transformer
turns ratio. The 4 secondary taps allow DC outputs of 48, 50, 52 and 54Vdc. The tap
switching is controlled by the Power Supply Controller board. The two transformer
assemblies are designated PS1 and PS2. PS1 provides power for 8 of the 16 PAs.
Four of these are on Z Plane A and four on Z Plane B. Therefore PS 2 provides
power for the remaining 8 PAs.
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• +20VDC
• -20VDC
• +10VDC
These voltages are sent to the Rectifier boards and then on to the controller boards.
The board contains 3 relays, A19K1, A19K2 and A19K3. When the transmitter is
turned on, A19K1 activates the main contactor (simply called K1) which then
applies AC to the PA power Supplies, while A19K2 applies AC to turn on the
exciter(s). A19K3 selects the low or high fan speed by actuating the fan speed select
relay K2 which is mounted near the main AC contactor.
Each transformer has 2, four wire WYE, secondaries with the center connection
being the rectified DC output of 52Vdc. The two secondary outputs are combined
via L1 and L2, for T1, and L3 and L4 for T2. C1 and C2, 120,000uF filter caps,
provide the final filtering. Each of the transformer secondary taps is connected to a
Rectifier Board.
The secondaries of T1 and T2 use the unique tap switching design to give a small
window of coarse regulation (approximately 2Vdc change per tap) to compensate
for 3 phase AC line variations.
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There are two rectifier boards mounted on the top of each power transformer. The
two boards were originally made as one board which is broken apart for assembly.
Therefore, there is an “A” side and a “B” side, both of which are shown on the same
schematic. The left side of the schematic is the “B” side and the right side is the “A”
side (except on sheet 3 which is “B” side only). There is also only one part number
for both boards. The “A” Rectifier Board is for the transformer secondary “A” with
the “B” Rectifier Board used with transformer secondary “B”. The Rectifier Boards
are operated in parallel and are tied together by a ribbon cable, J3, which is shown
in the middle of the schematic connecting the “A” and “B” sides.
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NOTE:
The circuit for the 48V tap will be explained here as the other three are identi-
cal, but are attached to different transformer taps.
The DRIVE_1 signal is used to activate the 48Vdc tap on T1 and T2 secondaries.
When active (HIGH) it causes the output of U2-17 to go low. This turns on Q28
which applies 10VB-SS, now called DRIVE_1, to R12 on the “B” side of the 48V
section. Interconnect cable J3 then connects the same signal to R25 on the “A” side
Rectifier Board 48V section.
NOTE:
The 10VB-SS (SS = Soft Start) will only be present if the DISCHARGE sig-
nal at J4-6 is inactive. See PA Power Supply Discharge later in this section for
more information.
The 10VB-SS forward biases diodes CR4, CR8 and CR12 on the “B” side and
CR13, CR17 and CR21 on the “A” side. This turns on the associated SCRs, Q4, Q8
and Q12 for the “B” side and Q13, Q17 and Q21 on the “A” side. Each of the SCR
anodes are tied to ground with the cathode connected through a 30 amp fuse to a tap
on one of the transformer secondaries. The “B” side is connected to L5, M5 and N5
with the “A” side connected to L4, M4 and N4 (see the Overall System Block
Diagram for these connections). Note that both the “A” and “B” side SCRs have
selected the same relative (lowest voltage) taps on each of the two transformer
secondaries.
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labeled SS1-B, SS2-B and SS3-B and are connected to the 48V taps on the
transformer “B” secondaries of T1 and T2. This allows the power supply to start
charging through R48, a 5 ohm 100W current limiting resistor. After about 2
seconds, the DRIVER 1 signal will activate the normal 48V tap SCRs which will tie
the taps directly to ground, bypassing R48.
a. First, it reverse biases CR31 which allows the gate of Q33 to pull high
through R54, thus shutting Q33 off. This removes the 10VB-SS used to acti-
vate the transformer taps. This prevents the PA Supply (and Soft Start) from
being activated while the DISCHARGE signal is active.
b. Second, it allows the base of Q37 to pull high, shutting it off. R62 will then
pull the gates of Q29 and Q31 low turning them on. Q29 and Q31 are
switches which tie the 52Vdc to R48, and the supply is discharged.
To determine if a tap has failed (blown fuse), refer to the Diagnostics Display. For
Power Supply 1, Press [HOME, STATUS, D,A,A,D] This will show you the screen
in Figure 4-12. Press D again to see the status of Tap 4. For Power Supply 2, Press
[HOME, STATUS, D,C,B,D].
Each transformer one center tapped secondary with the center connection being the
rectified DC output of 52Vdc. The DC output are filtered by L1, C1, C15 and C16
for T1, and L3, C2, C25 and C26 for T2. Each of the transformer secondary taps is
connected to an SCR which is controlled by ON/OFF signals from the PS Controller
board via the Rectifier Board.
The secondaries of T1 and T2 use the unique tap switching design to give a small
window of coarse regulation (approximately 2Vdc change per tap) to compensate
for AC line variations.
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NOTE:
The circuit for the 48V tap will be explained here as the other three are identi-
cal, but are attached to different transformer taps.
The DRIVE_1 signal is used to activate the 48Vdc tap on T1 and T2 secondaries.
When active (HIGH) it causes the output of U2-17 to go low. This turns on Q1
which applies 20VB-SS, now called DRIVE_1, to R16.
NOTE:
The 20VB-SS (SS = Soft Start) will only be present if the DISCHARGE sig-
nal at J4-6 is inactive. See PA Power Supply Discharge later in this section for
more information.
The 20VB-SS forward biases diodes CR3, and CR4. This turns on the associated
SCRs, CR4 and CR8 on each power supply. Each of the SCR anodes are tied to
ground with the cathode connected through a 100 amp fuse to a tap on one of the
transformer secondaries. Note that both power supplies have selected the same
relative (lowest voltage) taps on each of the transformer secondaries.
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a. First, it reverse biases CR31 which allows the gate of Q33 to pull high
through R54, thus shutting Q8 off. This removes the 20VB-SS used to acti-
vate the transformer taps. This prevents the PA Supply (and Soft Start) from
being activated while the DISCHARGE signal is active.
b. Second, it allows the base of Q9 to pull high, shutting it off. R62 will then
pull the gates of Q6, Q7, Q12 and Q13 low, turning them on. Q6, Q7, Q12
and Q13 are switches which tie the 52Vdc to R48, and the supply is dis-
charged.
To determine if a tap has failed (blown fuse), refer to the Diagnostics Display.
PS #1 PS #2
JP1 IN OUT
JP2 OUT IN
Transformer T1 has dual full wave rectifiers. The T1 secondary outputs are fused by
F3, F4, F5 and F6, and are then full wave rectified for two DC outputs of +10Vdc.
The +10Vdc is filtered by C1-C6 and connected to the rectifier boards, on top of the
PA power supply transformers, in the bottom of the transmitter. Transformer T2
secondaries are fused by F7, F8, F9 and F10 before going to dual bridge rectifiers.
The rectifier outputs are filtered by C7-C10 and supply +20Vdc and -20Vdc to the
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Rectifier Boards on the PA power supply transformers. All three voltages pass
through the rectifier boards and are sent to the Backplane Board to power all of the
controller PC boards.
4.5.4.1 Relays
There are three mechanical relays on the Low Voltage Power Supply Board
assembly A19. They are A19K1, A19K2 and A19K3. The relays are powered by
+12Vdc from the Life Support Board in the controller.
Upon transmitter turn on, the fan will run at high speed for one minute, then will
normally run at the low speed until a fault occurs or there is a significant increase in
temperature detected by the controller. The blower motor is a 2 speed, single phase
motor. Contactor K2 selects the fan speed and is controlled by the Master
Controller. The fan speed can also be manually set to HIGH speed or AUTO in the
Configuration Menus of the Diagnostics Display.
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However, the rest of the control system is designed to operate with the Master
Controller removed from the system in what is called Life Support Mode. The PA
and PS Controllers report to the Master Controller but operate independently to
allow them to continue operating even if the Master is removed. In the event of a
Master Controller failure the Life Support Board disconnects all Master Controller
control functions from the transmitter and initiates minimal protection and control
to keep the transmitter on the air. For more information on Life Support Mode, refer
to the Life Support Board description later in this section.
All the individual bits or bytes of information stored here have a default setting
which is stored in the firmware ROM. When the information in U39 is uploaded to
RAM it is checked against the default values. If it is considered to be out of
tolerance (or invalid data) it will automatically be replaced with the default value
from the ROM. When this happens the fault “EEPROM_DEF” (Default) will be
placed in the fault log. The only time this should happen is when a new EEPROM,
U39 is installed in the Master Controller. Since it is basically blank, all of the
default settings from the ROM will be written to U39 one at a time as it finds they
are out of tolerance. After this has happened, the EEPROM_DEF fault should never
happen again. If it does, U39 should be replaced since a memory location is
probably bad. For information on replacing EEPROM U39 see Section V,
Maintenance and Alignments
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The following is a listing of all of the Default Values which are stored in the
Firmware:
The APC loop starts at the forward power directional coupler. The forward sample
is connected to the Life Support Board where it is calibrated with R127 for 8.9V@
100% TPO at TP9. This voltage sample is then sent to the Master Controller
(schematic sheet 7) where it is squared by multiplier chip U1 (to make the voltage
from the coupler proportional to power) and divided by 10. This is then sent to U5-
6 where it is compared to APC_REF voltage (APC Reference).
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all transmitter power control functions including power level, foldbacks and mute.
This makes it a very important number to know and understand for troubleshooting.
NOTE:
As calibrated from the factory, the digital DAC_APC_REF number should be
approximately 660 (this number should be on the factory test data sheet). This
number can be checked by pressing [HOME, MORE, CONFIGURATION
C,B]. The DAC_APC_REF output voltage APC_REF can be metered at TP8
or in the Diagnostics Display, press [METERING, B,B].
The output at U5-7 is the difference between the forward power sample and the
APC_REF voltage. This difference can be measured at TP3 on the Master
Controller and is called the APC voltage. R13 and R102 divide this voltage down
for display on the Transmitter LCD Display on the right side of the controller. The
APC voltage is not the same as the APC_REF voltage. The dipswitch, S1-10, is
present to allow the APC loop to be opened for troubleshooting. This APC voltage
is now sent back to the Life Support Board (Schematic, sheet [3,B8]) and is called
MSTR_IPA_CTL (Master IPA Control).
If the Master Controller is operational, then the MSTR_IPA_CTL signal will pass
through to U5-4 which will in turn pass the signal if there are no System Mutes
present. Due to the low impedance of the circuit, the Manual PWR REF pot R25 has
little or no effect on the circuit. CR4 and R30 shift the positive APC voltage to a
proportional negative voltage which is passed on to IPA_AB1 or AB2 depending on
the position of K2. Remember that the gate bias on the RF amplifiers is -18V for
OFF and -0.6V for fully ON.
Since the exciter power is fixed, changing the IPA bias will increase or decrease the
IPA output which will then proportionately increase or decrease the output of the PAs.
EXAMPLE:
The following is an example of how the entire loop would work. For our example
the power output of the transmitter goes down due to a failed PA. This would
decrease the output of the forward power directional coupler and the voltage at the
input to the difference amp at U5-6 on the Master Controller Board. Since U5 has
almost infinite gain, the loop will try to force the forward power sample input to U5
to be the same as the APC_REF input. This will increase the APC voltage at TP3
and on the front panel APC reading. The increased APC voltage will pass through
the U5 analog switches (on the Life Support Board) bringing the input to U15-3 less
negative. This less negative voltage is sent to the IPA, increasing its output. More
drive to the PA will increase the transmitter RF output to compensate for the failed
PA. If the RF power output were to increase, the APC loop voltage would be
reduced, lowering the IPA and PA output.
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! CAUTION:
IN LIFE SUPPORT MODE THERE IS LIMITED OVERLOAD PROTECTION
AND NO FOLDBACK FUNCTIONS. ADJUSTING R25 TO MORE THAN 25%
RATED POWER WILL CAUSE THE TRANSMITTER TO SHUT OFF AND
COULD DAMAGE THE TRANSMITTER. REFER TO SETTING LIFE
SUPPORT POWER LEVEL IN SECTION V, MAINTENANCE.
Calibration Factors:
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These cal factors and A/D values will be approximately the same for all Z5
transmitters that are factory calibrated or have been field calibrated at the rated
transmitter power of 5kW as detailed in the Maintenance procedures. These
numbers are also stored in the Backup memory area of the EEPROM, U39 and can
be recalled if necessary. The actual numbers obtained during the factory calibration
are recorded in the Factory Test Data.
NOTE:
If the transmitter is calibrated at other than 5kW these numbers will change
and their new values should be recorded.
It is important to note that as long as the hardware calibration of the forward and
reflected directional couplers is not disturbed, the Cal Factors could be entered
manually and the transmitter calibration would be within a few percent of the
factory calibration. To access the edit controls for each parameter, go to the screen
containing the value and press and hold the [D] button and then press [C]. The edit
controls should now show up on the screen.
! CAUTION:
ENTERING A WRONG VALUE IN ONE OF THESE SCREENS COULD
CAUSE SERIOUS DAMAGE TO THE TRANSMITTER OR EXTERNAL
SYSTEMS. IT IS RECOMMENDED THAT THESE NUMBERS BE RECALLED
FROM THE BACKUP MEMORY OR BE OBTAINED BY FOLLOWING THE
CALIBRATION PROCEDURES AS OUTLINED IN SECTION V,
MAINTENANCE.
4.7.2.1 DAC_APC_REF
DAC_APC_REF [HOME, MORE, CONFIGURATION C,B] is a counter (internal
to the micro), whose output will be between 0 and 900, that is controlled by the
RAISE and LOWER buttons on the front panel. RAISE increases the count and
LOWER decreases the count. This number is then D/A converted to get the
APC_REF voltage which controls the APC loop discussed earlier in this section.
The correct APC_REF voltage for a specific DAC_APC_REF number can be
calculated from the formula:
Example: For the nominal DAC_APC_REF value of 660, APC_REF Voltage = 660
* 0.004883 = 3.22V and can be measured at TP8 on the Master Controller. This
DAC value is used to control transmitter power level for all conditions where the
Master Controller is operational and the APC Loop switch S1-10 is closed.
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The A/D FWD PWR reading must be squared to make the voltage from the coupler
linearly track the transmitter power output (Power is the square of the voltage).
The Forward Factor is now used for all forward power level settings. For example,
to set the Low power control to 2.5kW you press the lower button. This gradually
lowers the transmitter power output by reducing the DAC_APC_REF and therefore
the APC_REF voltage and transmitter power. This in turn lowers forward power
sample and the A/D_FWD_PWR number which can be calculated at 2.5kW as:
At an A/D FWD PWR reading of 570 the front panel Forward Power meter will
read 2.5kW.
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Once the APC_Factor is known, the controller uses this number to calculate the
DAC_APC_REF necessary to obtain the MAX HIGH, MAX LOW and UPS power
levels in the Diagnostics Display.
MAX HIGH SET screen [HOME, MORE, CONFIGURATION B,B] sets the
maximum power level when the HIGH ON button is pressed.
MAX LOW SET screen [HOME, MORE, CONFIGURATION B,C] sets the
Maximum power level when the LOW ON button is pressed.
UPS SET Screen [HOME, MORE, CONFIGURATION B,D,A] sets the power level
when the transmitter is operating on a backup UPS or generator AC supply.
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Once the operator has set a power level in kW in these screens, the controller uses
the OP_APC_Factor to find the DAC_APC_REF that would represent each of the
power levels and sets that number as the power level limit. This maximum
DAC_APC_REF setting is called DAC_MAX and is calculated for each mode from
the formulas below:
Example: If the transmitter is calibrated at 5kW (HIGH ON), and the desired MAX
Power setting is 6kW, this would be entered into the MAX HI SET screen.
Remember that for 5kW the nominal DAC_APC_REF is 660. The micro would
now use the formula:
This is now the highest possible number for the DAC_APC_REF and will limit the
transmitter power to 6kW. To prove that:
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The A/D_RFL_PWR reading must be squared to make the voltage from the coupler
linearly track the transmitter power output (Power is the square of the voltage).
The actual VSWR fault level in the transmitter is set at 1.5:1 (which is 200W). The
Foldback level is set at 1.35:1 (which is 111W). The Reflect Factor can now be used
to set the fault and foldback levels by calculating the A/D_RFL_PWR number that
would represent a specific power level using the formula:
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This says that when the output voltage from the reflected coupler is sufficient to
increase the A/D_RFL_PWR reading to 602, the reflected power is 111W.
Therefore, the VSWR_FB_LVL DAC is set to 602 and its dc output voltage will be
about 1.8V. This voltage is sent to U7-12 as one input to the open loop gain
differential amplifer. U7-13 is the calibrated voltage from the reflected coupler
(from Life Support Board). As long as there is little or no reflected power the
voltage at U7-13 will be zero and the U7-14 output will be at the positive rail. This
reverse biases diode CR1 which is connected to the APC Voltage at U5-10. If the
voltage from the coupler exceeds the VSWR_FB_LVL, U7-14 will try to go to the
negative rail (GND). This will forward bias CR1 and the APC voltage will be pulled
to ground through CR1 and R5. This in turn will reduce the reflected coupler output
and the clamp will be removed from the APC Voltage and the power will try to
come back to normal. Since this is happening extremely fast, once the reflected
coupler output voltage exceeds the VSWR_FB_LVL, the new APC loop will try to
keep the 2 inputs to U7 the same, preventing the reflected power from exceeding
111W. Basically, a new APC loop (using the output from the reflected coupler
instead of the forward) has been formed which takes precedence over the forward
power loop.
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NOTE:
If no faults occur during either of the 10 second time periods, then the strike
counter is reset and will allow 3 more strikes before muting the transmitter.
The slow ramp up in power after a strike should allow the foldback controls to limit
the transmitter power output before the fault thresholds are reached again. The slow
power ramps are designed to allow the transmitter to operate at the maximum
possible power level without over-dissipating the isolation resistors or exposing the
transmitter to excessive reflected power. This would mean that there would be a
fault in the log but it would be inactive and the transmitter would be in a foldback
condition.
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PA Controller #1 (PAC1)
• Turn on/Turn off of the PAs via the PA gate bias voltage.
• Metering, status and fault monitoring of the PAs and the isolation resistors associ-
ated with them.
• Control of the combiner isolation switches (located on the isolation boards)
which are associated with the PAs under its control.
• Crossover protection (the ability to mute the PAs which are controlled by the
other PA Controller Board in case of a failure).
4.7.4.1 PA Turn On/Turn Off
The PA Controllers primary responsibility is to turn the PAs on and off. The PAs are
turned on and off by varying the bias voltage on the gates of the MOSFETs on the
PAs. If the gate voltage is -0.6V, the PA is turned on full. If the gate voltage is -18V,
then the PA is turned off. This means the PA Controllers have the ability to turn off
or MUTE each PA individually, or all at the same time if it is necessary to MUTE
the entire transmitter RF output.
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4.7.4.2 Metering
The PA Controllers are responsible for metering of the following parameters:
NOTE:
The temperature of the different PA ISO resistors (A1-A8 and B1-B8) can
vary quite a bit, but are considered okay if they are under Ambient + 75°C.
Az and Bz, which also show up in these screens, are the temperature indications for
the 2.5kW, 2 way combiner isolation load resistors. A rise in this temperature would
indicate an imbalance between the outputs of the two foursomes on that Z Plane.
ISO_AB_LOAD is the temperature of the reject load on the 3dB hybrid which
combines the outputs of the Z Planes.
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NOTE:
The Power Supplies, PS1 and PS2, each power the PAs associated with the
same number PA Controller. This means that the loss of one power supply
will create the same scenario as loss of one PA Controller (the loss of 2 PA
per foursome).
• Control of the tap switching which is used to coarsely regulate the power supply
voltage to 52Vdc.
• Control of the Soft-Start and PA Power Supply Discharge functions.
• All power supply monitoring and fault detection. These include voltage, current,
temperature and status.
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The PS Controller will now check the power supply voltages via the DC Voltage
Samples from each power supply. These come into the board at J1 and J2, pins 13
and 14 from the rectifier boards. These signals pass through U7 which acts as a
linear amplifier and buffer to prevent the analog samples from overloading the front
end of the A/D converter in the micro controller IC, U6. Using these samples the PS
Controller will determine when and if it is necessary to change taps to increase or
decrease the DC PA voltage. It will try to maintain the voltage as close as possible
to 52Vdc.
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A sample of the voltage across the discharge resistor from each supply is sent to the
PS Controller at J1-20 and J2-20. If the voltage is more than 30Vdc, the comparator
will trip, and the output at U1-1 or U1-2 will go LOW. The fault signal
1_DISCH_SAMPLE or 2_DISCH_SAMPLE is then sent to U9-2 or U10-2 where it
is buffered before reaching the micro-controller. The PS Controller would then shut
down the power supply. The detection circuit contains a lot of hysterisis to prevent
false triggering.
4.7.5.5 RESET
There is a RESET line from the Life Support Board which is monitoring the
+20Vdc from the regulators on the Rectifier Boards. This is basically monitoring
the Low Voltage Power Supply. If the voltage falls below a set threshold, U37 on the
Life Support Board generates the RESET (active low) which is sent to all of the
controller boards (Master, PAC and PSC). On the PS Controller this RESET clears
U2 and U3, which brings their outputs low. This deactivates all of the DRIVER
signals, disconnecting all of the SCR taps and shutting off the supply. This also
activates the DISCHARGE(BAR) signal which then bleeds off the supply.
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• SAMPLE 1 and SAMPLE 2 are the voltage samples from the Rectifier Boards.
Primarily they are used to control the power supply tap switching. However they
are also digitally filtered by the micro by two filters. The first is a 50 to 60 HZ
band pass filter whose output is used to detect a loss of a rectifier fuse on the
transformer secondary, a non-critical fault. The second is a 100 to 120 Hz band
pass filter which is used to detect a severe primary phase imbalance or loss of
phase. Loss of phase is a critical fault which will shut the power supply off
momentarily (see “Power Supply Controller Faults” in Section 6 of this manual).
• HEAT SINK THER(mistor) is the temperature sensor located on the rectifier
heatsink. If the heat sink temperature exceeds 100°C it will shut the power supply
off.
NOTE:
There are test points located after U7 which give a place to check the analog
voltages actually going into the A/D converter.
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1. Normal Operational Mode. The Life Support Board basically acts as an interface
between the Master Controller and various parts in the transmitter when the Master
Controller is functioning properly.
2. Life Support Mode. This mode provides a minimal backup control system should
the Master Controller fail. If the Master Controller board fails, the Life Support
Board disconnects (via AND gates) all signals from the Master Controller and
allows the transmitter to stay on the air at 1/4 power with minimal fault protection
and no visible monitoring for the operator.
a. VSWR Protection
b. System Mute
c. Transmitter ON (LOW only) and OFF (both LOCAL and REMOTE inputs
are active)
d. Failsafe Interlock
e. External Interlock
4.7.6.1 Normal Operational Mode
The following contains all pertinent circuit operation when the Master Controller is
functioning properly.
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NOTE:
Pressing an ON command will not erase any faults from the Diagnostics Fault
Log. Basically, any components which were shut off due to a fault will now
be turned back on, such as PAs or controllers.
The External Interlock line going to U33-1 ties the external interlock into the OFF
command circuit. When the External Interlock is closed, this line is low and U33-1
ignores the input. If the External Interlock were opened, the line would go high
which would send a high to the RESET input on relay K4 and the main AC
contactor would disengage.
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4.7.6.1.2.2 Failsafe
The Failsafe input can be used for any purpose which requires muting of the
transmitter output, such as failure of the remote control, or external RF switching
systems. Customer connection to the Failsafe circuit can be done in one of three
places:
a. At the TB1 remote control terminal strip in the rear of the transmitter (see
Section II, Installation). As shipped from the factory, there is a jumper from
TB1-8 to TB1-10(ground).
b. It can also be connected directly to the Life Support Board to J4-7 and J4-8.
Be very careful when connecting to these terminals. The pressure necessary
to operate the Wago connector on the rear of the board must be properly sup-
ported to keep from bending and possibly damaging the Life Support Board.
c. Lastly, it can be connected at J20-8, a 37 pin D connector, located on the Dis-
play/Backplane Board directly behind the controller front panel. This con-
nects to the Life Support Board at J1-A6.
In any of the three cases, Failsafe is an active low signal which must be pulled low
before the transmitter will output any power. To use the failsafe, the factory jumper
must be removed.
When the failsafe circuit is satisfied, it will cause U23-8 and U25-4 to go low and
U25-6 will stay low, having no effect on transmitter operation. If the Failsafe
connection is opened, U23-8 and U25-4 will go high, but the signal is gated by U25-
5, which is the FAILSAFE_ENABLE signal from the Master Controller This line is
not used and is always high, allowing a Failsafe open condition to pass the high to
U29-10 which ties into the SYSTEM_MUTE circuit. In the Life Support Mode the
signal MASTER_NORMAL(BAR) will be high at U31-2 and will enable U25-5
and the Failsafe signal.
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Overall System Theory
a. At the TB1 remote control terminal strip in the rear of the transmitter (see
Section II, Installation). A jumper is installed at the factory to make the Exter-
nal Interlock connection. It is installed between TB1-7 and TB1-6(GND).
b. Life Support Board at J4-10 and J4-7 (ground). If connection is made here,
leave connection open at TB1-7.
External Interlock is an active low signal which must be pulled low before the
transmitter may be turned on. To use the External Interlock, the factory jumper from
TB1-7 to TB1-6(GND) must be removed. External Interlock circuit operation was
discussed earlier in the Transmitter Turn On discussion.
4.7.6.1.4 SYSTEM_MUTE
The SYSTEM_MUTE line is used to mute the RF output from the exciter and IPA.
It is the summation of mute signals from several sources which are discussed below.
The SYSTEM_MUTE is an active high signal at U30-6 and passes through to U38-
3. The signal then splits and goes to relay K1-13 as the exciter mute and to inverter
U13-7 as an IPA mute.
a. The low from K1-4 goes off the board to the IPA Backplane Board where it
actuates the exciter select relay K1 to the position shown on the schematic. It
also goes to the Master Controller as a status signal, so it knows which exciter
is physically selected.
b. The signal from K1-4 is also used to mute the off air exciter when in the Life
Support Mode, via U35-3 and U35-6, which tie into the exciter mute lines.
Exciter 2 is selected when EXCITER2_SELECT goes high which will SET K1. K1-
4 will go high and this will switch K1 on the IPA Backplane board to the exciter 2
position.
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Overall System Theory
a. The low from K2-4 goes off the board to the IPA Backplane Board where it
actuates the IPA select relays, K2 and K3 to the position shown on the sche-
matic.
b. It also goes to the Master Controller as a status signal, so it knows which IPA
is selected.
IPA AB2 is selected when IPA_SELECT_AB2 goes high which will SET K2. K2-4
will go high and this will switch K2 and K3 on the IPA Backplane board to the
IPA_AB2 position. K2 is also responsible for switching the IPA gate control voltage
(transmitter power control signal) to the active IPA.
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Overall System Theory
The IPA Voltage sample is taken from the voltage divider made up of R45 and R48.
This is sent to the Master Controller for monitoring and protection.
4.7.6.1.9.1 CPLR_DISC_FAULT
This is an interlock fault which will mute the transmitter if the cable to the forward
directional coupler is disconnected. The fault line is pulled up through R1 to +5V. If
the coupler is connected, the line is pulled low and no fault occurs. When
disconnected, the line will pull high and the Master Controller will mute the
transmitter.
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Overall System Theory
interrupted (which means the Master Controller has failed), U4 will time-out and go
to the RESET mode. The Q output will go low and Q_NOT will go high. The low
signal from the Q output is inverted at U16-13, and pulls the
MASTER_NORMAL(BAR) signal high (this signal is normally low when the
Master Controller is working). The high Q_NOT signal at U4-7 is inverted at U16-
14 and U16-15. U16-14 pulls the MSTR_NORMAL 1 signal low while U16-15
pulls the MASTER_NORMAL signal low (these signals are normally high when
the Master Controller is working).
4.7.6.2.1.1 MASTER_NORMAL
This signal goes low when the Master Controller fails and only has one function. It
is the control signal for U5-13, an analog switch. The input to the switch at U5-1 is
the analog control signal, MSTR_IPA_CTL from the Master Controller APC
circuit, which controls the IPA gate voltage and therefore the power output of the
transmitter. When the Master Controller is working, the analog IPA control signal
passes through to U5-2. Provided there is no SOFTSTART_MUTE or
SYSTEM_MUTE, the IPA control signal will also pass through to U5-3 and on to
U15-3. U15 buffers the signal and sends it to IPA select relay K2. K2 directs the IPA
control signal to the active IPA.
When the Master Controller fails, MASTER_NORMAL will go low, opening the
U5-13 switch. The MANUAL PWR REF pot R25 now controls the transmitter
power output. This is factory set for 1/4 of the rated transmitter power output.
4.7.6.2.1.2 MSTR_NORMAL 1
This signal goes low when the Master Controller fails. Its primary responsibility is
to disconnect all of the control lines coming from the Master Controller via AND
gates. It causes the following actions to occur:
a. MSTR_NORMAL 1 applies a low to AND gate U6-4, fan speed select gate.
When in Life Support Mode the fan will be forced to high speed operation
due to the possible higher than normal dissipations when running at reduced
power. The output of AND gate U6-6 passes through to U16-16 and on to the
Low Voltage Power Supply Board and the fan select relay, K3.
b. MSTR_NORMAL 1 applies a low to AND gate U6-10. This interrupts the
SUPPLY_DISABLE command from the Master Controller to the PS Control-
ler by holding U6-8 low. The SUPPLY_DISABLE is an active high com-
mand, which is used to place the PA Power Supplies in standby mode
(standby mode is when the tap SCRs are all shut off but the discharge circuit
is not activated).
c. MSTR_NORMAL 1 applies a low to AND gate U25-13. This inhibits the
Master Controller from giving the transmitter OFF command. The OFF com-
mand can still be given directly via the front panel overlay button or by
remote control, REM_OFF(BAR). The remote inputs REM_ON_LOW,
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Overall System Theory
4.7.6.2.1.3 MASTER_NORMAL(BAR)
This signal goes high when the Master Controller fails. It causes the following
actions to occur:
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Overall System Theory
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Overall System Theory
If the Master is not functioning (Life Support Mode), then the RFL PWR Overload
Adjust, R24 and comparator U3-2, will protect the transmitter from excessive
VSWR by shutting it off. R24 sets the reference voltage for U3-5, which is the
VSWR comparator for Life Support Mode. If the VSWR exceeds 150 watts
reflected in this mode the comparator will trip and U3-2 will go low. This is inverted
at U7-6 and becomes, LS_SYST_FAULT, which stands for Life Support System
Fault. This signal is sent to AND gate U6-1. U6-2 is connected to the
MASTER_NORMAL line. This line will be high only if the Master Controller has
failed, which is the case here for Life Support Mode. Therefore the
LS_SYST_FAULT will cause U6-3 to go high. Next, OR gates U33-3 and U33-6
will also go high, making U16-10 output high. This is connected to the RESET side
of latching relay, K4. When K4 resets, K4-14 will go low, which will send a low to
the Low Voltage Power Supply Board, via U16-12. The main AC contactor will
disengage and the transmitter will be shut off.
It is important to note that if the Master controller is working, then U6-3 would not
go high and therefore the LS_SYST_FAULT is not active. This is due to the fact
that the Master Controller has the primary responsibility for VSWR protection. This
circuit only has function when the Master Controller has failed and the transmitter is
running in the Life Support Mode.
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Overall System Theory
PA Designations on PA
Controller Schematics
PA Designations on Related Related
PAC PAC PAC PAC Combiner and Isolation Isolation
PA Designations #1 #2 #3 #4 Divider Schematics Relay # Resistor #
A1 PA6 PA8 (J8) K8 RT8
A2 PA5 PA7 (J7) K7 RT7
A3 PA8 PA6 (J6) K6 RT6
A4 PA7 PA5 (J5) K5 RT5
Z-PLANE A
A5 PA3 PA1 (J1) K1 RT1
A6 PA4 PA2 (J2) K2 RT2
A7 PA1 PA3 (J3) K3 RT3
A8 PA2 PA4 (J4) K4 RT4
B1 PA5 PA5 (J5) K5 RT5
B2 PA6 PA6 (J6) K6 RT6
B3 PA7 PA7 (J7) K7 RT7
B4 PA8 PA8 (J8) K8 RT8
Z-PLANE B
B5 PA4 PA4 (J4) K4 RT4
B6 PA3 PA3 (J3) K3 RT3
B7 PA2 PA2 (J2) K2 RT2
B8 PA1 PA1 (J1) K1 RT1
This chart is meant as an aid in tracking control, status and metering signals
between the PA Controllers and the individual PAs. The first column groups the PAs
by Z-Plane. The second column gives the actual PA designation or location as
silkscreened on the inside of the PA doors. As for columns 3 through 6, each PA
Controller is identical and has the ability to control 8 PAs, PA1-PA8. However, an
output labeled PA1 on the PA Controller schematic does not necessarily go to
amplifier A1 or B1. For example, On Z-Plane A, amplifier A4 is connected to any
input or output of PAC #2 that is labeled PA7, such as PA7_GATE. Note that on Z-
Plane B, amplifier B4 is connected to any input or output labeled PA8 on PAC #1.
This cross numbering is due to the fact that Z-Plane B is inverted compared to Z-
Plane A. The seventh column is actually the intermediate step between the PAs and
the PA Controllers and gives the designation and connector number for each of the
PAs. The last 2 columns give the component designator for the Isolation Switch and
Isolation Resistor for each of the PAs. The Isolation switches and resistors are
located on the Isolation boards mounted on the sides of the Z-Planes.
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Maintenance and
Alignment
5.1 Introduction
This section provides maintenance and alignment information, for the purpose of
routine maintenance and replacement of PC boards and other major components of
the Platinum Z5 FM BROADCAST TRANSMITTER.
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Maintenance and Alignment
DISCREPANCY
List all parts and components replaced or repaired. Include the following details:
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Maintenance and Alignment
5.2.3 Cleaning
Proper airflow is essential in keeping the transmitter in top working condition. If
outside air is brought into the building it should be well filtered to keep dirt out of
the building and the transmitter.
! WARNING:
THE PA MODULES ARE DESIGNED TO HANDLE VERY HIGH TEMPERATURES
AND MAY BE EXTREMELY HOT. DO NOT TOUCH THE MODULES WITH BARE
HANDS AFTER THE TRANSMITTER HAS BEEN RUNNING, ESPECIALLY IN HIGH
AMBIENT TEMPERATURE ENVIRONMENTS.
To locate the PA Temperature Monitoring press [METERING, C,A, then select the
desired Z-Plane]. Keeping a regular log of the PA temperatures versus Ambient
temperature will give a quick indication of a possible problem or that cleaning is
necessary. To check the ambient temperature reading press [METERING, C,D,B].
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Maintenance and Alignment
NOTE:
For further details, see “Self Diagnostics” portion of Section 6 in this manual.
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Maintenance and Alignment
! CAUTION:
THERE ARE 10 SMALL PINS WHICH CONNECT THE ISOLATION
RESISTORS TO THE Z-PLANE. THESE ARE EASILY BENT IF THE
ASSEMBLY IS NOT PULLED STRAIGHT OUT. IF BENT, THEY WILL HAVE
TO BE STRAIGHTENED BEFORE IT WILL BE ABLE TO BE RE-INSTALLED.
IF BENT TOO FAR, THE PINS MAY BREAK OFF WHEN STRAIGHTENED.
d. The Isolation assemblies for Z-Plane A must be taken out the front of the
transmitter. The Isolation assemblies for Z-Plane B can be taken out the front
or rear of the transmitter.
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Maintenance and Alignment
NOTE:
Each Isolation Board is programmed for a specific Z-Plane. Therefore, if
more than one Isolation assembly is removed at one time, mark each one as to
its proper location. The programming is a simple jumper selection on the PC
board. The jumper chart is printed on the PC Board next to the jumpers and
can also be found on the Isolation Board schematic if verification is required.
5.5.1.2 Inspection
All of the isolation resistors have a thermistor attached to them with a special epoxy.
Verify that all of the thermistors are firmly attached and that the epoxy has not
cracked as this will give incorrect temperature readings.
! CAUTION:
BE VERY CAREFUL WHEN DESOLDERING ANY OF THE RESISTORS AS
A LARGE AMOUNT OF HEAT IS REQUIRED. DO NOT PULL VERY HARD
OR THE FEED THROUGH HOLES ON THE PC BOARD COULD BE
DAMAGED.
The resistors should be ordered as an assembly, with the thermistor already attached
as this is very critical to proper transmitter operation.
The Isolation assembly should slide back into place fairly easily as long as none of
the pins are bent. Re-install the 4 hex standoffs and the 2 ribbon cables, making sure
that the cables are connected to the same port from which they were removed. Be
careful not to over-tighten the hex standoffs.
5.6 PA Replacement
Since field repair of the Power Amplifiers is not a recommended procedure, the
only option is to replace it (especially during the warranty period). A replacement
PA will include the 1/4 inch thick copper plate under the PC board. Do not remove
the PC Board from the copper plate. When installing the new PA, be sure to apply a
thin but even coating of thermal compound before re-assembly to the heatsink.
Tolerance on the screw holes will assure alignment into the Z-Plane connector.
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WARNING: Disconnect primary power prior to servicing.
Maintenance and Alignment
a. Proper position - the couplers should go back into the same hole from which
they came.
b. Orientation - mark the couplers with an arrow pointing up to be sure and
replace them correctly. Reversing a forward coupler makes it read reflected
and vise-versa.
c. Cable Number - write on the coupler, the number of the BNC cable which
attaches to it.
NOTE:
The directional couplers are held in place on the harmonic filter with 2 hose
clamps. Be sure to place the clamps as far toward the edge of the coupler
body as possible and do not over-tighten.
NOTE:
If both couplers are being replaced at the same time, Reflected Power should
be calibrated first, then the Forward Power. An external meter is required to
calibrate Reflected Power in this case.
(tolerance is +/- 0.1dB with directivity greater than 30dB. This is not guaranteed
since any minor variations can be factored out by using the calibration procedures).
For frequencies between 88 and 108MHz the actual coupling ratio can be
extrapolated linearly. For example: At 98 MHz the typical Forward Coupling ratio
is 47.9dB.
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Maintenance and Alignment
STEP 1 Turn the transmitter on at HIGH power and set the power output to a
power level which is less than the desired maximum power using the
Raise and Lower buttons.
STEP 2 To enter a new MAX HIGH setting go to the MAX HIGH SET
screen, [HOME, MORE, CONFIGURATION B,B] change to the
new maximum power level and press [BACK] to save the changes.
STEP 3 Press Raise to make sure the power level will not go above the new
MAX HIGH setting. The MAX HIGH setting in Step 2 can be
adjusted slightly to get the exact desired power level.
The MAX LOW Power limit is set as follows:
STEP 1 Turn the transmitter on at LOW power and set the power output to a
power level which is less than the desired maximum power using the
Raise and Lower buttons.
STEP 2 To enter a new MAX LOW setting go to the MAX LOW SET screen,
[HOME, MORE, CONFIGURATION B,C] change to the new
maximum LOW power level and press [BACK] to save the changes.
STEP 3 Press Raise to make sure the power level will not go above the new
MAX LOW setting. The MAX LOW setting in Step 2 can be
adjusted slightly to get the exact desired power level.
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WARNING: Disconnect primary power prior to servicing.
Maintenance and Alignment
STEP 1 Set the power to the desired TPO using the raise and lower buttons.
STEP 2 Go to the 100% TPO SET screen [HOME, MORE,
CONFIGURATION B,A]. Set the power level to your new TPO.
Press [BACK] to update and store the new information.
The front panel FWD PWR reading should be 100%. You may also want to change
the MAX HIGH and MAX LOW power settings to something more in line with
your new TPO as well. MAX HIGH sets the maximum power level when the HIGH
ON button is pressed, while MAX LOW sets the maximum power level when the
LOW ON button is pressed.
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Maintenance and Alignment
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WARNING: Disconnect primary power prior to servicing.
Maintenance and Alignment
STEP 9 Re-Adjust R127 on the Life Support Board until the external meter
reads 5kW or the TPO at which you are calibrating. The adjustment
will be sensitive, so be careful not to go too fast.
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Maintenance and Alignment
STEP 10 Set the power level in the FWD POWER CAL screen
[HOME,MORE,CONFIGURATION C,C] (see Figure 5-6) to
05.00kW or the TPO at which you are calibrating.
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Maintenance and Alignment
STEP 1 Shut the transmitter off. Turn R128 on the Life Support Board
maximum CCW. This reduces the VSWR sensitivity to minimum.
STEP 2 On the Diagnostics Display, check the VSWR fault and foldback
settings. Press [HOME, MORE, CONFIGURATION B,D,C,C]. This
is the screen used to set the VSWR Fault level. It should read 1.50. If
so, press [BACK]. If not, use the ABCD keys to set it to 1.50. Once
it is set press [BACK] and the screen information will be saved.
STEP 3 Press [D], to go to the VSWR Foldback screen. Set the VSWR
FOLDBACK to 1.49. Press [BACK] to save the settings.
STEP 4 Press [HOME, MORE, CONFIGURATION C,A,B]. Set the value of
“REFLECT FACTOR” to 0.000306, see Figure 5-7. To access the
edit controls for the screen press and hold the [D] and then press the
[C] button. Press [BACK] to save changes.
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Maintenance and Alignment
STEP 6 Press the HIGH ON button and then quickly press and hold the
LOWER button for 10 seconds. This will turn the transmitter on at
zero power output.
STEP 7 Raise the transmitter power very slowly until the Forward Power
meter reading is 150 watts (or 00.15 kW). If Forward Power is not
yet calibrated, then an external meter will have to be used.
STEP 8 Press [HOME, MORE, CONFIGURATION C,B]. You should now
be at the screen shown in Figure 5-8, A/D RFL PWR. Re-adjust
R128 until the A/D RFL PWR reading is 700. Go slowly, the
adjustment is sensitive.
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WARNING: Disconnect primary power prior to servicing.
Maintenance and Alignment
STEP 11 Shut the transmitter off and return the Reflected Power Directional
Coupler back to its normal position.
STEP 12 Press [HOME, MORE, CONFIGURATION B,D,C,D]. This takes
you to the Foldback Set screen. Set the VSWR FOLDBACK to 1.35
and press [BACK] to save the setting.
STEP 13 Turn the transmitter back on and press the RAISE button on the front
panel until you have 100% or nominal station TPO.
STEP 14 It is recommended that the following Cal Value be noted for future
reference since it may have changed from the reading in the factory
test data:
• REFLECT FACTOR from Figure 5-7 on page 5-14.
Reflected power calibration is now complete.
! WARNING:
BE SURE TO USE AN ANTI-STATIC WRIST STRAP WHEN HANDLING PC
BOARDS OR IC’S TO PREVENT DAMAGE TO THE COMPONENTS.
STEP 1 Turn off the transmitter and remove all power at the wall breaker.
STEP 2 Remove the two screws holding the controller assembly in place and
slide it out. It will come almost all of the way out before catching
and will then drop down in the front to about a 30 degree angle.
Then remove bracket across the boards.
STEP 3 Set all jumpers on the new Life Support Board to the same locations as
the board to be replaced. There are only 3 jumpers on the Life Support
Board. JP1 and JP2 select the main and alternate exciter mute as
active HIGH or LOW. Table 2-2 on page 2-30 shows the proper
settings for a Harris exciter. JP3 should be set from pins 1-2 for a Z5.
STEP 4 Be careful to mark and note where all cables connect to the defective
Life Support Board before removing. External Interlock and Failsafe
could also be connected to this board at J4.
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Maintenance and Alignment
STEP 5 Install the new Life Support Board, and reconnect all wires and
cables. Be very careful not to bend the PC board when installing any
wires into the Wago block on the rear of the card. The card should be
supported from the back side due to the pressure required to open the
Terminals.
STEP 6 Turn on the AC at the wall breaker but do not turn the transmitter on
yet. Make sure CB1, the circuit breaker in the rear of the transmitter
is also turned on.
STEP 7 Setting the +5V REF - with a digital voltmeter, check TP4, the +5V
REF(reference). The voltage should be 5.00V, +/- 0.01V. If not,
adjust R28 to make it so.
STEP 8 IPA Current Fault Adjustment - this adjustment only affects
operation in Life Support Mode. Adjust R23 on the Life Support
Board for 2.9Vdc at U3-7. This is sets the fault threshold to 10.0
amps of IPA current.
STEP 9 RFL PWR Overload Adjust - this adjustment only affects operation
in Life Support Mode. Adjust R24 on the Life Support Board for
2.1Vdc at U3-5. This sets the fault threshold to 150 Watts of
reflected power when Life Support Mode is active.
STEP 10 Set R127 Maximum CW. This sets power output at a minimum.
STEP 11 Set R128 Maximum CCW. This reduces the sensitivity of the VSWR
circuit.
STEP 12 Set R25 Maximum CCW.
! WARNING:
TURNING R128 MAXIMUM CCW DEFEATS THE VSWR PROTECTION. THE
REFLECTED POWER CALIBRATION SHOULD THEREFORE BE DONE FIRST TO
PREVENT DAMAGE TO THE TRANSMITTER (TRANSMITTER POWER IS ONLY
RAISED TO 150 WATTS FOR THE REFLECTED POWER CALIBRATION).
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Maintenance and Alignment
NOTE:
The switches set the board ID #. Once the ID for the board has been set, it
must be placed in the proper slot and the correct cables connected to that #
controller. An improper ID or incorrect cabling will generate cable or jumper
faults in the Fault Log and the transmitter will not turn on.
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Maintenance and Alignment
STEP 1 Shut the transmitter off and remove AC power from the transmitter.
STEP 2 Remove the defective Master Controller Board.
STEP 3 Carefully remove U39 from the new Master Controller Board and
replace with the EEPROM from the defective Master.
STEP 4 To transfer the Firmware IC’s from the old board to the new one or to
simply install new firmware refer to "5.15 Removing/Replacing
Firmware ICs" on page 5-24, then return here.
STEP 5 Set all dip switches on the new board according to the list below.
Typical settings are:
• S1-1 thru S1-4 - Customer set RS232 ID
• S1-5 ON for U39 model 25040 and Firmware part # 917-2435-203,
revision “AA” or later Master Controller code (S1-5 set to OFF
for use with U39 model 25C04 and any part number firmware).
• S1-6 thru S1-8 OFF (Factory use only)
• S1-9 OFF (ON = Microcontroller RESET)
• S1-10 ON (APC ON)
STEP 6 Install the new Master Controller Board and apply AC power to the
transmitter. It is a good idea to verify the transmitter configuration
settings in the Diagnostics Display.
NOTE:
To verify the most important configuration parameters, follow the steps listed
under "5.14.1 Configuration" on page 5-22, before continuing.
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WARNING: Disconnect primary power prior to servicing.
Maintenance and Alignment
STEP 7 Turn the transmitter on and check the calibration. If the transmitter
calibration and configuration seem to be okay, then this procedure is
finished. If it is still not working, U39 will have to be replaced using
the following procedure “Replacing EEPROM U39”.
! WARNING:
BE SURE TO USE AN ANTI-STATIC WRIST STRAP WHEN HANDLING PC
BOARDS OR IC’S TO PREVENT DAMAGE TO THE COMPONENTS.
STEP 1 Shut the transmitter off and remove AC power from the transmitter.
STEP 2 Remove the Master Controller Board. If only the EEPROM U39 is
being replaced then exchange U39 with the new one, re-install the
Master Controller Board and skip to STEP 6. If the Master
Controller Board is also being replaced then proceed with STEP 3.
STEP 3 Install the new U39 in the new Master Controller Board.
STEP 4 To transfer the Firmware ICs from the old board to the new one or to
simply install new firmware refer to "5.15 Removing/Replacing
Firmware ICs" on page 5-24, then return here.
STEP 5 Set all dip switches on the new board according to the list below and
install the Master Controller Board. Typical settings are:
• S1-1 thru S1-4 - Customer set RS232 ID
• S1-5 ON for U39 model 25040 and Firmware part # 917-2435-203,
revision “AA” or later Master Controller code (S1-5 set to OFF
for use with U39 model 25C04 and any part number firmware).
• S1-6 thru S1-8 OFF (Factory use only)
• S1-9 OFF (ON = Microcontroller RESET)
• S1-10 ON (APC ON)
STEP 6 Turn on the Low Voltage breaker in the rear of the transmitter. If the
EEPROM is blank, the Fault Log will register EEPROM_DEF
which means it loaded the default settings for the EEPROM (shown
in Table 5-1). Reset the fault Log.
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Maintenance and Alignment
STEP 7 All of the parameters in Table 5-1 are editable from the Diagnostics
Display and should be set to the values listed on the Factory test
Data sheet not necessarily the default values listed. If the Factory
Test Data is not available or you are not sure that the values in the
Factory Test Data are still valid then verify, and where necessary,
change the values to those listed in Table 5-1. (To edit any of these
screens, press and hold [D] and then press [C]. The edit controls
should appear on the screen).
STEP 8 Press the HIGH ON button and then quickly press and hold the
LOWER button for 10 seconds. This will turn the transmitter on at
zero power output.
STEP 9 Proceed to "5.14 System Configuration and Calibration" on page 5-
22.
Platinum Z5
Parameter Default Settings
Forward Factor 0.007697 (see Figure 5-3)
Reflect Factor 0.000306 (see Figure 5-7)
IPA Factor 200
Exciter Factor 200
CAL Frequency Set to your frequency
(Default = 98MHz)
Operating Frequency Set to your frequency
(Default = 98MHz)
Cal APC Factor 07.58 (see Figure 5-4)
100% TPO Set 5.00kW
Max High Set 6.00kW
Max Low Set 2.50kW
UPS Setting 2.50kW
Low Power Alarm 4.50kW
VSWR Foldback 1.35
VSWR Fault 1.50
NOTE: Set to Factory Test Data numbers if available
888-2408-002 5-21
WARNING: Disconnect primary power prior to servicing.
Maintenance and Alignment
a. Configuration
b. Calibration
5.14.1 Configuration
The transmitter should be turned off, but with AC power applied from the wall
breaker. The REMOTE DISABLED LED should be lit on the front panel of the
transmitter. For the following setup refer to the Diagnostics Display Menu Tree for
more details of how to get to System Calibration and Setup screens referred to
below.
NOTE:
For the following procedures do not press [HOME] or [BACK] unless specif-
ically told to do so.
5-22 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Maintenance and Alignment
888-2408-002 5-23
WARNING: Disconnect primary power prior to servicing.
Maintenance and Alignment
5.14.2 Calibration
To finish replacing the Master Controller EEPROM U39 a complete calibration is
required. To calibrate the transmitter refer to the following procedures in this order:
! WARNING:
REFLECTED POWER CALIBRATION SHOULD BE COMPLETED FIRST TO PRO-
VIDE VSWR PROTECTION DURING THE FORWARD POWER CALIBRATION
PROCEDURE. THIS REQUIRES THE USE OF AN EXTERNAL WATT METER
CAPABLE OF READING 150 WATTS.
! WARNING:
BE SURE TO USE AN ANTI-STATIC WRIST STRAP WHEN HANDLING PC
BOARDS OR IC’S TO PREVENT DAMAGE TO THE COMPONENTS.
5-24 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Maintenance and Alignment
Firmware IC removal:
• Shut off the Low Voltage breaker in the back of the transmitter.
• Pull out the controller and remove the pc board hold-down bracket.
• It will be necessary to remove the appropriate PC board and place it on an anti-
static work surface (a large anti-static bag works well if an anti-static mat is not
available). PA and PS controllers have cables attached at the rear of the card
which need to be noted and then removed.
• Note that the PA Controllers 1 and 2 have an ID setting which means they must
be placed back in the same slot from which they were removed.
• Before removal, notice that the IC has one corner which is beveled and the IC
socket has a pointer etched in the top which is pointing to the beveled corner. See
Figure 5-10.
• The manufacturers do make a special extraction tool for these type of IC’s but it
has been found that a sharp meter lead or ice pick actually works better for
extracting them. Place the sharp tool point into one of the slots at the corners of
the IC pry it up just a little. Then move to the opposite corner and pry it up a little.
Work back and forth from one corner to the other until the IC comes out.
• If the IC is going to be re-installed and you need to set it down, make sure it is
placed on an anti-static mat or in an anti-static bag.
Firmware IC Installation:
• To install the firmware IC’s, you first need to match the U## component designa-
tor printed on the IC label with the proper socket on the board (the socket has a
label printed on the board). For example U18 and U28 are for the Master Control-
ler and must be placed in the correct socket.
• To install the IC, simply place the chip over the socket with the beveled edge ori-
ented correctly and press it in with your thumb. Be sure to press evenly across the
top of the IC.
5-26 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
6.1 Introduction
In order to assist in the troubleshooting of the Platinum Z5 transmitter this section
will concentrate in the following areas:
There are only 6 analog adjustments in the transmitter and control system, with
most of them being factory, one-time, adjustments. This all but eliminates mis-
adjustment as a cause of failure. The controller itself is also modular, using at least 5
separate boards, with its own self diagnostics for communications between the
microprocessors and read/write tests for the on board memory. There is also the
redundancy factor provided by the Life Support Board, which will operate the
transmitter at a reduced power level if the Master Controller fails.
888-2408-002 6-1
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
! WARNING:
PRODUCT AND ENVIRONMENTAL SAFETY-TOXIC MATERIALS THIS PRODUCT
CONTAINS BERYLLIUM OXIDE. THE PRODUCT IS ENTIRELY SAFE PROVIDED
THAT THE BEO DISC IS NOT DAMAGED. ALL PERSONS WHO HANDLE, USE OR
DISPOSE OF THIS PRODUCT SHOULD BE AWARE OF ITS NATURE AND OF
THE NECESSARY SAFETY PRECAUTIONS. AFTER USE, DISPOSE OF AS
CHEMICAL OR SPECIAL WASTE ACCORDING TO THE REGULATIONS APPLY-
ING AT THE LOCATION OF THE USER. IT MUST NEVER BE THROWN OUT WITH
THE GENERAL OR DOMESTIC WASTE.
NOTE:
These are typical power levels operating into a dummy load with minimal
VSWR and low ambient temperature. These power levels are not guaranteed
and are given merely as an approximate guideline to aid in troubleshooting.
6-2 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
Platinum Z5
Best Case Power Out Worst Case Power Out
1 PA Failed 100% 100%
2 PA Failed 100% 75%
1 Module Removed 95% 95%
2 Modules Removed 75% 40%
*1 Power Supply Failed 20% 20%
*1 PA Controller Failed 20% 20%
*Loss of a PA Controller or Power Supply represents an equivalent loss of 8
of the 16 PAs.
888-2408-002 6-3
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
6-4 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
NOTE:
If no faults occur during either of the 10 second time periods, then the strike
counter is reset and will allow 3 more strikes before muting the transmitter.
The slow ramp up in power after a strike should allow the foldback controls to limit
the transmitter power output before the fault thresholds are reached again.The slow
power ramps are designed to allow the transmitter to operate at the maximum
possible power level without over-dissipating the isolation resistors or exposing the
transmitter to excessive reflected power. This would mean that there would be a
fault in the log but it would be inactive and the transmitter would be in a foldback
condition.
888-2408-002 6-5
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
• Page 1 is Status
• Page 2 is Metering and Faults
• Page 3 is Configuration, Test and Software Revision.
It greatly simplifies the display by letting you see the entire tree with all of the
screens, guiding you to the screen you want. The only thing missing is the 6 control
buttons, HOME and BACK on the left side of the display and ABCD to the right. To
avoid confusion, every line from one screen to the next is labelled A, B, C or D
where it leaves a screen, to correspond with the keypress required on the actual
display. The function and use of the buttons is very straight forward. However, an
explanation is given in Section III, Operation, for these and all other front panel
transmitter controls.
6-6 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
• AMB - Ambient
• INTLK - Interlock
• RFL - Reflected
• FLT - Fault
• REF - Reference Voltage
• CPLR - Directional Coupler
• NC - Not Connected
• IPA_AB - IPA for Z-Planes A&B
• OT - Over-Temperature
• OC - Over-Current
• UC - Under-Current
888-2408-002 6-7
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
• Table 6-3 on page 6-35 includes faults that are associated with the Master Con-
troller Board (which includes the IPA).
• Table 6-4 on page 6-37 includes faults that are associated with the PA Controller
Boards, PAs and ISO Loads.
• Table 6-5 on page 6-39 includes faults that are associated with the PS Controller
Board and the power supply itself.
These tables are meant as a summary and quick reference point. The rest of this
section will be dedicated to giving detailed information on each of these faults.
6-8 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
• SYSTEM TEST
• CONTROL HARDWARE
888-2408-002 6-9
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
To run the SYSTEM test press [MORE TEST C]. This will bring up the screen in
Figure 6-5. Press [D] to run the test or [C] to go back to the previous menu.
NOTE:
Due to operational variables, it is possible to get false indications which place
a fault in the log and abort the test. If the System Test fails, note the fault in
the Fault Log, clear the fault log, and run the test again to verify the problem.
This test should be used as part of a routine maintenance program at least once a
year. It should also be done if major combiner components are removed and/or
replaced, such as a Z-Plane or Isolation Board or if cabling is disconnected and re-
connected to the Z-Planes or Isolation Boards.
• PA Muting Test
• PA ISO Resistor and Thermistor Test
• PA RF Switch Test
6.7.1.1 PA Muting Test
Each PA will be muted for 1 second, one at a time. The controller then checks the
current draw of each PA, which should be close to zero. If it finds a PA that is
drawing too much current while it is supposed to be muted it will abort the test and
report an A#_MUTE_FLT or B#_MUTE_FLT. For more information refer to PA
MUTE Faults later in this Section.
6-10 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
888-2408-002 6-11
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
a. LCD/LED Test - This is a test of all of the LCD segments and LEDs on the
front panel to make sure the overlay indicators are operational. Pressing [B]
will active the test. Press [B] again to shut off the test.
b. EEPROM TEST - This will test EEPROM U39 on the Master Controller (the
only socketed IC on the board). This is where all of the user data and the Fac-
tory Default Settings are stored. This test should only be done if there is a
problem recalling the Factory Default Settings in the Diagnostics Display or
if the Master Controller needs to be replaced. If it fails the test, U39 will have
to be replaced and a complete “System Configuration and Calibration” will
have to be done per the procedure in Section V.
c. Main DAC Test - This test should only be done as a last resort in a case where
the system control appears erratic. To run the test requires an oscilloscope. It
is a test of the main Digital-To-Analog-Converter on the Master Controller
Board. To run the test shut the transmitter off and press [MORE, TEST, D,D].
The display will read “Main DAC test is running.” With the scope probe,
monitor TB1-36 on the Remote Control Terminal strip which is labelled
“SPARE OUT” or on the Master Controller Board at U9-14 or either side of
R47. There should be a 28Hz sinewave at about 4Vp-p. If the sinewave is
present the DAC is working. If not, the Master will have to be replaced per
the procedures in Section V. Pressing BACK shuts off the test.
6-12 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
888-2408-002 6-13
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
This fault protects against a thermistor (temperature sensor) circuit being open. The
thermistors are used on all amplifiers, iso loads, and the power supplies to sense
temperatures and use pull up resistors to +V. As the temperature increases, the
resistance of the thermistor goes down, lowering the voltage on a detector input,
which gives an increased temperature reading. If the thermistor circuit becomes
open, the detector input goes high which gives a cold temperature reading. This
leaves the device to which the thermistor is connected, unprotected from an over-
temperature condition. Once this fault is detected it will stay active in the log until
the Fault Log is reset.
NOTE:
If one of the thermistors or connecting cables is shorted, a temperature fault
for the device it is connected to will be registered in the Fault Log, not a
THERMISTOR fault. A shorted thermistor or cable will give a very hot read-
ing which will not change, about 155° C or higher. If the thermistor for one of
the PA ISO resistors has shorted the fault “PA_ISO_OT” is triggered and the
transmitter will be shut off (see PA_ISO_OT under PA Controller Faults).
Troubleshooting:
6-14 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
4. System ISO Temp - ISO_AB. Located on the 3dB hybrid which com-
bines the Z-Planes. Is above the PA Modules under the rectangular
cover. The sense line (BNC coax) comes out the top of the box.
5. Power Supply Temps - PS1 and PS2. These sensors are part of a screw
connector bolted to the top of the power supply heatsink (it is covered
with heat-shrink tubing).
b. Once the problem thermistor is located, shut off the Low voltage supply with
CB1 in the rear of the transmitter. Use an ohmmeter to check the resistance of
the thermistor. It should be from 10K to 50K ohms depending on which ther-
mistor is being checked.
c. If the thermistor is not open, turn the low voltage back on and check to see if
there is voltage across the thermistor. No voltage to the thermistor means an
open between the controller and the thermistor. Trace the connection back to
the controller board. Also, note that in this case the RFI boards have a series
inductor which may have opened.
6.9.2 EEPROM_DEF, EEPROM U39 Default Load
This fault means that when the controller loaded the transmitter settings from the
EEPROM U39 on the Master Controller, one or more of the values was considered
to be invalid or out of tolerance and was replaced with a Default value from the
firmware prom. This fault is an indication that the EEPROM U39 should be
replaced. (Refer to Section V, Maintenance and Alignments, for the replacement
procedure). The only time this fault should occur is when a new EEPROM U39 is
being installed. In this case it is random data and all defaults will be loaded
automatically. However, after the first default load it should never happen again.
888-2408-002 6-15
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
If a PAC_REF fault appears along with the MSTR_REF fault, then the +5V
reference is most likely the problem. If only the MSTR_REF fault is present then
the Master Controller or a connection between the Life Support Board and the
Master Controller should be suspected. The +5V REF can also be checked at TP19
on the Master Controller Board. Note that CR11 will supply +5Vdc to TP19 if the
actual +5V REF has failed, but with the diode drop it will be less than 4.6Vdc and
adjusting R28 on the Life Support Board will have no effect.
6-16 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
! CAUTION:
TURN OFF ALL POWER TO THE TRANSMITTER AT THE WALL BREAKER
BEFORE ATTEMPTING TO SERVICE THE BLOWER MOTOR. THE
THERMAL PROTECTION, INTERNAL TO THE MOTOR, IS AUTOMATIC. IT
WILL SHUT THE BLOWER OFF IF THE MOTOR TEMPERATURE GETS
TOO HIGH, BUT IT WILL ALSO AUTOMATICALLY TURN IT BACK ON
AFTER A FEW MINUTES AS THE TEMPERATURE GOES DOWN.
888-2408-002 6-17
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
6-18 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
NOTE:
Amibient temperature is sensed with a thermistor on the IPA Backplane
Board.
888-2408-002 6-19
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
• ISO_Az and ISO_Bz - These 2 are the 2.5kW ISO loads located in the middle of
the Isolation Boards. Their component designation is R9 on the Isolation Board
schematic.
• ISO_AB - This one is the ISO (reject) load on the 5kW hybrid which is combin-
ing the outputs of the Z-Planes. It is physically located above the 5kW power
block. The component designation is A2A5R1 on the Overall Wiring Diagram.
All of these loads are monitored for temperature by the Master Controller and both
of the PA controllers simultaneously. The responsibility for system protection
belongs to the Master Controller, with the PA Controllers acting as backup in case
of a Master failure.
NOTE:
All PA and ISO temperature faults are based on actual thermistor tempera-
tures and/or a predicted value of temperature based on the rate of rise in tem-
perature over a given period of time. Therefore, a resistor temperature which
is predicted to reach 130°C will cause an overload the same as an actual read-
ing. Due to the prediction, it is possible to get over-temperature faults even
though the actual temperature reading is not above the threshold.
6-20 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
For instance, the PA Controllers have the ability to control and monitor 8 amplifiers.
These lines to and from the amplfiers are labeled PA1-PA8 on the PA Controller
schematic. Since PAC#1 and PAC#2 control and monitor different amplifiers it
would not be possible to put the correct labels on the schematic with respect to
specific amplifier connections. As an example, the gate control voltage to amplifier
A4 comes from PA Controller#2. Tracing the signal from the A4 gate voltage input
back to PA Controller #1 would reveal that it is actually connected to the
PA7_GATE signal on the PA Controller schematic. PAC#1 also has a PA7_GATE
output, but it goes to amplifier B3.
888-2408-002 6-21
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
Table 4-1 on page 4-60 is intended to ease this confusion. For instance, in the
process of troubleshooting a PA problem it is found that amplifier B2 has no gate
control voltage. Tracking this back to its source can be tricky. Table 4-1 gives you
the necessary information to skip steps or at least verify your path.
Also be aware that there could also be a problem on the RFI Filter boards which are
in series with all of the lines between the controllers and the PA components.
However, it should be noted that the Z5 control system is adaptive. With the failure
of one PA, the other 3 PAs in that foursome will have a reduced PA current foldback
level due to the increased combiner mismatch. If a second PA fails, it depends on
where it is located in relation to the first one as to the action the controller will take
when reducing the current foldback limit on the PAs. Basically, this means that with
6-22 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
2 PAs failed, the transmitter could be as high as 97% power or worst case around
84% (possibly less based on individual operating conditions), depending on the
location of the failed PAs. See “Multiple PA Failures in a Foursome ” earlier in this
chapter.
! CAUTION:
WHEN A MUTE FAULT OCCURS, BE SURE TO SHUT THE TRANSMITTER
OFF BEFORE REMOVING ANY MODULES TO PREVENT ARCING OF THE
PA EDGE CONNECTORS.
888-2408-002 6-23
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
NOTE:
The individual PA ISO resistor temperatures can vary quite a bit but are to be
considered okay if they are under ambient temperature + 75°C. For example,
with an ambient temperature of 25°C the PA ISO temperatures are okay if
they are under 100°C (25°C + 75°C).
6-24 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
6.11.9 PA_ISO_OT
This is a general over-temperature fault which will shut the transmitter off if one of
the PA Isolation resistors in the combiner physically reaches 170°C (no prediction).
This protects against a failure in the combiner system where the Isolation resistor
does not get switched out of circuit. The primary cause would be a failure of the
Isolation Switch associated with the resistor.
However, a shorted thermistor (each PA isolation resistor has one attached to it for
temperature sensing) could also cause this fault since it will give what appears to be
a maximum temperature reading, greater than 170°C.
If this fault is triggered, all of the PA ISO temperatures should be checked. Since the
transmitter was shut off, they all should have cooled down. If one of them is still
extremely hot, above 150°C, then a thermistor (or the line to it) is probably shorted.
If all of the readings have cooled down then it is probably a failure of the RF
Switch. To locate the correct RF Switch and/or ISO Load get the A# or B#_ISO
(there should also be one of these in the Fault Log) fault number and use Table 4-1
to cross reference.
888-2408-002 6-25
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
NOTE:
A severe AC phase imbalance or complete loss of phase could trigger this
fault. If an AC phase loss fault is logged at approximately the same time, then
this fault should be ignored.
6-26 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
• PAC1_J1 or PAC2_J1
• PAC1_J2 or PAC2_J2
• PAC1_J11 or PAC2_J11
• PAC1_J12 or PAC2_J12
888-2408-002 6-27
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
a. Critical
b. Non-Critical
Critical faults will shut the power supply off, while the non-critical faults give a
fault indication on the front of the controller and are written into the fault log.
If the transmitter has the dual PS Controller option then the cables can be swapped
between the 2 controller cards (W11 would be attached to PSC #1 and W12 would
be attached to PSC #2 before swapping but this is not critical). If the problem moves
to a different power supply then the controller is bad and should be replaced.
Under Critical Fault conditions the power supply is going to be turned off. The only
way to reset a critical fault is by pressing one of the ON buttons on the front panel,
which will send out a TX_RESTART command to all of the controller boards. The
system will try to re-initialize and come back up to full power. If the faults are still
present, the power supply will simply fault off again.
6-28 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
NOTE:
Since one power supply controller is able to control up to two power supplies,
one of the power supplies can be turned off, due to a fault, while the other one
continues to operate normally. Due to the distribution of voltage to the PAs,
this will affect all of the PAs associated with one of the PA Controllers.
Therefore the effect is the same as the loss of a PA Controller and the trans-
mitter will have a maximum power output of about 33% of nominal.
888-2408-002 6-29
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
It is also important to note that there could be several other faults show up as a result
of a phase loss:
• PAC#_VOLTS
• IPA_LOW
• EXC#_AFC
These faults are incidental and simply occur due to the timing of when the phase
loss occurs and which components see it first.
6-30 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
6.12.2.7 PS#_JUMP
If a power supply tap fails and the next one available is two or more taps away, a
JUMP fault is triggered and the supply will be shut off and discharged. The only
situations where this could happen are:
If tap 3 is being used and fails, and tap 2 and tap 4 have failed previously.
Note that if the power supply chassis is not properly grounded, or is completely
floating, this induces a considerable amount of 50/60Hz in the voltage sample lines
to the controller so as to erroneously trip this type of fault. The fault is logged as
PS1_TAP1 (up to TAP4) or PS2_TAP1 (up to TAP4). This fault is the same for 3
phase and single phase transmitters.
Table 6-2 on page 6-32 shows the SCRs and fuses on each Rectifier Board
associated with each of the taps. Each transformer has an “A” side and a “B” side
Rectifier Board.
Figure 6-7 on page 6-33 is a component locator for the 3 Phase Rectifier assembly.
It is a top view with the Rectifier Boards oriented horizontally instead of vertically.
Figure 6-8 on page 6-34 is a component locator for the Single Phase power supply
Rectifier assembly.
888-2408-002 6-31
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
6-32 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
888-2408-002 6-33
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
6-34 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
MSTR_REF +5V reference fault. Indicates +5V Mute XMTR (IPA & Exciter, Power supplies)
reference is < 4.6V
REF_WARNING Indicates +5V Reference is out of Reports fault in Log without shutting down the
tolerance at the Master Controller Board PAs.
with error of more than 0.25V but < 0.4V
RFL_PWR Reflected power has exceeded VSWR Will follow 3 Strike Routine (described in
overload threshold Section 6) Transmitter will mute and try to
slowly ramp power back up to normal.
INTLK External Interlock fault Turn off XMTR, light INTERLOCK LED
FAILSAFE Failsafe fault, AC on and power supply in Mute XMTR, blink INTERLOCK LED
standby mode
POWER_FAIL AC power supply failed, +20V power Mute XMTR & save fault time. Transmitter will
supply on Life Support Board is less than automatically return to operation when power
12V. returns.
LOW_AIR Low air flow fault at 25% (88 cf/m) Low-fan TO high-fan, OR high-fan TO AC off
UPS Logic LOW detected at Remote UPS Transmitter is switched to the UPS Forward
input Power setting
CPLR_NC Forward power Directional coupler cable Mute XMTR. Restart required to restore
is not connected power
IPA_AB1_MUTE IPA_AB1 current still present with Vg < - Mute XMTR (exciter and PAs)
15V
IPA_AB1_LOW IPA_AB1 power is < 30% of calibrated Mute, then switch to other IPA
output with Vg = 0V
IPA_AB1_LOW IPA_AB1 power is < 30% of calibrated Mute, then switch to other IPA
output with Vg = 0V
IPA_AB1_OC IPA_AB1 current has exceeded the Mute, then switch to other IPA
14.5A threshold
IPA_AB1_OT IPA_AB1 temperature has exceeded Mute, then switch to other IPA
100oC
888-2408-002 6-35
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
IPA_AB1_OUT IPA_AB1 is not inserted completely into Switch to IPA_AB2 if it is not faulted
the connector
IPA_AB2_MUTE IPA_AB2 current still present with Vg < - Mute XMTR (exciter and PAs)
15V
IPA_AB2_LOW IPA_AB2 power is < 30% of calibrated Mute, then switch to other IPA
output with Vg = 0V
IPA_AB2_OC IPA_AB2 current has exceeded the Mute, then switch to other IPA
14.5A threshold
IPA_AB2_OT IPA_AB2 temperature has exceeded Mute, then switch to other IPA
100oC
PAC1_COMM Communication lost between Master and Request another controller to mute
the PA controller
ISO_AB Reject Load ISO_AB, on the 3dB hybrid, Will follow 3 Strike Routine (described in
is > 145oC Section 6)
EXC1_FAULT The exciter has signaled the transmitter Exciter AFC fault and/or Exciter FAULT are
EXC1_LOW that it has a problem. For more detected by the exciter and are recorded in
EXC2_FAULT information on exciter faults, refer to the the transmitter fault log. No action will be
EXC2_LOW exciter manual. taken until an exciter low power condition is
detected. Controller will then delay 10
seconds before switching to another exciter, if
it is available.
EXC#_AFC Phase Locked Loop not locked 10 Sec to recover, then switch to 2nd Exciter
(if available)
AMB_WARNING Ambient Temperature Warning > 50o Switch Fan to high speed
degree
AMB_TEMP Ambient temperature critical > 60oC Ambient Temperature > 60oC rf mute, > 65oC
AC OFF
6-36 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
PAC#_REF +5V voltage reference fault (< 4.6V) Mute all PAs for the designated PA Controller
(n = 1 or 2) Transmitter will go to about 20% power and energize all its relays
as long as only one PA Controller was
affected.
PAC#_VOLTS PSn fault, take out its PAs, other Mute all its PAs & energize all its relays
controller’s PAs still operate
PAC#_-15V Without -15V, PACn has lost its ability to Request another controller to mute the PAs
MUTE the PAs under its control. controlled by designated PAC.
A#_OC The designated Power Amplifier has Mute XMTR 120ms, switch out the PA and
B#_OC exceeded 14.5A (where # is a number release the mute on the rest of the amplifiers
from 1-8).
A#_OT The designated Power Amplifier has Mute XMTR 120ms, switch out the PA and
B#_OT o release the mute on the rest of the amplifiers.
exceeded 100 C (where # is a number
from 1-8).
A#_OUT The designated PA is not properly seated Mute XMTR 120ms, switch out the PA and
B#_OUT in the connector. Make sure the module release the mute on the rest of the PAs. Re-
is properly inserted and the thumbscrews inserting the PA into the connector should
on the PA module are engaged (where # clear the fault and re-initialize the PA and the
is a number from 1-8). system.
A#_MUTE_FLT Designated PA cannot be muted. Any Mute XMTR (exciter and PAs)
B#_MUTE_FLT time PAs are muted the system checks to
see if any PA is drawing current. If so,
then the controller does not have the
ability to mute that PA and the mute fault
is activated.
A#_UC Designated Power Amplifier’s current is Mute XMTR 120ms, switch out the PA and
B#_UC less than 10% of the Foursome Ave. release the mute on the other PAs.
current. Could Indicate a failed PA, loss
of rf drive to that PA, a power supply
problem or a control problem.
A#_ISO PA isolation load temperature > 150oC. Mute XMTR 120ms, switch out the PA and
B#_ISO These loads are located on the Isolation release the mute on the rest of the PAs.
Boards connected to each Z-Plane.
888-2408-002 6-37
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
PAC#_ISOAZ Designated ISO load Temp > 145oC. Will follow 3 Strike Routine (described in
PAC#_ISOBZ Means ISO_APC foldback has failed to Section 6)
reduce temperature of the load. Fold-
back level is 135 oC.
NOTE: These are the large ceramic
loads in the middle of the Isolation
Boards which are used as the Isolation
resistors for the 2 way combiners on
each Z-Plane. Heating is caused by PA
imbalance.
PAC#_ISOAB Designated ISO load Temp > 145oC. Will follow 3 Strike Routine (described in Sec-
Means ISO_APC foldback has failed to tion 6)
reduce temperature of the load. Fold-
back level is 135 oC.
NOTE: This is the load on the 5kW 3dB
hybrid which is combining the Z-Plane
outputs. Heating is caused by imbalance
between Z-Plane outputs.
6-38 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
PSC# +20V +20V DC supply to PSC failed Shut PS OFF and discharge
PS#_DSCHG Discharge circuit failed which means the Transmitter is shut OFF
PS will not discharge. If discharge
resistor is open, a PS#_START fault will
prevent the transmitter from being turned
on again. The same resistor is used for
both purposes.
PS#_START Not able to soft start. Could be an SCR Shut PS OFF and discharge
problem or open soft start/discharge
resistor (Mounted on top of each
transformer).
PS#_HS_TEMP SCR heat sink temperature overload Shut PS OFF and discharge
PS#_PHS_LS Transformer primary phase loss or Transmitter will Mute for 20 seconds, then try
severe imbalance to turn on again. This will be repeated until
successful.
PS#_JUMP Upper or lower tap not available once Shut power supply off and discharge
current tap failed
PS#_TAP1 Tap 1 failed. One or more of the Tap1 fault indication. PSC will automatically
secondary SCRs for the 48V tap have switch to Tap2 if it is not faulted. If Tap2 is
failed on the designated Power Supply. faulted, off shut Tx off with PS#_JUMP fault.
PS#_TAP2 Tap 2 failed. One or more of the Tap2 fault indication. PSC will automatically
secondary SCRs for the 50V tap have switch to Tap1 if it is not faulted. If Tap1 is
failed on the designated Power Supply. faulted off, switch to Tap3. If Tap3 is faulted
off, shut TX off with PS#_JUMP fault.
PS#_TAP3 Tap 3 failed. One or more of the Tap3 fault indication. PSC will automatically
secondary SCRs for the 52V tap have switch to Tap2 if it is not faulted. If Tap2 is
failed on the designated Power Supply. faulted off, switch to Tap4. If Tap4 is faulted
off, shut TX off with PS#_JUMP fault.
PS#_TAP4 Tap 4 failed. One or more of the Tap4 fault indication. PSC will automatically
secondary SCRs for the 54V tap have switch to Tap3 if it is not faulted. If Tap3 is
failed on the designated Power Supply. faulted off, shut TX off with PS#_JUMP fault.
PS#_COMM PS Controller not able to communicate Fault indication. No transmitter action taken.
with the Master
888-2408-002 6-39
WARNING: Disconnect primary power prior to servicing.
Troubleshooting
6-40 888-2408-002
WARNING: Disconnect primary power prior to servicing.
Parts List
888-2408-002 7-1
WARNING: Disconnect primary power prior to servicing.
Parts List
7-2 888-2408-002
WARNING: Disconnect primary power prior to servicing.