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5-36

888-2463-001

3/6/08

WARNING: Disconnect primary power prior to servicing.

Diamond Series™

Section 5 Maintenance and Alignments

5.10.3 Replacing the Cabinet Controller Board

The Cabinet Controller board at the top of the PA Cabinet has several switch settings
which should most likely be set the same as the board being replaced. Table 5-2, Table
5-3, and Table 5-4 are provided here for quick reference for all of the switch settings of
S1, S3 and S6. There is also a +5.00V reference which should be checked at TP50 and
set if necessary using R97. See Figure 5-14 on page 5-39 for component locations.

NOTE:

Switch S2 on the Cabinet Controller board is not used. Set to “1” for all Cabinets.

5.10.3.1 EEPROM U22

It is also necessary to remove the EEPROM U22 from the bad Cabinet Controller board
and install it on the replacement board. Provided that the EEPROM is still good, this
will transfer all phase, gain and calibration information to the new board and no user
adjustment will be required beyond those mentioned in the previous paragraph. If the
EEPROM U22 must be replaced with a new on, then the following will have to be done:

•

Module and Cabinet Phasing

•

Cabinet Forward power, Reflected power and Drive power calibrations.

5.10.3.2 Interlock Configuration and Jumper JP17

It is very important to check for JP17 on the board being replaced to determine if it has
been removed. However, JP17 was not present on older Cabinet Controller Boards, it
was just a trace on the board. The following scenarios can be used to determine if JP17
should be installed or removed.

1.

For PA Cabinet #1 JP17 should always be installed. The last 3 scenarios are

for PA Cabinets 2-5.

2.

If all cabinets are supposed to respond to a common external interlock sig-

nal then JP17 should be left installed on all Cabinet Controllers.

3.

If each cabinet is supposed to respond to a separate external interlock sig-

nal and the common system external interlock JP17 should be installed on
all Cabinet Controllers along with the appropriate sections of S6.

4.

If each cabinet is supposed to respond ONLY to a separate external inter-

lock signal then JP17 should be installed on PA Cabinet 1 and removed on
PA Cabinets 2-5. PA Cabinets 2-5 should then have one section of S6
(switches 6-10) set to ON.

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Summary of Contents for DiamondCD Series

Page 1: ...mondCD Series ATSC UHF Transmitter T M No 888 2463 001 Copyright Harris Corporation 2008 All rights reserved TECHNICAL MANUAL 888 2463 001 DiamondCD Series ATSC UHF Transmitter Printed March 6 2008 Rev F2 ...

Page 2: ...d 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 busines...

Page 3: ...ctions 1 2 and 5 D 01 10 03 48909 Updated Table 5 3 to include new S3 1 dipswitch settings E 5 09 03 49292 Updated Section 5 Changes include Power Supply Strap ping information added and Driver Setup procedure redone for clarity along with various small updates E1 7 08 03 N A Updated Parts List Minor change to Module Phasing in Sec tion 2 Installation Step 11 page 2 24 F 10 28 03 49606 Updated Tab...

Page 4: ...MRH 2 888 2463 001 3 6 08 WARNING Disconnect primary power prior to servicing ...

Page 5: ...ANATIONS 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...

Page 6: ......

Page 7: ...d fire protection 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 ENCLO SURES GATES PANELS OR SHIELDS ALWAYS USE...

Page 8: ...viii 888 2463 001 3 6 08 WARNING Disconnect primary power prior to servicing ...

Page 9: ...rtation to a hospital as quickly as possible e If arms or legs are affected keep them elevated 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...

Page 10: ......

Page 11: ... Connections 2 9 Keyboard Connections 2 10 PA Cabinet Connections 2 11 Interlocks 2 14 Determining Cabinet Style 2 15 Installing Power Supplies 2 15 Installing PA Modules 2 16 Initial Turn on 2 17 PA Cabinet AC Voltage Check 2 17 Check the PA Cabinet LVPS DC Voltage 2 18 Control Cabinet AC Voltage Check 2 19 Control Cabinet LVPS DC Voltage Check 2 20 Power Up and Alignment 2 21 CAN BUS Check Out 2...

Page 12: ...led Circuit Description 4 18 Detectors 4 18 Cabinet Controller 4 19 Reject Power Samples 4 19 PA Cabinet Power Samples 4 19 Fault Monitoring 4 19 PA Cabinet Configuration 4 20 Module Fault Logic 4 20 CAN Interface 4 20 RS 232 RS 485 Interface 4 21 Xtal 4 21 Flash Memory 4 21 Watchdog 4 21 Parallel Control Interface 4 21 EPROM U22 4 22 Module Phasing Control 4 22 Analog Voltage Reference 4 23 32VDC...

Page 13: ...r Calibration 5 27 Module Phasing 5 28 PA Module Auto Phasing 5 28 PA Module Manual Phasing 5 29 Cabinet Phase and Gain 5 30 Board Change Procedures 5 32 Main Controller Board Hot Swap 5 32 Life Support Board Hot Swap 5 34 AC OK Set Point 5 35 AC FAIL Set Point 5 35 Replacing the Cabinet Controller Board 5 36 EEPROM U22 5 36 Interlock Configuration and Jumper JP17 5 36 In System Programming ISP Pr...

Page 14: ...t 7 1 Appendix A Cutting and Soldering Transmission Line Suggested Procedure For Cutting And Soldering Transmission Line A 1 Transmission Line Cutting and Flange Soldering Procedure A 1 Cutting the Transmission Line A 8 Soldering Transmission Line Flanges A 8 Soldering Procedure A 9 Cleaning The Soldered Joint A 10 Alternate Cleaning Method A 11 Appendix B Surge Lightning and Grounding Considerati...

Page 15: ... 3 Operation provides identification and functions of all external panel con trols and indicators GUI Graphical User Interface information is provided in the Diamond Software manual 888 2470 001 Section 4 Theory of Operation provides block diagram and detailed theory of opera tion Section 5 Maintenance and Alignments provides preventative and corrective main tenance information Section 6 Troublesh...

Page 16: ...he different models and system specifications The Diamond HD series DTV transmitter consists of two or more discrete functional cabinets The minimum transmitter configuration consists of one system control cabinet and one power amplifier cabinet See Figure 1 1 Larger versions consist of a single control cabinet and up to five PA cabinets Figure 1 1 Transmitter Front View PA CABINET PA MODULES 1 16...

Page 17: ...d below in Table 1 1 Table 1 1 Diamond Transmitter Models and Power Levels Model of PA Modules Peak Power DHD8P1 4 8 kW DHD10P1 6 10kW DHD15P1 8 15 kW DHD20P1 12 22 kW DHD30P1 16 31 kW DHD45P2 24 12 in each cabinet 45 kW DHD60P2 32 16 in each cabinet 60 kW DHD90P3 48 16 in each cabinet 88 kW DHD90P4 48 12 in each cabinet 88kW DHD120P4 64 16 in each cabinet 119 kW DHD150P5 80 16 in each cabinet 149...

Page 18: ...the top 8 modules while the 4 way uses only the top 4 modules Figure 1 2 b shows the new cabinet with the new style combiner and detectors This shows the 16 way combiner As before the 8 module combiner uses the top 8 modules and the 4 way only uses the top 4 modules but the 12 module combiner uses the top 6 and bottom 6 modules the middle 4 modules are removed This combiner also has a 6 way config...

Page 19: ...PA PA PA PA PA PA Filter Filter SM PTE 310M DataInput SM PTE 310M DataInput O ptional C ontrol M eters R em ote PS1 PS2 Exciter Select S Control Cabinet PACabinet Exciter Exciter Exciter Exciter D D 1D river isnot required Exciter output is sufficient todrivethePACabinet Exciter Exciter D river Exciter Exciter D river PA PA PA PA PA PA PA PA PA PA PA PA PA PA PA PA Filter Filter S M PTE 310M DataI...

Page 20: ...i t t e r PA CAB 2 SMPTE 310M Data Input SMPTE 310M Data Input Optional Control Meters Remote PS1 PS6 Exciter Select S Control Cabinet PA Cabinet Exciter Exciter Driver Exciter Exciter Driver PA PA PA PA PA PA PA PA PA PA PA PA PA PA PA PA PA PA PA PA PA PA PA PA PA PA PA PA PA PA PA PA PA CAB 2 PA CAB 3 PA CAB 4 PA CAB 5 G y s e l 3 5 Cabinet Combiner Filter Filter S p l i t t e r PA CAB 2 PA CAB...

Page 21: ...nt of wiring in the transmitter while allowing large amounts of information to be gathered from each PA cabinet The Main Controller is also responsible for communicating the information gathered to the front panel GUI Graphical User Interface computer and to the parallel remote control connections on the System I O board The GUI connects to the Main Controller via a serial com port and provides me...

Page 22: ...all the system level protection and makes all the critical decisions necessary for transmitter protection in the event of a Main Controller failure The Life Support board monitors the activity and health of the Main Controller If a failure of the Main Controller is detected the Life Support takes over all critical control decisions When the Main Controller is operable the Life Support board will p...

Page 23: ...rd of the event This includes the date and time the fault occurred This fault log will capture the most recent 99 faults The meter logging feature also takes a snapshot of the transmitter meter readings based on user preferences of what is logged and when it is taken and creates a unique record The meter log can hold up to 99 records Report and Print functions allow the fault and or meter logs to ...

Page 24: ...ltage power supplies diode or ed for redundancy Module RF combiner which includes RF circulators at the output of each PA module and circulator reject loads RF Detectors for cabinet forward and reflected power and for each PA module reject load AC Phase loss monitor A rear door permits access to the combiner and other components Intake air enters through either the rear door internal cooling fan o...

Page 25: ...cated to the Cabinet Controller via the CAN serial bus Module on off control is via the serial interface and a separate parallel control The modules are hot pluggable to allow on air maintenance and repair Modules include temperature compensation and AGC to control gain stability over the ambient temperature range of the transmitter Each PA module has a pair of touch switches behind the front faca...

Page 26: ...tter model combiners are installed for 4 way 6 way 8 way 12 way and 16 way applications 1 2 5 4 Cabinet Combiner For 2 cabinet transmitters the PA cabinets are driven in quadrature and a hybrid is used to combine the cabinets For transmitters utilizing 3 or more PA Cabinets the cabinets are driven in phase and a Geysel style cabinet combiner is used Up to five PA Cabinets can be combined 1 2 5 5 C...

Page 27: ...iter can be used with any ATSC DTV UHF or VHF transmitter This exciter is described in a separate instruction book The CD1A digital exciter includes closed loop digital adaptive equalization A serial diagnostic and monitoring port is also provided The APEX DTV Exciter The APEX is Harris next generation 8 VSB exciter for use in UHF or VHF ATSC transmitters It uses adaptive equalization to compensat...

Page 28: ...1 14 888 2463 001 3 6 08 WARNING Disconnect primary power prior to servicing Diamond Series Section 1 Introduction ...

Page 29: ......

Page 30: ...1 16 888 2463 001 3 6 08 WARNING Disconnect primary power prior to servicing Diamond Series Section 1 Introduction ...

Page 31: ...dapted for each particular installation 2 2 1 Space Requirements Refer to Transmitter Outline drawing To allow for servicing the transmitter a minimum clearance of 4 feet in front of and 5 feet behind the cabinets is recommended Minimum clearances are shown in the drawing NOTE There is a recessed cable tray in the top of each PA Cabinet that is used for cabi net interconnect wiring It is concealed...

Page 32: ...nized parts are used to support copper RF transmission line the two must be separated using adhesive backed rubber strips or tape to prevent corrosion The basic transmitter generally includes harmonic filters and directional couplers One or more combiners are present in multiple cabinet systems All other RF line components are purchased separately Be sure to obtain all components necessary for you...

Page 33: ...40 480 volts 50 60 Hz If voltage variations in excess of 10 are anticipated the transmitter power input must be equipped with automatic voltage regulators optional equipment capable of correcting the mains voltage AC power to the transmitter should be run in metallic conduit connected to earth ground for safety and to provide shielding against interference All phases should be run within the same ...

Page 34: ... 222 8200 or at the following address Harris Broadcast Communications Division P O Box 4290 Quincy Il 62305 Attn Customer Service Department The equipment becomes the property of the customer when the unit is delivered to the carrier Carefully unpack the unit and perform a visual inspection to determine that no apparent damage has been incurred during shipment Retain all shipping materials until i...

Page 35: ...ore the boxes should be prepared in advance to help the unloading process Remove the cabinets from the truck and set in a location where they cannot be damaged WARNING DO NOT USE THE MOLDED COVERS FOR PUSHING PULLING OR LIFTING The Control cabinet and skid together weigh approximately 500 pounds 227 kg The skid itself weighs 30 pounds 14 kg Each PA Cabinet weighs approximately 1100 pounds 500 kg w...

Page 36: ...nets together using at least 2 of the holes near the top of each cabinet The cabinets should be shimmed until the bolt hole line up and the cabinet sides are parallel and touching Do not use the bolts to pull the cabinets together NOTE If the floor is to be tiled or covered after the transmitter is in place additional shims must be used to allow the power supply covers to fit properly Failure to d...

Page 37: ...loads and antenna Be sure to make any desired VSWR measurements of the RF plant before making final connections to the cabinets NOTE See Appendix A for general guidelines on how to cut and fit rigid transmission lines 2 5 1 RF Line Optimization Once the RF system and interconnecting transmission line are completed it is recommended that the system return loss be measured and adjusted if required T...

Page 38: ...et to facilitate inter cabinet wiring Install the serial parallel and PA Cabinet RF Drive cables in this tray It is accessed by removing the machine screws that hold the cover down The serial CAN bus termination is also in this tray at the top of the PA Cabinet furthest from the Control Cabinet NOTE The cabinet inter connect cables are bundled and shipped inside the cable trays on top of the indiv...

Page 39: ...le phase AC input Single phase AC connects to TB1 in the lower rear of the Control Cabinet There are provisions for dual AC feeds into the cabinet For redun dant AC inputs remove the wire jumpers on the terminal block One feed connects to TB1 1 and TB1 2 The second single phase input connects to TB1 4 and TB1 5 TB1 3 and TB1 6 are Ground NOTE The single phase lines hot and neutral must be connecte...

Page 40: ...d be a good idea to have one ready There are at present 3 different hardware versions of the GUI computer From the front panel and in operation they are identical but from the back they are different For one of the GUIs there is only one connection for a keyboard and it has the earlier style 6 pin DIN connector on the back the back of the GUI is completely enclosed on this one This GUI will not ac...

Page 41: ...agram in Section 500 of the Schematic Package and or the AC Power Flow Diagram in Section 700 WARNING DISABLE AND LOCK OUT STATION PRIMARY POWER BEFORE PRIMARY POWER CABLES ARE CONNECTED TO THE EQUIPMENT The LVPS step down transformer T1 in the bottom of each PA Cabinet should be tapped for the correct AC mains voltage 240Vac or 480Vac See the PA Cabinet Wiring Diagram and Figure 2 3 below for app...

Page 42: ...lation Figure 2 3 Tapping for T1 LVPS Stepdown Transformer Forward Reflected RF cables After the Directional Coupler line section is attached to the RF output of the PA Cabinet connect the forward or incident sample to J8 and the reflected sample to J9 connectors located on top of the PA Cabinet 240Vac 480Vac ...

Page 43: ...ries 3 phase AC input The 3 phase AC input connects to the PA Cabinet at TB1 in the lower rear compartment The three wires connect to pins 7 13 and 19 of TB1 as shown in Figure 2 4 A safety ground would connect to E1 a cabinet ground block just to the right of TB1 Figure 2 4 TB1 3 phase AC Connection Terminals ...

Page 44: ...fault indication is latched on the GUI display and must be reset with the Reset button or with a transmitter on command NOTE Transmitter action is determined by switches S3 6 and S3 7 below ON External Interlock fault indication is not latching and will disappear as soon as the interlock is satisfied Intended for Main Alternate transmitter operation where the External Interlock is used for switchi...

Page 45: ... Supplies There is one switching power supply for every two RF Amplifiers The switching power supplies weigh about 35 pounds 16 kg each To install a power supply rest the rear of the supply on the runner slide the supply in straight until it makes contact with the blind connector in the rear Firm pressure will seat the power supply into the connector Make sure the circuit breaker on the front of t...

Page 46: ...abeled as 1 at the top down to a possible 16 at the bottom as shown in Figure 2 6 Figure 2 6 PA Module Numbering Front View Cabinet Controller Module Slot 1 Module Slot 2 Module Slot 3 Module Slot 4 Module Slot 5 Module Slot 6 Module Slot 7 Module Slot 8 Module Slot 9 Module Slot 10 Module Slot 11 Module Slot 12 Module Slot 13 Module Slot 14 Module Slot 15 Module Slot 16 Cabinet Controller Module ...

Page 47: ... BEFORE PROCEEDING WITH THE FOLLOWING PRO CEDURE STEP 1 Verify that all circuit breakers are OFF STEP 2 Disconnect the AC inputs to the Low Voltage Power Supply assembly in the lower rear of the PA Cabinet by un plugging in line connectors P3 and P4 shown below in Figure 2 7 Figure 2 7 120Vac Connections to LVPS P3 P4 WARNING ALL DOORS AND PANELS ON ALL UNITS MUST BE CLOSED AND LATCHED PRIOR TO CH...

Page 48: ... 1 and 2 going into the Low Voltage Power Supply LVPS assembly STEP 7 Turn OFF all circuit breakers and reconnect plugs P3 and P4 STEP 8 Repeat for each PA Cabinet 2 9 2 Check the PA Cabinet LVPS DC Voltage NOTE The following procedure applies to each PA Cabinet STEP 1 Unplug J7 the DC output of the LVPS assembly in each PA Amplifier Cabinet STEP 2 Activate power supply A by turning ON the circuit...

Page 49: ...rs to both Low Voltage Power Supplies Wait for the LEDs on the LVPS assembly to fade out then reconnect J7 2 9 3 Control Cabinet AC Voltage Check STEP 1 Turn OFF all circuit breakers STEP 2 Disconnect AC inputs to the LVPS assembly in the rear of the Control Cabinet by un plugging in line connectors P3 and P4 as shown in Figure 2 8 Figure 2 8 120Vac Connection to LVPS P3 P4 STEP 3 Turn ON the LVPS...

Page 50: ...e on each pin of the jack from which J7 was removed a Pin 1 GND b Pin 2 7 5VDC c Pin 3 7 5VDC d Pin 4 15VDC e Pin 5 15VDC f Pin 6 GND g Pin 7 Key h Pin 8 GND STEP 4 Turn OFF the LVPS A circuit breaker and turn ON the LVPS B circuit breaker STEP 5 Verify the DC voltages again on each pin of the same jack STEP 6 Turn OFF LVPS B circuit breaker Wait for the LEDs on the LVPS assembly to fade out then ...

Page 51: ...l verify that the transmitter is OFF The light bar above the GUI will be Blinking RED since none of the PA Modules are plugged in yet STEP 4 Turn ON all circuit breakers in the lower rear of each PA Cabinet Leave the individual Power Supply circuit breakers in the front of the PA Cabinet s OFF WARNING DO NOT SWITCH OFF THE GUI POWER WITHOUT FIRST SHUTTING DOWN THE GUI USING THE STANDARD WINDOWS SH...

Page 52: ...upler line section This number would be entered into the power meter as the offset b Use the GUI to monitor the cabinet power output This method does not use a precision coupler but it should have been calibrated in the factory PA Currents should also be monitored if this method is used These reading should be re calibrated later STEP 3 Turn on the exciter circuit breaker Lower the exciter s power...

Page 53: ...les are now producing power and there is minimal cabinet reflected power STEP 8 Repeat STEP 7 while watching the forward and reflected power meters until all the power supplies and modules are turned ON The reflected Power Supply 1 Power Supply 2 Power Supply 3 Power Supply 4 Power Supply 6 Power Supply 5 Power Supply 7 Power Supply 8 Supplies Modules 1 and 2 Supplies Modules Supplies Modules Supp...

Page 54: ... STEP 11 If necessary adjust the Module Phasing as described below Module Phasing should be used to get the module combiner reject loads below 4 0 to 2 is normal a Go to the Main Menu and select Module Phasing This will bring up the window shown in Figure 2 10 Figure 2 10 Module Phasing b Click on one of the module numbers and then press the Auto Phasing button This will bring up a small pop up wi...

Page 55: ...r level for that cabinet to match the external power meter d Press SAVE DATA The GUI power meter for the cabinet and the external meter should now agree STEP 14 Repeat for each PA Cabinet 2 9 8 Bringing Up RF Output Multiple PA Cabinets After all PA Cabinets have been brought up to power using the previous procedure use this procedure to bring the full transmitter up to power STEP 1 Connect the po...

Page 56: ...familiar with the procedure then go to the Cabinet Phasing screen and select a cabinet to adjust Then push the applicable increase decrease button on the screen usually Phase first then amplitude if necessary The objective is to minimize all the reject load powers Note that the reject load power bar changes scale as reject load power reduces below 2 STEP 8 Continue to increase power output until t...

Page 57: ... Pins 1 2 Full Isolation JP1 pins 2 3 All transmitter control functions are ground switching and require the remote control equipment to sink at least 15mA to activate the function The Pinout of J1 is listed in Table 2 2 Table 2 2 J1 System I O Board Remote Control Connections Connections Function J1 1 Transmitter ON J1 2 Transmitter OFF J1 3 RF Output Power Raise J1 4 RF Output Power Lower J1 5 S...

Page 58: ...Remote Status Outputs Connection Function J2 1 thru J2 16 12Vdc source from System I O board Fused at 1 25A by R60 J2 17 thru J2 19 No Connection J2 20 Transmitter On J2 21 Summary Fault J2 22 Exciter Driver A On Air J2 23 Exciter Driver B On Air J2 24 Exciter Driver in Manual Switch Mode J2 25 Exciter Driver A Faulted J2 26 Exciter Driver B Faulted J2 27 Remote Control Disable at Transmitter J2 2...

Page 59: ... transmitter including the GUI Remote GUI or ISP applications Table 2 4 J3 System I O Board Remote Power Metering Connection Metered Parameter J3 1 Total Forward Output Power J3 2 Total Reflected Output Power J3 3 PA Cabinet 1 Forward Power Output J3 4 PA Cabinet 1 Reflected Power Output J3 5 PA Cabinet 2 Forward Power Output J3 6 PA Cabinet 2 Reflected Power Output J3 7 PA Cabinet 3 Forward Power...

Page 60: ...2 30 888 2463 001 3 6 08 WARNING Disconnect primary power prior to servicing Diamond Series Section 2 Installation ...

Page 61: ... be updated at a later date all information pertaining to loading updating and operating the GUI software is contained in a separate Technical Manual called DiamondCD Software Manual part number 888 2470 001 All software updates will come with an updated software manual 3 3 Push Button Controls Soft touch push buttons on the front of the Control Cabinet control the basic functions of the transmitt...

Page 62: ...of the light indicates the overall transmitter operating condition Green Normal operation no faults Red This is a summary fault indication Referring to the Transmitter Control Screen will indicate the functional area that generated the fault Yellow This indicates there is a Control System outage and the transmitter is operat ing under the control of the Life Support Board The information shown on ...

Page 63: ... with a second driver module is available A Graphical User Interface GUI touch screen is used to receive input commands from the operator and gives status of the transmitter Serial communication can also be used for input output The Main Controller communicates with the Cabinet Controller in each PA Cabinet and the Module Controller board in each PA module through a Controller Area Network CAN bus...

Page 64: ...e driver pallet will shut down by its protection circuits in case of a fault See the description in the PA module section of the instruction book for the description of the pallet The driver is self protecting for temperature overloads and overcurrent Shut down is accomplished by shutting off the bias The output power of the driver is monitored If the output power drops below a preset level a sign...

Page 65: ...y diagnose any problem and has the processing power to make decisions to keep the transmitter on the air as well as display all data necessary to operate maintain and troubleshoot the transmitter The transmitter can be operated both locally and remotely by the discrete logic based Life Support system The Parallel Remote circuits are directly interfaced to the Life Support system This discrete para...

Page 66: ...controller via the CAN bus and is processed All system input and output I O such as Exciter Driver Cabinet Combiner and reject loads are also interfaced and processed by the Main Controller 4 3 2 Main Controller functions The Main controller is on air serviceable The primary functions of the Main controller are a Transmitter ON OFF both CAN and parallel 1 ON command is a 100ms pulse which turns on...

Page 67: ...f the DiamondCD is to provide basic Life Support control and protection for the transmitter in case the main microprocessor fails in the Main Controller This CPLD logic based life support circuitry resides primarily on the Life Support board in the Control Unit with some additional logic circuits on the Cabinet Controller board The Life Support circuitry consists of basic logic gates and timers as...

Page 68: ...Graphical User Interface GUI consists of a flat panel touch display and a Single Board Computer SBC used as the control point for the DiamondCD solid state UHF transmitter It displays all the transmitter information graphically in block diagram and pictorial form The GUI is a Windows applications which will run under Windows NT or 95 98 The GUI connects to the Main Controller via RS 232 serial int...

Page 69: ...cuit in the exciter The External interlock when opened will inhibit the PA cabinet or the modules within the cabinet jumper selectable on the Cabinet Controller When the entire cabinet is inhibited the power supplies modules and air handling are inhibited 4 4 Single PA Cabinet The main difference in the various transmitter models is the number of RF Power Amplifiers used Each PA Cabinet contains a...

Page 70: ...e system ON OFF and module phasing voltage Each PA Cabinet is a stand alone unit The only external input it requires from the Control cabinet is the interlock chain which is passive and does not require the Control Cabinet to be powered to operate ON and OFF operation can be done by push buttons on the Cabinet Controller board The Cabinet Controller is microprocessor based with a discrete logic ba...

Page 71: ...et Controller PA CABINET INTERLOCK SETTINGS DIPSWITCH S3 Switch Function Normal Setting Position Action S3 1 thru S3 5 Special Factory Tests OFF OFF Normal Operation ON Test Function S3 6 External Interlock Auto Restart OFF OFF Closing external interlock returns cabinet to operation ON Cabinet START command required to restart cabinet after external interlock closed S3 7 External Interlock Partial...

Page 72: ...er Supply 4 4 6 Low Voltage Power Supplies The PA Cabinet has redundant Low Voltage Power Supplies that supply 15 volts at 5 amps and 7 5 volts at 13 amps The voltage from each supply is diode or ed together on the Low Voltage Distribution board They supply voltage to the Cabinet controller and to the Module Controllers 4 5 Multiple PA Cabinets The higher power transmitter models use multiple PA C...

Page 73: ...tion of the cabinet level components 4 6 2 1 AC Fail Upon AC failure each PA Cabinet Controller in the PA Cabinets will send an active LOW signal to its corresponding pin on J1 pins 12 14 and 16 17 of the Life Support Board Any failure of a single phase AC input to the PA Cabinet will cause the AC_FAIL at this input illuminate DS13 on the Life Support board and will report to the complex programma...

Page 74: ...t J3 28 29 The signals to the switch are labeled A_MODE_CMD and B_MODE_CMD 4 6 2 4 Remote Control Interface The inputs and outputs for remote control are protected from transients by diodes inverters and output AND gates connected as buffers These inputs outputs are connected to the CPLD through their protection circuits 4 6 2 5 Exciter Control The Main Controller will have first priority for Exci...

Page 75: ...ver Auto Switch is enabled by connectiing JP5 While adjusting VSWR JP3 can be set to 2 3 allowing the VSWR indication to surpass the threshold without counting it in the 3 strike counter Under normal operation when the transmitter has failed the 3 strike the VSWR fault will mute the Exciter 4 6 2 7 Exciter Driver selector For dual Exciter Driver transmitters S1 and S2 are used to switch the Drive ...

Page 76: ... of a transmitter shut down due to an operational problem The transmitter ON OFF state Drive switch position and remote enable disable status are held in their last state by latching relays K1 K2 and K3 4 6 2 12 Control Panel Interface The commands from the front of the transmitter at the Control Panel pass through the Life Support board The inputs are clamped with diodes to eliminate transients a...

Page 77: ...on 4 6 2 16 Remote Metering The Forward and Reflected power samples for each PA cabinet are buffered by U36 U39 before going to the remote metering connection 4 6 3 Driver The DD 1 Driver has five major circuit blocks which will be discussed here These assemblies are single rack mounted in a pull out drawer chassis 4 6 3 1 Driver Preamp The Preamplifier provides a portion of the overall RF gain of...

Page 78: ...pending on application 4 6 3 3 Driver Controller The Driver Controller board handles the closed loop bias regulation for the RF Preamp RF Pallet and AGC function for the Driver chain Circuit monitoring fault reporting and remote control interface are on this board On board regulators power the Controller circuits Most of the other sub assemblies in the Driver module interface into this Control Boa...

Page 79: ...en the Driver is turned OFF or if there is a fault condition Bias output voltage from U4 is monitored by U8 and compared to a voltage In the event of a FET failure the bias voltage would go to the rail maximum and U8 will send a FET failure pulse to the CPLD 4 6 3 3 2 Temperature Temperature protection is accomplished by a thermistor mounted on the heat sink This voltage is buffered by U2 and comp...

Page 80: ...critical 5 volts for the assembly U15 supplies more sensitive and lower current 5 volt reference The 28 volt input line is protected by self resetting PTC fuses 4 6 3 4 Output Board The RF Output board provides a sample of the RF output signal to the Driver Controller board for AGC purposes It connects to the Controller with a coax to be detected on the Controller 4 6 3 5 Power Supply The Power Su...

Page 81: ...2 2 PA Cabinet Power Samples The Forward Power Reflected Power and the Input Power samples are always feeding differential amplifiers so their loading will always be present unlike the multiplexed samples These power samples are sent to the microprocessor for display and monitoring The Fast_AC input monitors the cabinet AC input The multiplexed Reject Power samples and the PA Cabinet Power samples...

Page 82: ...ly S3 7 closed the full cabinet will be disabled when an external interlock is broken When the external interlock is satisfied S3 6 open the cabinet will return to operation S3 6 closed will make a start command necessary to restart the cabinet 4 7 2 4 PA Cabinet Configuration The DiamondCD transmitter can be configured for multiple cabinets and cabinets with fewer than 16 modules in them This all...

Page 83: ...ts provide 4 19 Mhz frequency for the micro 4 7 2 9 Flash Memory Fast memory for the microprocessor is furnished by U24 and U34 to allow for field code updates 4 7 2 10 Watchdog The watchdog circuitry will monitor the condition of the microprocessor and will initialize a software reset if an operations problem occurs The micro will output a signal for the watchdog circuit U23 127 TP35 at least onc...

Page 84: ...rupt the turn on of the transmitter with the System OFF at U39 13 if any faults or interlocks are present The CPLD also has a watchdog circuit The microprocessor pulses watchdog chip U45 faster than the time period on the one shot Its Q output will stay in a stable condition as long as the input pulse train continue If they stop due to a micro problem the one shot time period will expire and send ...

Page 85: ...eans of PA Module protection and compensation as well as interfacing to the Main Controller via CAN bus and an RS485 port which can be used as a bench test or for a back up communications bus The Module controller in each PA module will control that amplifier s basic operation and gain over frequency compensation It monitors and protects the amplifier in failure mode The micro processor based modu...

Page 86: ...OFF command Local enable disable from Cabinet Controller Module fault condition 4 8 1 1 1 AGC Vs Number Of Working Pa Pallets A velocity PID algorithm is used for the AGC closed loop system which will automatically compensate the changes of operational frequency temperature and the number of working RF pallets During a pallet failure the Module Controller lowers the gain of that module proportiona...

Page 87: ...e pass FET switches OFF 4 8 1 2 1 Three Strike action Should a momentary failure situation occur power glitch the RF Module Controller will have a three strike action to recover the RF module from fault and to localize the fault strike instead of restarting the whole system by the Main Controller The three strike policy is The three strike is within a 10 second window After that the module will be...

Page 88: ... the front panel switch while removing the module or through the Module Controller by sending a disable command from the Transmitter Control Panel The DC Switch circuit has seven current sensors to provide Pallet current information to the Module Controller circuit 4 8 2 Phase and Gain Each PA module has a Phase and Gain board to compensate for small phase and amplitude differences between modules...

Page 89: ...ollows the PA Driver Pallet stage in the RF path and distributes the signal to the six pallet inputs It uses a 2 stage corporate structure for broadband performance The first stage splits the input signal into two by using a Wilkinson 1 4 wave length microstrip divider The second stage uses two 3 way structures one on each of the first stage outputs 4 8 5 RF Pallet The PA Module contains 6 paralle...

Page 90: ...h The oscillator output is rectified to 10 volts to supply the initial voltage to the gate of the pass MOSFET to cause conduction The source voltage is fed to the pallets through J1 and also is fed back through a charge pump consisting of CR3 and C10 which adds 10 volts to the 32 volt source voltage this holds the pass FETs in saturated conduction mode reducing the voltage drop across it When the ...

Page 91: ...trigger pulse to the one shot U18 4 This pulse period is less than 1 ms which is faster than the time period of the one shot so the one shot is unable to return to its stable state The output will remain HIGH as long as the input trigger is present When the micro has a problem the watchdog trigger pulses stop allowing the Q output to go LOW going through the AND gate turning the pass FETs OFF A se...

Page 92: ...d signals L1 and L2 form a filter in conjunction with the capacitance of the diodes to maintain a 50 ohm condition in the TV band T5 splits the input signal path into two paths The main path and the detector path CR12 and U3 in the detector path detect the input signal and amplify buffer the resulting DC signal R62 provides adjustment of the scaling The buffers output is available on I O connector...

Page 93: ...and associated components provide closed loop constant current bias control for Q5 and Q6 OP Amp U2 provides the linearization interface between the Vector Modulator control input at J1 8 and J1 10 and it s attenuator PIN diodes There are two identical circuits one for the modulator s 0 degree path and one for the 90 degree path The first op amp in each path operates as a variable gain stage in re...

Page 94: ...ghly reactive low input impedance s of these devices By keeping a symmetry in the layout most of the reflected input power will be absorbed by the isolation load R1 offering a good match at the input of the pallet b Input Balun transformer It transforms the unbalanced input one signal refer enced to ground into a balanced one two signals 180 degrees from each other These two signals will drive the...

Page 95: ...t of phase signals coming from each drain into an unbalanced 50 ohm output d Output 3dB hybrid This hybrid combines the amplified signal from the two sepa rate push pull pairs isolates the output circuit of each push pull pair and improves output return loss 4 9 4 Hybrids Hybrids are a special RF circuit whose properties are useful for combining RF power from two sources and for attenuating and ph...

Page 96: ...ill result in power reflected back into the hybrid Signals reflected back into the hybrid by a mismatch are treated in the same manner as input signals incident upon that port 4 9 4 2 Combining a Two equal amplitude signals applied in quadrature to adjacent ports will sum and reappear at one opposite port b The sum port will be the port directly opposite the input port with lagging relative phase ...

Page 97: ... are both set for 50 ohms ports 2 and 3 see matched terminations and the pots absorb all of the power with no power being reflected from them back into the hybrid this gives maximum attenuation see Figure 4 2 If the pots are set for zero ohms a short circuit the signals that appear at ports 2 and 3 still in quadrature and equal in amplitude are completely reflected back into the hybrid Thus all of...

Page 98: ...PIN diodes are biased off they appear as open circuits resulting in 50 ohm loads seen at ports 2 and 3 Thus all of the RF power is absorbed in the 50 ohm resistors giving maximum attenuation If the diodes are biased on they appear as short circuits resulting in short circuits appearing at ports 2 and 3 This causes complete reflection of the RF power incident on ports 2 and 3 and the RF recombines ...

Page 99: ...UNNING ESPECIALLY IN HIGH AMBIENT TEMPERA TURE ENVIRONMENTS SPECIAL GLOVES HAVE BEEN PROVIDED IN THE REAR OF THE CONTROL CABINET OR CAN BE OBTAINED FROM HARRIS PART 0990006483 OR GRAINGER ITEM 4JF36 5 2 Routine Mechanical Maintenance 5 2 1 Cleaning Use a vacuum cleaner as required to clean the cabinets Be aware of static discharge problems with the use of high velocity air in dry climates when cle...

Page 100: ...s This is most important in the high current circuits cabinet AC feed AC breaker to DC power supplies power supply to DC bus DC bus to module connectors etc Also check wires for lead dress and abrasions High current wires may be physically jolted from their positions by current surges at turn on RF cables rarely give trouble but should be checked for tight connection Inspect for signs of cables be...

Page 101: ...le the transmitter remains on the air One power supply serves two PA Modules Access to the power supplies is obtained by removing the cover at the bottom front of the PA Cabinet which is held in place by magnetic catches To remove the power supply turn the breaker on the power supply to be removed to the OFF state remove the two screws holding the power supply assembly in the transmitter frame and...

Page 102: ... 888 2463 001 3 6 08 WARNING Disconnect primary power prior to servicing Diamond Series Section 5 Maintenance and Alignments Figure 5 1 PA Power Supply Strapping Jumpers are located behind the front panel ...

Page 103: ...ained from Harris part 099 0006 483 or Grainger Item 4JF36 Thermoshield Seamless Thermal gloves Cotton Knit 5 4 1 Removal The PA Modules can be removed while the transmitter is on the air There are pressure switches under each handle one on each side on the PA Modules Pulling on the front handles operates these switches which will disable the module by disconnecting the 32Vdc in the module allowin...

Page 104: ...lade screwdriver 7 64 size Allen wrench with torque indicating mechanism 15 inch pounds The Pallet replacement procedure is as described below WARNING THE DIAMOND PA MODULES ARE DESIGNED TO HANDLE VERY HIGH TEMPERA TURES AND MAY BE EXTREMELY HOT UP TO 90O F 50O C ABOVE ROOM TEM PERATURE DO NOT TOUCH THE MODULES WITH BARE HANDS AFTER THE TRANSMITTER HAS BEEN RUNNING ESPECIALLY IN HIGH AMBIENT TEMPE...

Page 105: ...e STEP 5 Unsolder the input and output ribbon wires from the pallet side leaving them attached on the combiner and splitter Carefully bend them up and out of the way Remove the 7 Allen head mounting screws holding the pallet in place STEP 6 Carefully lift up the pallet using the copper clamps situated over the RF Transistors as handles NOTE Lifting the pallet can be made easier by using a flat bla...

Page 106: ...r wire passing underneath the pallet is entirely inside of the designated channel in the heat sink and is not between the pallet and the heat sink STEP 12 Install the seven mounting screws and torque each to 15 inch pounds STEP 13 Solder the brown DC power wire onto the newly installed pallet using the soldering iron and Sn63Pb37 solder STEP 14 Use an Ohmmeter to check the resistance from the brow...

Page 107: ...bly for monitoring total system forward and reflected power driver power and for up to 5 cabinet combiner reject loads Calibration procedures for each of these are contained in the following paragraphs Please Read This Before Calibrating The PA Cabinet is setup with a rear door interlock that will allow the transmitter to operate for 2 minutes after the door is opened the fans will shut off If the...

Page 108: ... rated forward power measured at the test load Measure the cabinet or system output power with a precision coupler and digital power meter calorimetric can also be used if available STEP 2 Go to the Power Calibrations screen shown in Figure 5 3 Check the detector voltage reading for the stage you are calibrating If it is 4V 0 5V the rf detector requires no adjustment and you can continue to the ne...

Page 109: ... the rf detector to finish the procedure 5 5 2 Reflected Power Calibration This calibration is done basically the same as the Forward Power Calibration however it uses the Forward Power sample with a 10dB pad inserted in the line the 10dB pad is stored in a holder in the back of the Control Cabinet This will calibrate the reflected metering to 10 of the forward power Use the following procedure to...

Page 110: ... apply to Control Cabinet STEP 6 Verify approximately 4Vdc appears on the GUI Power Calibrations screen 4 2 2 1 and that the RFLD button is pressed for the stage you are calibrating STEP 7 Using the INCREASE DECREASE and SLOW FAST buttons adjust the reflected power to 10 of the forward power reading noted earlier move the decimal point to the left one place EXAMPLE Set the reflected reading to 100...

Page 111: ...WLY WHILE WATCHING THE DIGITAL POWER METER TO PRE VENT DAMAGE TO THE SENSOR THE FACTORY TEST DATA SHOULD SHOW THE NOMINAL DRIVE POWER TO BE MEASURED HERE STEP 3 Turn the transmitter on and measure the Driver power STEP 4 Go to the Power Calibrations screen shown in Figure 5 3 Check the detector voltage reading for the Drive stage If it is 4V 0 5V the rf detector requires no adjustment and you can ...

Page 112: ...t load Turn off either PA cabinet to calibrate the reject load STEP 2 Go to the Power Calibrations screen shown in Figure 5 3 Check the detector voltage reading for the Reject load to be calibrated If it is 4V 0 5V the rf detector requires no adjustment and you can continue on with the next step to finish the software calibration If it is not within this range then you will need to refer to paragr...

Page 113: ...or that will handle more than 1 watt average power As of Mid year 2002 PA cabinets started implementing the new style PA module combiner and 8 way detectors As far as operation is concerned there is no difference from the previous combiner and detectors However this changes the calibration procedures for the module combiner reject load detectors Figure 5 4 shows a rear view of the 2 PA Cabinets Fi...

Page 114: ...JP1 on the RF detector to the TEST position pins 2 3 STEP 3 Select a cable with adaptors if necessary that will allow a direct connection from the exciter SMA output to the detector input to be calibrated STEP 4 First set the exciter power to zero Connect one end of the cable to the exciter and the other end to the power sensor on the digital power meter STEP 5 Increase the exciter output until th...

Page 115: ...s to the op amp are switched the same The 3 gain settings are Low dipswitches 1 4 ON Mid dipswitches 2 5 ON High dipswitches 3 6 ON STEP 10 Measure the voltage at the test point in the RF Detector assembly for the stage you are calibrating The detectors are sectional with the adjustments located directly below the input All 8 test points are located on the one end but correspond directly to the in...

Page 116: ...5 18 888 2463 001 3 6 08 WARNING Disconnect primary power prior to servicing Diamond Series Section 5 Maintenance and Alignments Figure 5 5 PA Module Reject Load Calibration Screen ...

Page 117: ...o Connect one end of the cable to the exciter and the other end to the power sensor on the digital power meter STEP 4 Increase the exciter output until the digital power meter reads 50mW This will remove the effect of any line loss in the cable and assure 50mW is actually being applied to the detector Figure 5 6 Remove Detector Cables for Calibration STEP 5 Move the cable from the power sensor to ...

Page 118: ...adjustment holes See Figure 5 7 STEP 8 Once the detector voltage reads 4V it should also read 100 If not select the detector button below the voltage reading and use the increase decrease and Fast Slow buttons at the bottom of the screen to set that detector to 100 STEP 9 Press Save Data You must press this button after each detector is set If you select another detector before saving it will lose...

Page 119: ...TEST position pins 2 3 STEP 3 The RF input should be at the level specified in the calibration procedure being followed STEP 4 Measure the voltage at the test point in the RF Detector assembly for the stage you are calibrating The detectors are sectional with the adjustments located directly below the input All 8 test points are located on the one end but correspond directly to the input number J1...

Page 120: ...rom the directional coupler follow ing the procedure 5 5 2 Reflected Power Calibration on page 5 11 b On the Exciter AGC board preset R83 VSWR gain pot fully CCW c On the Main Controller board in the control rack monitor TP4 Exc A d Inject a DC voltage of 1 5 1 7 volts into the RF detector in the back of the con trol cabinet at TP2 You can use a 1 5 volt battery connected to the test point and cha...

Page 121: ...nt of 1 amp See Figure 5 9 for location of R77 f Turn OFF the Driver by depressing S2 on the Driver Control Board 5 7 2 Setting Bias for the Driver Pallet The following procedure should be used when replacing the Driver Pallet or to simply re bias the pallet as part of a complete DD 1 Driver tune up The amplifier in the DD 1 driver pallet is the same as the amplifier pallet used in the PA modules ...

Page 122: ... the DD 1 Driver STEP 3 On the Driver Control Board move JP9 to the 1 2 position and JP12 to the 2 3 position See Figure 5 9 for location of jumpers STEP 4 Turn R59 RF Amp Bias Adjust on the Driver Control board fully CCW ten turn pot See Figure 5 9 for location of R59 STEP 5 Remove the cover from the amplifier pallet and turn both bias pots on the pallet R7 and R10 fully CCW for minimum bias they...

Page 123: ...e pair of the RF transistors Q1 Q2 or Q3 Q4 then the other pair to ground this shuts off 1 2 of the pallet When the bias for either pair is shorted to ground the voltage across R42 should be 25mV indicating that the operating pair is biased to 2 5 amps To shut off the upper pair in Figure 5 8 short across R30 and re adjust R10 for 25mV across R42 To shut off the lower pair short across R31 and re ...

Page 124: ...nnect it to a digital power meter to measure and set this level using the exciter power adjust Once set re connect the cable to the Driver RF input c Apply AC power to the DD 1 and turn ON the Driver by pressing S1 on the Driver Control Board see Figure 5 9 d Adjust Driver Control R89 CW for a 4 volt indication at TP25 see Figure above for control and test point locations e Turn the transmitter ON...

Page 125: ...ion the on board enable disable ON OFF is the only control point 5 7 7 Auto start The Driver can be set to be enabled when the AC power is applied to the driver or wait until an ON command is applied either on board or external from the Driver When JP8 is jumpered 2 3 the Driver will be enabled as soon as AC power is applied With JP8 1 2 the Driver will be enabled by pressing the on board ON switc...

Page 126: ... the modules Reject levels should be less than 4 5 8 1 PA Module Auto Phasing As of GUI revision 2 3 0 the Automatic phasing function is available This procedure can be done while on the air but it will take up to 15 minutes or more depending on the severity of the module phasing To use the Auto Phasing STEP 1 First select the first module in the group of four which has the problem Module 1 5 9 or...

Page 127: ...effect each other the most If it is an even number module 2 4 6 select the odd number module immediately below it to act upon Example If reject 8 is too high select reject 7 and start modifying the phase of 7 STEP 1 Select the module to be phased by pressing the module s numbered button Module 1 is selected in the figure If the module that needs adjustment is an odd number 1 3 5 select the even nu...

Page 128: ...onfirmation query 5 9 Cabinet Phase and Gain Obviously cabinet phase and gain is only for multiple cabinet transmitters The Cabinet Phase and Gain screen shown in Figure 5 11 can be accessed directly from the Main Menu or from the Module Phasing screen The screen is monitoring the power levels from each of the cabinet combiner reject loads The procedure is simple STEP 1 Select the cabinet to adjus...

Page 129: ...3 6 08 888 2463 001 5 31 WARNING Disconnect primary power prior to servicing Section 5 Maintenance and Alignments Diamond Series Figure 5 11 Cabinet Phase and Gain Screen 4 3 ...

Page 130: ...n the following order then remove the PC Board See Figure 5 12 for connector locations J9 J10 J11 J8 J5 J6 J4 J3 J2 J1 c Remove EEPROM U3 from the old board and install it in the new board This will carry all configuration and calibration settings to the new board If the EEPROM needs to be replaced with a new one then the following will have to be done System Forward and Reflected power calibratio...

Page 131: ... Series Figure 5 12 Main Controller Connector Locations J8 J9 J5 J6 J7 J1 J2 J3 J4 Main Controller Board Connector Locations Connector Side J10 J11 Harris Protocol Can Bus Exciter B Exciter A RS 232 to RS 232 to GUI Interface Drive Change Remote I O LVPS Parallel Mode Control To Life Support LS Discrete From Life Support ...

Page 132: ... for connector locations J3 J4 J2 J5 J6 J7 J1 J9 J8 d The GUI will now have ON OFF capability only e Install the replacement LIFE SUPPORT board and reconnect the cables in reverse order Set all dipswitches and jumpers to the same position as the old board f Adjust R123 for 1 85Vdc at TP32 on the Life Support Board This sets the VSWR Foldback point when in Life Support Mode g The last step to finis...

Page 133: ...usted at TP31 is calculated by this formula Vdc TP31 95VAC x VDC TP33 measured AC line voltage Example With a measured AC line voltage of 110 VAC and TP33 measuring 8 Vdc adjust the voltage TP31 to be 6 91Vdc 95 x 8 110 6 91Vdc 5 10 2 2 AC FAIL Set Point The AC FAIL set point is adjusted using R121 and measured at TP30 in the same way as the AC OK set point This AC FAIL line voltage trip should be...

Page 134: ...paragraph If the EEPROM U22 must be replaced with a new on then the following will have to be done Module and Cabinet Phasing Cabinet Forward power Reflected power and Drive power calibrations 5 10 3 2 Interlock Configuration and Jumper JP17 It is very important to check for JP17 on the board being replaced to determine if it has been removed However JP17 was not present on older Cabinet Controlle...

Page 135: ...n where the External Interlock is used for switching S3 2 PA Cabinet Reflected Power Trip Adjust OFF Switch Combinations shown at right Caution The standard VSWR Trip point should be used unless instructed otherwise by Harris Personnel S3 2 OFF and S3 3 OFF Standard 178 Watt Trip Point S3 2 ON and S3 3 OFF 215 Watts S3 2 OFF and S3 3 ON 310 Watts S3 2 ON and S3 3 ON 413 Watts S3 3 OFF S3 4 S3 5 Sp...

Page 136: ... Cabinet 2 Set to ON if separate external interlocks are being used for each PA Cabinet Set to OFF if all PA Cabinet are wired to a common external interlock 7 External Interlock for Cabinet 3 Set to ON if separate external interlocks are being used for each PA Cabinet Set to OFF if all PA Cabinet are wired to a common external interlock 8 External Interlock for Cabinet 4 Set to ON if separate ext...

Page 137: ...3 6 08 888 2463 001 5 39 WARNING Disconnect primary power prior to servicing Section 5 Maintenance and Alignments Diamond Series Figure 5 14 Cabinet Controller Component Locator ...

Page 138: ...nd Alignments 5 11 In System Programming ISP Procedures The software loaded into each of the transmitters controllers can be updated in the field using the ISP or In System Programming feature Detailed instructions on using the ISP applications are contained in the DiamondCD Software Manual Harris part 888 2470 001 ...

Page 139: ...s from the Main controller 6 1 3 Main Controller If the Main Controller fails control of the transmitter will automatically shift to the Life Support controller The light bar on the front of the Control Cabinet would turn yellow and there would be a flashing yellow light on the Life Support Board During this mode the Life Support Controller provides basic ON OFF control In Life Support mode both f...

Page 140: ...TTER IS OPERATED WHEN BOTH THE LIFE SUPPORT AND MAIN CONTROLLERS ARE NOT WORKING THERE IS NO SYSTEM LEVEL VSWR PRO TECTION AND IS THEREFORE NOT RECOMMENDED EXCEPT FOR EMERGENCY OPERATION 6 1 5 GUI Troubleshooting The GUI is a Windows based computer with a touch screen for a navigation interface The first line of defense against problems related to operating or navigating in the GUI is to simply re...

Page 141: ...LECTRICAL SHOCK IS POSSIBLE 6 2 Fault Listings The following is a listing of the faults which can occur and that would show a fault indication on the GUI The faults are grouped by the screen on which they appear Please note that all of the GUI screens have a number in the title bar at the top such as Transmitter Control 4 0 Drive Chain 2 1 etc To see what the actual fault indications would look li...

Page 142: ...tch in dual drive transmitters if other drive chain is okay 6 2 2 DD 1 Driver 2 2 The following faults are internal to the driver The GUI will only indicate a summary fault flag on the screen This summary fault will cause a switch to the alternate Exciter Driver drive chain if available To determine the actual cause of the internal Driver fault there is an LED on the Driver Control Board inside th...

Page 143: ...oard contains a bias control circuit which when adjusted properly will reduce the total pallet bias to 4 amps and keep it there As LDMOS FETs age their idle current tends to drop The Bias control circuit then increases the bias to compensate If the actual pallet bias drops below 4 amps the bias control circuit will no longer be able to increase the bias and the Driver will be shut off with the ind...

Page 144: ...able fault is an LDMOS Fault since it is the only one which can normally be attributed to a specific pallet 6 2 3 1 Frequency Channel frequency or frequency band reported by module does not match system settings This should match the settings in the GUI configuration screen Non latching Just a warning Normally can only occur if a new module not set to the proper frequency is inserted in the transm...

Page 145: ... the module the module should be sent in for repair If the Com Fault stays with the slot do the following Visually check the pins in the stationary module connector at the back of the module slot several modules may have to be removed to gain access The center of the module connector containing the rf input cable and 4 white ribbon cables can be removed from the rear of the PA Cabinet if necessary...

Page 146: ... 8 LDMOS Fail FET failure based of pallet current levels Fault is set for each push pull pair Fault is set when pallet current is less than 60 of highest pallet current in module If pallet current is below 40 the whole pallet is considered bad which is 2 LDMOS failures 3 push pull pair failures are allowed without shutting off the module If a 4th fails it is considered a critical failure and the m...

Page 147: ...odules have this fault then check the power supply voltage readings the GUI and try swapping the supply with another Remember that each odd numbered module is powered from the same supply as the next highest even numbered module 1 2 3 4 etc If the power supply is ruled out and this is the only module with this fault the module should be swapped with another to rule out the slot into which the modu...

Page 148: ...utput power ADC numbers being equal usually somewhere close to 800 Press the SHOW metering button to see the DAC and ADC readings AGC Out 1 and AGC Out 2 are used to control the module phase and gain The factory numbers are given in the factory test data Moving them up or down together will change the module gain while moving them in opposite directions will change the module phase relative to the...

Page 149: ...PA Cabinet The 3 phase ac line voltage is either missing or has a severe imbalance between the phases This fault protects the blower moter from a loss of phase Transmitter will automatically turn back on as soon as AC power returns 6 2 4 3 LVPS A or B Fault Low voltage power supply failure No effect as long as the other supply is working Non latching 6 2 4 4 EEPROM Error detected while writing to ...

Page 150: ...re Probably means the fan is not on The cabinet will trip off after 2 minutes if airflow does not return The PA Cabinet does not automatically turn back on when fault goes away Transmitter ON command is required reset the system and return the cabinet to air This also applies in Life Support Mode 6 2 4 8 Com Fail Cabinet Controller is not responding to the Main Controller 6 2 5 Control Cabinet 2 0...

Page 151: ...d read 15 or 23 etc which actually means interlocks 1 and 5 or interlocks 2 and 3 have been tripped 6 2 5 5 AC Mains Fault AC power dropped below threshold which is set via controls on the Life Support Board Configuration saved to micro and micro resets itself No OFF command is sent to PA Cabinets which are now operating independently When AC power returns to the Control Cabinet it will issue an O...

Page 152: ...rvicing Diamond Series Section 6 Troubleshooting 6 2 6 Power Supplies 3 2 Fault 32V not present at module module is the detector Attached modules will not have RF output and will 3 strike and report errors This fault could also be caused by power supply over temperature ...

Page 153: ...BASIC DD1 992 9914 010 7 9 Table 7 15 PWA DRIVER PREAMP 992 9925 001 7 10 Table 7 16 PWA DRIVER CONTROL 992 9926 001 7 10 Table 7 17 PWA OUTPUT 992 9927 001 7 10 Table 7 18 ASSY 8 SECTION RF DETECTOR 992 9916 002 7 11 Table 7 19 PWA 8 SECTION RF DETECTOR 992 9922 001 7 11 Table 7 20 CABINET BASIC H P PA 992 9897 020 7 11 Table 7 21 CONTROLLER CABINET 992 9899 001 7 13 Table 7 22 PWA CABINET CONTRO...

Page 154: ...ALL 4 P A CAB 994 9751 004 7 27 Table 7 50 TRANSMITTER DHD90P3 994 9816 001 7 27 Table 7 51 KIT RF MYAT DIAMOND 3PA 943 5510 300 7 31 Table 7 52 KIT RF DIE DIAMOND 3 PA 943 5510 301 7 31 Table 7 53 KIT XMTR INSTALL 3 P A CAB 994 9751 003 7 32 Table 7 54 TRANSMITTER DHD60P2 994 9815 001 7 32 Table 7 55 KIT RF MYAT DIAMOND 2PA 943 5510 200 7 35 Table 7 56 KIT RF DIE DIAMOND 2 PA 943 5510 201 7 36 Ta...

Page 155: ...190 000 PLUG WHT 500 HOLE 8 0 EA SIDES 358 3203 000 BOLT CARRIAGE 1 2 13X8 2 0 EA SHIPPING SKID 358 3490 000 END STOP 264 TERM BLOCK 4 0 EA PART OF TB3 TB005 358 3491 000 END PLATE 264 TERM BLOCK 2 0 EA PART OF TB3 TB005 358 3669 000 PLATE SEPARATOR 281 4 COND 2 0 EA 1 TB001 1 TB002 398 0552 000 FUSE SLOW CARTRIDGE 10A 250V 2 0 EA F1 A12FL1 F2 A12FL1 402 0200 000 CLIP FUSE 1 INCH 1 0 EA AT001 404 ...

Page 156: ...LR VARIABLE UHF 2 0 EA DC001 IS FOR CABINET DRIVE POWER METER DC002 IS FOR APEX IPA SAMPLE DC001 DC002 646 1353 000 NAMEPLATE XMTR EQUIPMENT 1 0 EA F C C PLATE SECURES TO REAR DOOR OF CONTROL CABINET 746 0248 000 UPS 450VA 120VAC 50 60HZ 1 0 EA A014 827 6893 001 PLATE 4 0 EA GROUNDING PLATES 843 5494 565 WIRING DIAGRAM CTRL CAB HP 0 0 EA 843 5494 606 BLOCK DIAGRAM CAN SYSTEM AR 0 0 EA 852 9219 013...

Page 157: ... 943 5494 320 SHELF AIR SEAL UPPER 1 0 EA UPPER SHELF 943 5494 349 PANEL FRONT UPS RACK MTG 1 0 EA A014 943 5494 359 PLATE CONTROL CABINET SHIM 2 0 EA TO RAISE CABINET 0 25 INCH 943 5494 360 PLATE CONTROL CABINET SHIM 2 0 EA TO RAISE CABINET 0 25 INCH 943 5494 493 COVER FRONT DOOR 2 0 EA 943 5494 494 PLATE FRONT DOOR 1 0 EA 943 5494 496 FOAM FRONT DOOR 1 0 EA 943 5494 508 UPS FRONT INSET PANEL 1 0...

Page 158: ... 0 EA J007 610 1321 000 PLUG 15 PIN D STRAIGHT 2 0 EA J009 J017 612 1131 000 RECEPTACLE 25 POS D 5 0 EA J004 J012 J013 J025 J027 612 1163 000 RECEPTACLE 37 POS D 2 0 EA J002 J003 612 1184 000 SHUNT JUMPER 0 1 CENTERS 1 0 EA 1 JP001 612 1227 000 RCPT 9 PIN D PC MT 5 0 EA J010 J011 J026 J033 J034 612 1341 000 RECP D 15 PIN STRAIGHT 2 0 EA J014 J015 992 9906 002 PWA SYSTEM I O SMT 1 0 EA Table 7 4 CO...

Page 159: ...ption Qty UM Reference Designators M 055 0100 005 THERMAL COMPOUND 8OZ JAR 0 0 EA 300 1485 000 SCR 4 40 X 5 16 2 0 EA 1 U031 1 U041 304 0087 000 NUT HEX 4 40 2 0 EA 1 U031 1 U041 308 0003 000 NO 4 FLAT WASHER BRS 2 0 EA 1 U031 1 U041 312 0045 000 WASHER SPLIT LOCK 4 2 0 EA 1 U031 1 U041 358 1928 000 JUMPER 1 4 LG 1 8H 4 0 EA JP006 JP007 JP008 JP009 382 1638 000 IC 1085CT 5 ESD 1 0 EA U041 382 1639...

Page 160: ...AG PCB MT 2 0 EA F001 F003 404 0513 000 HEAT SINK PA1 1CB 2 0 EA XCR003 XCR004 472 1777 000 XFMR PWR DUAL PRI DUAL SEC 1 0 EA T001 508 0582 000 CAP 0 22UF 630VDC 10 2 0 EA C005 C011 516 0974 000 CAP 1000PF 5 100V C0G 3 0 EA C001 C004 C008 522 0570 000 CAP 2 2UF 50V 20 1 0 EA C014 522 0578 000 CAP 1 0UF 50V 20 2 0 EA C006 C009 542 1603 000 RES 0 01 OHM 3W 1 2 0 EA R010 R011 548 2400 301 RES 1K OHM ...

Page 161: ... 2817 000 SCR THUMB 6 32 X 1 4 2 0 EA COVER RF LOCTITE 358 1214 000 SCREWLOCK FEMALE 1 0 EA LOCTITE 358 2588 000 FLAT CABLE MOUNT 1 0 EA 358 3466 000 END PLATE W FIXING FLANGE 2 0 EA 1 TB001 1 TB002 358 3704 000 SLIDES DRAWER 1 0 EA 398 0552 000 FUSE SLOW CARTRIDGE 10A 250V 2 0 EA FL001 404 0899 003 PAD THERMAL INTERFACE 1 0 EA A002 414 0302 000 CORE FERRITE 1 0 EA W001 424 0017 000 GROMMET 5 16 M...

Page 162: ...signators F 358 1928 000 JUMPER 1 4 LG 1 8H 4 0 EA JP003 JP004 JP005 JP006 382 1643 000 IC MKC03 24D15 DC CONV ESD 1 0 EA U013 384 0880 000 LED GREEN RT ANGLE MTG ESD 1 0 EA DS007 384 0882 000 LED RED RT ANGLE MTG ESD 1 0 EA DS008 522 0640 121 CAP 68UF 50V 20 1 0 EA C021 604 0935 000 SW PB SINGLE SECT 2 0 EA S001 S002 610 0874 000 HEADER UNSHOUDED 6 PIN 1 0 EA J007 610 0900 000 HEADER 3 CKT STRAIG...

Page 163: ...T REAR PA 041 1310 035 GASKET EMI 3 16 MAX COMP 10 0 FT FRONT PA 055 0120 004 CONDUIT LKNUT 5 1 0 EA S001 088 0020 015 TAPE SCOTCH FOAM 0 0 RL 8 FEET REQ D FROM FREE FLOOR STOCK A018 A019 A020 A021 A022 A023 A024 A025 250 0550 013 CABLE ASSY SHORT PWR DISTR 4 0 EA 250 0550 014 CABLE ASSY LONG PWR DISTR 4 0 EA 357 0103 001 MODULE FRONT CLAM SHELL 1 0 EA CONTROLLER 357 0103 003 COVER POWER SUPPLY PA...

Page 164: ...E DIAMOND CABLES 0 0 EA 917 2515 322 CABLE PKG RIBBON PA CABINET 1 0 EA 917 2515 337 CABLE PA CABINET AC MAINS 1 0 EA 917 2515 357 CABLE POWER SUPPLY CONTROL 1 0 EA 917 2515 374 LABEL P A CABINET 12 WAY 1 0 EA 917 2515 376 LABEL PA CABINET 4 8 16 WAY 1 0 EA 917 2515 378 CABLE PA CONTROL 1 0 EA 922 0900 418 BUSHING ALIGNMENT PIN 1 0 EA FOR REAR DOOR ALIGNMENT 922 1300 005 HOOK FRONT PANEL 2 0 EA 92...

Page 165: ...A033 992 9917 001 ASSEMBLY AC DISTRIBUTION 1 0 EA A017 992 9919 001 ASSEMBLY LOW VOLTAGE SUPPLY 1 0 EA A026 992 9980 014 COUPLER RF SAMPLE 1 0 EA DC001 992 9980 021 ASSY DETECTOR 8 WAY 1 0 EA 2ND UNIT A35 IF NEEDED CALLED OUT ON XMTR FORMAT BOM A034 Table 7 21 CONTROLLER CABINET 992 9899 001 Harris PN Description Qty UM Reference Designators E 448 0815 000 HINGE ADJUSTABLE BLACK 2 0 EA 943 5494 14...

Page 166: ...15 PIN STRAIGHT 1 0 EA J006 843 5504 071 SCH AMPLIFIER MODULE BACKPLANE0 0 EA 843 5504 073 PWB AMPLIFIER MODULE BACKPLANE1 0 EA Table 7 24 ASSY 4 SECTION RF DETECTOR 992 9916 001 Harris PN Description Qty UM Reference Designators F 308 0009 000 25 FLAT WASHER BRS 4 0 EA USED ON J1 J4 358 1214 000 SCREWLOCK FEMALE 1 0 EA 939 8210 058 HOUSING DETECTOR 1 0 EA 992 9921 001 PWA 4 SECTION RF DETECTOR 1 ...

Page 167: ...7 27 PA MODULE 600W 470 550MHZ 992 9898 005 Harris PN Description Qty UM Reference Designators H 817 2416 242 PA MODULE SPEC BAND A 600W 0 0 EA 943 5494 149 DIVIDER EMI SHIELD 1 0 EA A007 992 9898 011 MODULE BASIC PA 1 0 EA 992 9909 001 PWA PA PALLET SPLTR BAND A B 1 0 EA A007 992 9975 001 PWA PALLET BAND A 6 0 EA A008 A009 A010 A011 A012 A013 992 9975 002 PWA BAND A DRIVER PALLET 1 0 EA A005 992 ...

Page 168: ...HZ 994 9782 003 Harris PN Description Qty UM Reference Designators C 252 0465 000 WIRE RIBBON 5 X 50 MIL 0 FT USED TO SOLDER RF OUT RF IN ON A5 A8 A13 404 0899 003 PAD THERMAL INTERFACE 1 0 EA A5 A8 A13 817 2515 032 REPLACE INSTRUCT PA PALLET 1 0 EA 992 9973 001 PWA PALLET BAND D 1 0 EA USED AS A5 A8 A13 Table 7 33 KIT SPARE PALLET 470 550MHZ 994 9782 004 Harris PN Description Qty UM Reference Des...

Page 169: ...3 5494 353 WIRING DIAG POWER SUPPLY 0 0 EA 917 2515 355 CABLE PKG POWER SUPPLY 1 0 EA 943 5494 282 PANEL FRONT POWER SUPPLY 1 0 EA 943 5494 284 BRACKET CIRCUIT BREAKER 1 0 EA CB001 943 5494 291 SCREW SHOULDER 6 32 4 0 EA 2 J001 2 J002 943 5494 529 CHASSIS HALF PS 2 0 EA Table 7 38 PWA MOV AC 198 250 VAC 992 8553 001 Harris PN Description Qty UM Reference Designators E 296 0345 000 TUBING SHRINKABL...

Page 170: ...25 000 LATCH RAISED ADJ LEVER 3 0 EA FOR REAR DOOR 843 4999 072 CLAMP FILTER SUPPORT 2 0 EA 917 2100 082 CABLE MOTOR PA 1 0 EA B001 917 2515 027 ANGLE FAN GUARD MOUNTING 4 0 EA 922 0900 402 BLOCK HINGE REAR DOOR 3 0 EA 922 0900 407 PIN ALIGNMENT 1 0 EA FOR REAR DOOR ALIGNMENT 943 4999 073 MODIFICATION VENTURI 1 0 EA PART OF B001 943 4999 428 CLAMP FILTER CENTER 1 0 EA 943 4999 429 CLAMP FILTER END...

Page 171: ...ITS OF PART NUMBER INDICATES CHANNEL XX US CHANNELS 14 69 484 0510 000 FILTER UHF DTV ABSORBATIVE 0 0 EA 1 REQ D USED WHEN VENDOR PASSIVE POWER IS SPECIFIED TO BE ORDERED FROM SCHEDULE A LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL XX US CHANNELS 14 69 484 0513 000 FILTER UHF DTV REFLECTIVE 0 0 EA 1 REQ D USED WHEN VENDOR DIELECTRIC IS SPECIFIED TO BE ORDERED FROM SCHEDULE A LAST TWO DIGITS OF...

Page 172: ...UHF 1000W 0 0 EA 80 REQ D FOR 701 860 MHZ 2CIR1 2CIR16 3CIR1 3CIR16 4CIR1 4CIR16 5CIR1 5CIR16 6CIR1 6CIR16 620 3065 001 SPLITTER POWER 16 WAY 0 0 EA 5 REQ D FOR 470 638MHZ 2A31 3A31 4A31 5A31 6A31 620 3065 002 SPLITTER POWER 16 WAY 0 0 EA 5 REQ D FOR 636 860MHZ 2A31 3A31 4A31 5A31 6A31 620 3077 001 SPLITTER UHF RF 5 WAY 0 0 EA 1 REQ D FOR 470 638 MHZ 1A10 620 3077 002 SPLITTER UHF RF 5 WAY 0 0 EA ...

Page 173: ...WA MOV AC 198 250 VAC 0 0 EA 5 REQ D THIS VOLTAGE 2A17A1 3A17A1 4A17A1 5A17A1 6A17A1 992 8553 005 PWA MOV AC 384 552VAC 0 0 EA 5 REQ D THIS VOLTAGE 2A17A1 3A17A1 4A17A1 5A17A1 6A17A1 992 9896 005 CABINET BASIC CONTROL HP AR 1 0 EA UNIT 1 992 9897 020 CABINET BASIC H P PA 5 0 EA UNIT 2 3 4 5 6 992 9898 005 PA MODULE 600W 470 550MHZ 0 0 EA 80 REQ D THIS FREQUENCY 2A1 2A16 3A1 3A16 4A1 4A16 5A1 5A16 ...

Page 174: ...INGLE EXCITER IS ORDERED 994 9749 001 KIT REAR DOOR AIR 5 0 EA FAN MOTOR IS VOLTAGE DEPENDENT KIT IS USED ON PA CABINET 994 9749 002 KIT EXTERNAL AIR 0 0 EA OPTION 5 REQ D REPLACES 994 9749 001 KIT IS USED ON PA CABINET 994 9751 005 KIT XMTR INSTALL 5 P A CAB 0 0 EA 1 REQ D ADD AS A LINE ITEM MISC INSTALLATION MATERIALS TO INSTALL TRANSMITTER 994 9752 005 KIT 208 240V SPARE PARTS 0 0 EA OPTION 1 R...

Page 175: ... Reference Designators X 484 0507 000 FILTER UHF DTV REFLECTIVE 0 0 EA 1 REQ D USED WHEN VENDOR PASSIVE POWER IS SPECIFIED TO BE ORDERED FROM SCHEDULE A LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL XX US CHANNELS 14 69 484 0510 000 FILTER UHF DTV ABSORBATIVE 0 0 EA 1 REQ D USED WHEN VENDOR PASSIVE POWER IS SPECIFIED TO BE ORDERED FROM SCHEDULE A LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL...

Page 176: ... 007 CIRCULATOR UHF 1000W 0 0 EA 64 REQ D FOR 701 860 MHZ 2CIR1 2CIR16 3CIR1 3CIR16 4CIR1 4CIR16 5CIR1 5CIR16 620 3065 001 SPLITTER POWER 16 WAY 0 0 EA 4 REQ D FOR 470 638MHZ 2A31 3A31 4A31 5A31 620 3065 002 SPLITTER POWER 16 WAY 0 0 EA 4 REQ D FOR 636 860MHZ 2A31 3A31 4A31 5A31 620 3076 001 SPLITTER UHF RF 4 WAY 0 0 EA 1 REQ D FOR 470 638 MHZ 1A10 620 3076 002 SPLITTER UHF RF 4 WAY 0 0 EA 1 REQ D...

Page 177: ...53 005 PWA MOV AC 384 552VAC 0 0 EA 4 REQ D THIS VOLTAGE 2A17A1 3A17A1 4A17A1 5A17A1 992 9896 005 CABINET BASIC CONTROL HP AR 1 0 EA UNIT 1 992 9897 020 CABINET BASIC H P PA 4 0 EA UNIT 2 3 4 5 992 9898 005 PA MODULE 600W 470 550MHZ 0 0 EA 64 REQ D THIS FREQUENCY 2A1 2A16 3A1 3A16 4A1 4A16 5A1 5A16 992 9898 006 PA MODULE 600W 547 638MHZ 0 0 EA 64 REQ D THIS FREQUENCY 2A1 2A16 3A1 3A16 4A1 4A16 5A1...

Page 178: ... AIR 0 0 EA OPTION 4 REQ D REPLACES 994 9749 001 KIT IS USED ON PA CABINET 994 9751 004 KIT XMTR INSTALL 4 P A CAB 0 0 EA 1 REQ D ADD AS A LINE ITEM MISC INSTALLATION MATERIALS TO INSTALL TRANSMITTER 994 9752 005 KIT 208 240V SPARE PARTS 0 0 EA OPTION 1 REQ D FOR 208 240V XMTR 994 9752 006 KIT 430 480V SPARE PARTS 0 0 EA OPTION 1 REQ D FOR 430 480V XMTR 994 9782 002 KIT SPARE PALLET 636 741MHZ 0 0...

Page 179: ...6 1 8 EIA 10 0 EA 620 1238 000 FLANGE FIXED 3 1 8 EIA 24 0 EA 620 2589 000 FIXED FLANGE 6 1 8 EIA 10 0 EA 843 5510 400 LAYOUT RF EQUIPMENT DHD120P4 0 0 EA 994 8442 001 KIT PROBE 1 50 6 1 8 LINE 2 0 EA 994 8442 005 KIT PROBE 1 125 3 1 8 LINE 4 0 EA Table 7 49 KIT XMTR INSTALL 4 P A CAB 994 9751 004 Harris PN Description Qty UM Reference Designators D 003 4010 045 CU STRAP 020 X 2 130 0 FT GROUND SY...

Page 180: ... FUEL AND VENDOR ANDREW PPP IS SPECIFIED LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL XX US CHANNELS 14 69 484 0528 000 FILTER UHF DTV ABSORBATIVE 0 0 EA 1 REQ D USED WHEN STF COOL FUEL AND VENDOR DIELECTRIC IS SPECIFIED LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL XX US CHANNELS 14 69 484 0531 000 FILTER UHF DTV REFLECTIVE 0 0 EA 1 REQ D USED WHEN STF COOL FUEL AND VENDOR ANDREW PPP IS SP...

Page 181: ...AX 3PA 1 0 EA 939 8210 092 SCH LIST BASIC DIAMOND HP 0 0 EA COMMON DOCUMENTATION FOR ALL XMTR POWER LEVELS 939 8210 127 SCHEMATIC LIST DHD90P3 0 0 EA XMTR POWER LEVEL DEPENDENT DOCUMENTATION 943 5510 202 4 1 16 TEST LOAD LINE KIT MYAT 0 0 EA OPTION 1 REQ D IF MYAT RF COMPONETS ARE REQUESTED SUFFICIENT QUANTITIES TO CONNECT FROM THE PA CABINETS TO THE DTV MASK FILTER 943 5510 203 4 1 16 TEST LOAD L...

Page 182: ...ENCY ONE REQUIRED 1A8 WITH SINGLE EXCITER TWO REQUIRED 1A8 1A9 WITH DUAL EXCITER 992 9914 002 DRIVER 547 TO 638 MHZ DD1 0 0 EA OPTION THIS FREQUENCY ONE REQUIRED 1A8 WITH SINGLE EXCITER TWO REQUIRED 1A8 1A9 WITH DUAL EXCITER 992 9914 003 DRIVER 636 TO 741 MHZ DD1 0 0 EA OPTION THIS FREQUENCY ONE REQUIRED 1A8 WITH SINGLE EXCITER TWO REQUIRED 1A8 1A9 WITH DUAL EXCITER 992 9914 004 DRIVER 736 TO 860 ...

Page 183: ...rence Designators D 618 0378 000 LINE XMISSION 3 1 8 3 0 EA 618 0626 000 XMSN LINE 4 1 16 20 1 0 EA 620 0544 000 CONN ANCHOR INS 3 1 8 50 OHM 9 0 EA 620 0637 000 FLANGE FXD 3 1 8 CU 18 0 EA 620 0908 000 HARDWARE KIT 3 1 8 16 0 EA 620 1893 000 ELBOW 90 DEG 3 1 8 6 0 EA 620 2137 000 CONN 4 1 16 ANCHOR INS 5 0 EA 620 2142 000 ELBOW 4 1 16 90 DEG 3 0 EA 620 2172 000 HARDWARE SET 4 1 16 9 0 EA 620 2393...

Page 184: ...Reference Designators V 484 0505 000 FILTER UHF DTV REFLECTIVE 0 0 EA 1 REQ D USED WHEN VENDOR PASSIVE POWER IS SPECIFIED TO BE ORDERED FROM SCHEDULE A LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL XX US CHANNELS 14 69 484 0508 000 FILTER UHF DTV ABSORBATIVE 0 0 EA 1 REQ D USED WHEN VENDOR PASSIVE POWER IS SPECIFIED TO BE ORDERED FROM SCHEDULE A LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL ...

Page 185: ... FOR 596 704 MHZ CIR1 CIR16 3CIR1 3CIR16 620 2957 007 CIRCULATOR UHF 1000W 0 0 EA 32 REQ D FOR 701 860 MHZ CIR1 CIR16 3CIR1 3CIR16 620 3034 000 COMBINER 3DB HYB 470 638MHZ 0 0 EA 1 REQ D FOR 470 638MHZ COMBINES 2 PA CABINETS RF OUTPUT PORTS 620 3035 000 COMBINER 3DB HYB 636 860MHZ 0 0 EA 1 REQ D FOR 636 860MHZ COMBINES 2 PA CABINETS RF OUTPUT PORTS 620 3065 001 SPLITTER POWER 16 WAY 0 0 EA 2 REQ D...

Page 186: ... TWO DIGITS OF PART NUMBER INDICATES CHANNEL XX US CHANNELS 14 69 992 8553 001 PWA MOV AC 198 250 VAC 0 0 EA 2 REQ D THIS VOLTAGE 2A17A1 3A17A1 992 8553 005 PWA MOV AC 384 552VAC 0 0 EA 2 REQ D THIS VOLTAGE 2A17A1 3A17A1 992 9896 005 CABINET BASIC CONTROL HP AR 1 0 EA UNIT 1 992 9897 020 CABINET BASIC H P PA 2 0 EA UNIT 2 3 992 9898 005 PA MODULE 600W 470 550MHZ 0 0 EA 32 REQ D THIS FREQUENCY 2A1 ...

Page 187: ...AS A LINE ITEM MISC INSTALLATION MATERIALS TO INSTALL TRANSMITTER 994 9752 005 KIT 208 240V SPARE PARTS 0 0 EA OPTION 1 REQ D FOR 208 240V XMTR 994 9752 006 KIT 430 480V SPARE PARTS 0 0 EA OPTION 1 REQ D FOR 208 240V XMTR 994 9782 002 KIT SPARE PALLET 636 741MHZ 0 0 EA OPTION 1 REQ D FOR 636 741MHZ 994 9782 003 KIT SPARE PALLET 736 860MHZ 0 0 EA OPTION 1 REQ D FOR 736 860MHZ 994 9782 004 KIT SPARE...

Page 188: ...ELBOW 90 DEG EQUAL LEG 3 0 EA Table 7 57 KIT XMTR INSTALL 2 P A CAB 994 9751 002 Harris PN Description Qty UM Reference Designators D 003 4010 045 CU STRAP 020 X 2 110 0 FT GROUND SYSTEM 252 0003 000 WIRE STRD 20AWG WHT 100 0 FT 253 0059 000 CABLE 2C 22AWG AUDIO 50 0 FT 354 0005 000 TERM LUG RED SPADE 6 30 0 EA 354 0384 000 CONTACT PIN 80 0 EA 610 0762 000 354 0385 000 CONTACT SOCKET 40 0 EA 612 0...

Page 189: ...NEL XX US CHANNELS 14 69 484 0530 000 FILTER UHF DTV REFLECTIVE 0 0 EA 1 REQ D USED WHEN STF COOL FUEL AND VENDOR ANDREW PPP IS SPECIFIED LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL XX US CHANNELS 14 69 484 0533 000 FILTER UHF DTV REFLECTIVE 0 0 EA 1 REQ D USED WHEN STF COOL FUEL AND VENDOR DIELECTRIC IS SPECIFIED LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL XX US CHANNELS 14 69 556 0058 ...

Page 190: ... LIST DHD45P2 0 0 EA XMTR POWER LEVEL DEPENDENT DOCUMENTATION 943 5494 654 TRANSLATION RIBBON PKG 2 0 EA ADAPTER CABLES FOR PA CONTROLER USED WITH 12 WAY ONLY 943 5510 102 3 1 8 TEST LOAD LINE KIT MYAT 0 0 EA OPTION 1 REQ D IF MYAT RF COMPONETS ARE REQUESTED SUFFICIENT QUANTITIES TO CONNECT THE OUTPUT OF THE DTV MASK FILTER TO THE TEST LOAD THROUGH THE PATCH PANEL OR COAX SWITCH 943 5510 103 3 1 8...

Page 191: ... 2A23 2A25 3A19 3A21 3A23 3A25 992 9914 001 DRIVER 470 TO 550 MHZ DD1 0 0 EA OPTION THIS FREQUENCY ONE REQUIRED 1A8 WITH SINGLE EXCITER TWO REQUIRED 1A8 1A9 WITH DUAL EXCITER 992 9914 002 DRIVER 547 TO 638 MHZ DD1 0 0 EA OPTION THIS FREQUENCY ONE REQUIRED 1A8 WITH SINGLE EXCITER TWO REQUIRED 1A8 1A9 WITH DUAL EXCITER 992 9914 003 DRIVER 636 TO 741 MHZ DD1 0 0 EA OPTION THIS FREQUENCY ONE REQUIRED ...

Page 192: ... 1 CD1A PERMISSIBLE 994 9912 001 EXCITER APEX 0 0 EA OPTION ORDER 1 OR 2 EXCITERS AS REQUIRED 1APEX W 1 CD1A PERMISSIBLE Table 7 59 KIT 4 BLANK MOD P S 994 9783 002 Harris PN Description Qty UM Reference Designators K 357 0103 001 MODULE FRONT CLAM SHELL 4 0 EA PART OF BLANK MODULE ASS Y 358 3190 000 PLUG WHT 500 HOLE 8 0 EA 943 5494 484 BLANK PANEL P S 2 0 EA PART OF BLANK P S ASS Y 943 5494 485 ...

Page 193: ...AY STRIPLINE COMBINER 992 9898 005 PA MODULE 600W 470 550MHZ 0 0 EA 4 REQ D THIS FREQUENCY 992 9898 006 PA MODULE 600W 547 638MHZ 0 0 EA 4 REQ D THIS FREQUENCY 992 9898 007 PA MODULE 600W 636 741MHZ 0 0 EA 4 REQ D THIS FREQUENCY 992 9898 008 PA MODULE 600W 736 806MHZ 0 0 EA 4 REQ D THIS FREQUENCY 992 9900 007 ASSY PWR SUPPLY 240VAC 5KW 0 0 EA 2 REQ D THIS VOLTAGE 992 9900 008 ASSY PWR SUPPLY 480VA...

Page 194: ...REQ D USED WHEN STF COOL FUEL AND VENDOR DIELECTRIC IS SPECIFIED LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL XX US CHANNELS 14 69 484 0530 000 FILTER UHF DTV REFLECTIVE 0 0 EA 1 REQ D USED WHEN STF COOL FUEL AND VENDOR ANDREW PPP IS SPECIFIED LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL XX US CHANNELS 14 69 484 0533 000 FILTER UHF DTV REFLECTIVE 0 0 EA 1 REQ D USED WHEN STF COOL FUEL AND ...

Page 195: ...ECT THE OUTPUT OF THE DTV MASK FILTER TO THE TEST LOAD THROUGH THE PATCH PANEL OR COAX SWITCH 943 5510 103 3 1 8 TEST LOAD LINE KIT DIE 0 0 EA OPTION 1 REQ D IF DIELECTRIC RF COMPONETS ARE REQUESTED SUFFICIENT QUANTITIES TO CONNECT THE OUTPUT OF THE DTV MASK FILTER TO THE TEST LOAD THROUGH THE PATCH PANEL OR COAX SWITCH 988 0022 483 DHD BASIC CNSLD SYSTEM 0 0 EA DO NOT SHIP FOR IN HOUSE CUSTOMER T...

Page 196: ...6 WAY 1 0 EA 992 9980 021 ASSY DETECTOR 8 WAY 1 0 EA 2ND UNIT A34 PART OF BASIC PA CABINET 2A35 994 9746 002 KIT SINGLE EXCITER 0 0 EA OPTION 1 REQ D WHEN SINGLE EXCITER IS ORDERED 994 9749 001 KIT REAR DOOR AIR 1 0 EA FAN MOTOR IS VOLTAGE DEPENDENT KIT IS USED ON PA CABINET 994 9749 002 KIT EXTERNAL AIR 0 0 EA OPTION 1 REQ D REPLACES 994 9749 001 KIT IS USED ON PA CABINET 994 9751 001 KIT XMTR IN...

Page 197: ...5 KIT PROBE 1 125 3 1 8 LINE 2 0 EA Table 7 64 KIT XMTR INSTALL 1 P A CAB 994 9751 001 Harris PN Description Qty UM Reference Designators D 003 4010 045 CU STRAP 020 X 2 100 0 FT GROUND SYSTEM 252 0003 000 WIRE STRD 20AWG WHT 100 0 FT 253 0059 000 CABLE 2C 22AWG AUDIO 50 0 FT 354 0005 000 TERM LUG RED SPADE 6 30 0 EA 354 0384 000 CONTACT PIN 80 0 EA 610 0762 000 354 0385 000 CONTACT SOCKET 40 0 EA...

Page 198: ...F PART NUMBER INDICATES CHANNEL XX US CHANNELS 14 69 484 0530 000 FILTER UHF DTV REFLECTIVE 0 0 EA 1 REQ D USED WHEN STF COOL FUEL AND VENDOR ANDREW PPP IS SPECIFIED LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL XX US CHANNELS 14 69 484 0533 000 FILTER UHF DTV REFLECTIVE 0 0 EA 1 REQ D USED WHEN STF COOL FUEL AND VENDOR DIELECTRIC IS SPECIFIED LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL XX...

Page 199: ...1 PA 0 0 EA OPTION 1 REQ D IF DIELECTRIC RF COMPONETS ARE REQUESTED SUFFICIENT QUANTITIES TO CONNECT FROM THE PA CABINET TO THE DTV MASK FILTER 943 5510 102 3 1 8 TEST LOAD LINE KIT MYAT 0 0 EA OPTION 1 REQ D IF MYAT RF COMPONETS ARE REQUESTED SUFFICIENT QUANTITIES TO CONNECT THE OUTPUT OF THE DTV MASK FILTER TO THE TEST LOAD THROUGH THE PATCH PANEL OR COAX SWITCH 943 5510 103 3 1 8 TEST LOAD LINE...

Page 200: ...LE EXCITER TWO REQUIRED 1A8 1A9 WITH DUAL EXCITER 992 9914 004 DRIVER 736 TO 860 MHZ DD1 0 0 EA OPTION THIS FREQUENCY ONE REQUIRED 1A8 WITH SINGLE EXCITER TWO REQUIRED 1A8 1A9 WITH DUAL EXCITER 992 9916 001 ASSY 4 SECTION RF DETECTOR 1 0 EA 1A013 PA CABINET DEPENDENT 1 REQ D FOR 1 2 PA CABINETS 992 9980 018 COMBINER 12 WAY 1 0 EA 992 9980 021 ASSY DETECTOR 8 WAY 1 0 EA 2ND ASSY A34 PART OF BASIC P...

Page 201: ...3 1 8 50 OHM 3 0 EA 620 0637 000 FLANGE FXD 3 1 8 CU 6 0 EA 620 0908 000 HARDWARE KIT 3 1 8 6 0 EA 620 1893 000 ELBOW 90 DEG 3 1 8 2 0 EA 994 8442 005 KIT PROBE 1 125 3 1 8 LINE 2 0 EA Table 7 67 TRANSMITTER DHD15P1 994 9811 001 Harris PN Description Qty UM Reference Designators V 484 0505 000 FILTER UHF DTV REFLECTIVE 0 0 EA 1 REQ D USED WHEN VENDOR PASSIVE POWER IS SPECIFIED TO BE ORDERED FROM S...

Page 202: ...OL CABINET RTAC SAMPLE AT6 AT7 556 0158 000 ATTENUATOR 6DB 5W 1 0 EA 1AT3 620 0122 000 ADAPTER N PLUG N JACK RT ANG 1 0 EA 1AT3 620 2957 004 CIRCULATOR UHF 1000W 0 0 EA 8 REQ D FOR 470 518 MHZ CIR1 CIR8 620 2957 005 CIRCULATOR UHF 1000W 0 0 EA 8 REQ D FOR 518 598 MHZ CIR1 CIR8 620 2957 006 CIRCULATOR UHF 1000W 0 0 EA 8 REQ D FOR 596 704 MHZ CIR1 CIR8 620 2957 007 CIRCULATOR UHF 1000W 0 0 EA 8 REQ ...

Page 203: ... OF PART NUMBER INDICATES CHANNEL XX US CHANNELS 14 69 992 8553 001 PWA MOV AC 198 250 VAC 0 0 EA 1 REQ D THIS VOLTAGE 2A17A1 992 8553 005 PWA MOV AC 384 552VAC 0 0 EA 1 REQ D THIS VOLTAGE 2A17A1 992 9896 005 CABINET BASIC CONTROL HP AR 1 0 EA UNIT 1 992 9897 020 CABINET BASIC H P PA 1 0 EA UNIT 2 992 9898 005 PA MODULE 600W 470 550MHZ 0 0 EA 8 REQ D THIS FREQUENCY 2A1 2A8 992 9898 006 PA MODULE 6...

Page 204: ...0 EA OPTION 1 REQ D FOR 430 480V XMTR 994 9782 002 KIT SPARE PALLET 636 741MHZ 0 0 EA OPTION 1 REQ D FOR 636 741MHZ 994 9782 003 KIT SPARE PALLET 736 860MHZ 0 0 EA OPTION 1 REQ D FOR 736 860MHZ 994 9782 004 KIT SPARE PALLET 470 550MHZ 0 0 EA OPTION 1 REQ D FOR 470 550MHZ 994 9782 005 KIT SPARE PALLET 547 638MHZ 0 0 EA OPTION 1 REQ D FOR 547 638MHZ 994 9783 002 KIT 4 BLANK MOD P S 2 0 EA BLANKS TO ...

Page 205: ...0 0 EA 1 REQ D FOR UPGRADE TO 12 WAY STRIPLINE COMBINER 992 9898 005 PA MODULE 600W 470 550MHZ 0 0 EA 8 REQ D THIS FREQUENCY 992 9898 006 PA MODULE 600W 547 638MHZ 0 0 EA 8 REQ D THIS FREQUENCY 992 9898 007 PA MODULE 600W 636 741MHZ 0 0 EA 8 REQ D THIS FREQUENCY 992 9898 008 PA MODULE 600W 736 806MHZ 0 0 EA 8 REQ D THIS FREQUENCY 992 9900 007 ASSY PWR SUPPLY 240VAC 5KW 0 0 EA 4 REQ D THIS VOLTAGE ...

Page 206: ... IS SPECIFIED LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL XX US CHANNELS 14 69 484 0530 000 FILTER UHF DTV REFLECTIVE 0 0 EA 1 REQ D USED WHEN STF COOL FUEL AND VENDOR ANDREW PPP IS SPECIFIED LAST TWO DIGITS OF PART NUMBER INDICATES CHANNEL XX US CHANNELS 14 69 484 0533 000 FILTER UHF DTV REFLECTIVE 0 0 EA 1 REQ D USED WHEN STF COOL FUEL AND VENDOR DIELECTRIC IS SPECIFIED LAST TWO DIGITS OF P...

Page 207: ... 5510 100 KIT RF MYAT DIAMOND 1PA 0 0 EA OPTION 1 REQ D IF MYAT RF COMPONETS ARE REQUESTED SUFFICIENT QUANTITIES TO CONNECT FROM THE PA CABINET TO THE DTV MASK FILTER 943 5510 101 KIT RF DIE DIAMOND 1 PA 0 0 EA OPTION 1 REQ D IF DIELECTRIC RF COMPONETS ARE REQUESTED SUFFICIENT QUANTITIES TO CONNECT FROM THE PA CABINET TO THE DTV MASK FILTER 943 5510 102 3 1 8 TEST LOAD LINE KIT MYAT 0 0 EA OPTION ...

Page 208: ...S VOLTAGE DEPENDENT KIT IS USED ON PA CABINET 994 9749 002 KIT EXTERNAL AIR 0 0 EA OPTION 1 REQ D REPLACES 994 9749 001 KIT IS USED ON PA CABINET 994 9751 001 KIT XMTR INSTALL 1 P A CAB 0 0 EA 1 REQ D ADD AS A LINE ITEM MISC INSTALLATION MATERIALS TO INSTALL TRANSMITTER 994 9752 005 KIT 208 240V SPARE PARTS 0 0 EA OPTION 1 REQ D FOR 208 240V XMTR 994 9752 006 KIT 430 480V SPARE PARTS 0 0 EA OPTION...

Page 209: ...07 CIRCULATOR UHF 1000W 0 0 EA 12 REQ D FOR 701 860 MHZ 620 3065 001 SPLITTER POWER 16 WAY 0 0 EA 1 REQD FOR 470 638MHZ 2A31 620 3065 002 SPLITTER POWER 16 WAY 0 0 EA 1 REQ D FOR 636 860MHZ 2A31 700 1413 000 ATTENUATOR 40DB 1KW 12 0 EA 917 2515 354 CABLE SPLITTER TO MODULE 12 0 EA 939 8210 015 COAX CIRCULATOR ATTN 12 0 EA 943 5494 069 MOUNTING SCREW PA REJECT SINK 24 0 EA 943 5494 249 PLATE AIR BA...

Page 210: ...7 58 888 2463 001 7 08 03 WARNING Disconnect primary power prior to servicing Section 7 Parts List Diamond Series ...

Page 211: ...in Table A 1 are some tools and materials that have proven effective for RF Feed Line Construction A 2 Transmission Line Cutting and Flange Soldering Procedure a Determine the flange face to flange face length of the transmission line run needed If the run includes an elbow see Figure A 2 to determine the elbow length b Subtract twice the cutback dimension of the flange This dimension varies with ...

Page 212: ...ert the inner conductor The line is ready to install Table A 1 Installation Tools and Materials Welding Torch Set Chalk Line Oxygen and Acetylene Tanks Hacksaw and Extra Blades Welder s Mask or Goggles Wrenches Power Band Saw can be rented and Extra Blades Crowbar Silver Solder 1 16 inch diameter 30 45 Hard Stay Silv 45 Aladdin 45 HARRIS part number 099 0002 238 Rope Paste flux Engelhard Ultra Flu...

Page 213: ...3 6 08 888 2463 001 A 3 WARNING Disconnect primary power prior to servicing Appendix A Cutting and Soldering Diamond Series Figure A 1 Outer Conductor Measurements ...

Page 214: ...isconnect primary power prior to servicing Diamond Series Appendix A Cutting and Soldering Figure A 2 Measurements When Elbows Are Used Figure A 3 Measurements for Cutback of Inner Conductor Figure A 4 Guide for Use with Hand Hack Saw ...

Page 215: ...3 6 08 888 2463 001 A 5 WARNING Disconnect primary power prior to servicing Appendix A Cutting and Soldering Diamond Series Figure A 5 Cutting with Hand Band Saw ...

Page 216: ...A 6 888 2463 001 3 6 08 WARNING Disconnect primary power prior to servicing Diamond Series Appendix A Cutting and Soldering Figure A 6 Swing Arm Band Saw Cutting Tips ...

Page 217: ...463 001 A 7 WARNING Disconnect primary power prior to servicing Appendix A Cutting and Soldering Diamond Series Figure A 7 Crimped Cut Exaggerated Figure A 8 Bevel and Remove Burrs Figure A 9 Torch Aiming Location ...

Page 218: ...t creeping and the saw is in alignment See Figure A 6 CAUTION DO NOT OVER TIGHTEN THE VISE USED WITH THESE SAWS IT WILL BE DIFFICULT TO PUT THE FLANGE ON AN OUT OF ROUND PIPE d METHOD 4 Tubing Cutter This is generally not recommended Many cuts end up with crimped ends due to dull cutters or trying to cut too fast Use with cau tion Avoid if possible unless someone is available that has had a lot of...

Page 219: ...N f Stand the line on end vertical for soldering flange to be soldered pointing down Ensure that the flange remains square with the outer conductor g Using a 3 or 4 torch tip heat the entire circumference of the line and flange Keep the torch moving and heat 2 or 3 inches of the line flange at a time Aim the torch at the copper just above the crack between the flange and the line This will minimiz...

Page 220: ...IXING PROCEDURE ALWAYS PUT WATER IN THE CON TAINER FIRST AND THEN ADD ACID TO THE WATER ADDING WATER TO A CON TAINER OF ACID MAY RESULT IN A VIOLENT DANGEROUS REACTION a Prepare three plastic 5 gallon buckets as follows 1 Bucket 1 Water 2 Bucket 2 One quart muriatic acid in four gallons of water SEE WARN INGS ABOVE 3 Bucket 3 One pound baking soda in five gallons of water b After soldering is fini...

Page 221: ...D EMERGENCY PROCEDURES ON THE NAVAL JELLY CONTAINER BEFORE USING 0 a After soldering the flange dip the end of the line into water or spray it with a hose until it is cool b Using a small paint brush apply a coating of Naval Jelly to the torch black and flux scale on the outside and inside of the line Let the Naval Jelly set from 10 to 20 minutes c Scrub the line with Scotch Brite or the BBQ Grill...

Page 222: ...A 12 888 2463 001 3 6 08 WARNING Disconnect primary power prior to servicing Diamond Series Appendix A Cutting and Soldering ...

Page 223: ... in the case of a direct lightning strike However surge protectors installed immediately after the main power disconnect switch in the power distribution panel will afford some protection from electrical surges induced in the power lines Surge protection devices are designed to operate and recover automatically When operated within specifications a surge protector does not require testing adjustme...

Page 224: ...t levels less than 500 microvolts making them susceptible to noise appearing on ground wires or adjacent wiring Thus all ground wiring must be low in impedance as well as low in resistance without splices and as direct as possible Four basic grounds are required a AC ground b DC ground c Earth ground d RF ground B 2 1 Ground Wires Ground wires should be at least as large as specified by the local ...

Page 225: ...late Where excessive high frequency noise on the AC ground is a problem a metal plate having an area of at least 10 square feet embedded in concrete and connected to the AC ground will assist in noise suppression The connection to AC ground should be shorter than 5 feet as direct as possible and without splices Local wiring codes will dictate the minimum wire size to be used Peripheral Equipment G...

Page 226: ...tage differentials on the ground plane to below levels which will produce noise or interference to communication circuits The basic earth electrode subsystem consist of driven ground rods uniformly spaced around the facility interconnected with a minimum of 1 0 AWG bare copper cable The cable and rods should be placed approximately 40 inches 1 meter outside the roof drip line of the structure and ...

Page 227: ... plane with a copper strap RF transmission line from the antenna must be grounded at the entry point to the building with copper wire or strap equivalent to at least no 6 AWG Wire braid or fine stranded wire must not be used All building main metallic structural members such as columns wall frames roof trusses and other metal structures must be made electrically continuous and grounded to the faci...

Page 228: ...B 6 888 2463 001 3 6 08 WARNING Disconnect primary power prior to servicing Diamond Series Appendix B Surge Lightning and ...

Page 229: ... primary power prior to servicing Diamond Series Appendix C Pioneer Power Supply Manual C This section contains the Pioneer Magnetics 32 Vdc power supply manual It contains information regarding power supply installation maintenance and repair ...

Page 230: ...C 2 888 2463 001 3 6 08 WARNING Disconnect primary power prior to servicing Diamond Series Appendix C Pioneer Power Supply ...

Page 231: ...isconnect primary power prior to servicing Appendix C Pioneer Power Supply Diamond Series PM33215F 8 Instructional Manual Rev 3 4 23 2007 1 Instruction Manual Model PM33215F 8 Type Number 32D157 156A 240 480VAC Single Phase Strappable ...

Page 232: ...ents Pioneer Magnetics Inc 1745 Berkeley Street Santa Monica California 90404 Telephone 310 829 6751 Fax 310 453 3929 E mail pmi pioneermagnetics com Web www pioneermagnetics com This manual is the proprietary property of Pioneer Magnetics It is submitted under a confidential relationship with Harris Corporation for the purpose of including this material into their Diamond Transmitter Documentatio...

Page 233: ...ental 4 Section 4 Installation Procedure 4 Section 5 Description 5 x Series and Parallel Configurations 5 x Working Block Diagram 6 x Theory of Operation 7 Section 6 Specifications 9 Section 7 Outline Drawing and Mounting 11 Section 8 I O Interface Connections 12 Section 9 Quick Bench Testing 13 Section 10 Replacing AC Input Fuses 16 Section 11 Replacing Fan Assembly 20 Section 12 Ordering Parts f...

Page 234: ... voltage and current of the Power Supply is hazardous to untrained personnel Exercise caution when connecting and energizing the power supply Section 3 Environmental The power supply is intended for use in commercial and industrial controlled environments and is designed to meet UL requirements for Pollution Degree 2 A reasonably dust proof enclosure is recommended Section 4 Installation Procedure...

Page 235: ...ly is specifically designed for applications that require either 240VAC or 480VAC Single Phase AC Input The AC Input connection is strappable for either 240VAC or 480VAC as shown in Fig 1 below N N AC INPUT GND L AC INPUT N L G L N G L GND N L G Vadj N L G INPUT WIRING DIAGRAM FOR 480 VAC INPUT NPUT WIRING PUT I DIAGRAM FOR 240 VAC IN Vadj J5A J5A INPUT WIRING DIAGRAM FOR 208 240VAC Jumpers Jumper...

Page 236: ... 001 3 6 08 WARNING Disconnect primary power prior to servicing Diamond Series Appendix C Pioneer Power Supply PM33215F 8 Instructional Manual Rev 3 4 23 2007 6 Fig 2 Working Block Diagram for the Model PM33215F 8 ...

Page 237: ...e high voltage storage caps 380VDC and is controlled by aux hybrid Z2 Starting from AC line the input is fed through 20A fuse then the EMI filter input rectifier inrush circuit and into a boost converter operating at 66kHz The input voltage is then boosted up to 380VDC The boost converter is controlled by the Power Factor Correction circuit The instanteneous input current is modulated and is propo...

Page 238: ...in option connector As can be seen from the block diagram the fan is powered by both flyback house keeping power supplies one on each of the boards the master and the slave The duty cycle of the boost converter and the full bridge converter are set by the control hybrids on the master board Both the master and the slave boards have the same regulation ratios and therefore provide the same impedanc...

Page 239: ...al fuse is provided on both master slave modules Surge Protection Not included DC Output Power 5000W Voltage current 32V 157A Adjustment range 5 10 of nominal output voltage Polarity Output is isolated It may be referenced plus minus as required Remote Sense Compensates for up to 0 5v total loop drop in the output line Static regulation Line r0 25 over full line range Load r0 25 zero load to full ...

Page 240: ...s 3 min per octave sweep dwell 15 min at resonance Non operating from 5 to 17 hz 0 10 in double amplitude from 17 to 500hz 1 5g peak 3 axes 5 min per octave sweep dwell 15 min at resonance Shock Operating 5g half sine 11msec 3 axes Non Operating 15g half sine 11msec 3 axes Cooling Forced air internal fan Airflow exits at connector end Safety Designed to meet UL1950 CSA22 2 no 950 and TUV to EN6095...

Page 241: ...dix C Pioneer Power Supply Diamond Series Section 7 Outline Drawing Mounting Mounitng x symbol indicates standard mounting holes x 6 mounting holes are provided on both 5 sides and on one 8 side of the power supply x All mounting holes are for 8 32 screws with max penetration of 3 16 ...

Page 242: ...lectrically Competent Person as defined in the IEC 60215 Safety Standard Option Connector DB25 156A Pin 1 DC OK Return Pin 2 DC OK Source Pin 4 Remote Sense Pin 6 Remote Sense Pin 8 Remote Enable Input Pin 9 Remote Enable Return AC Input Two sets of three position terminal blocks using 6 32 screws These terminal blocks can be wired for 240VAC or 480VAC The terminals are wired for 480VAC at the fac...

Page 243: ...llowing procedure x Remove the 2 screws that retain the power supply x Shut off the breaker to the power supply to be removed Caution the breaker must be off before the power supply is removed to prevent connector damage There is sufficient capacitor storage capacity to keep the power supply fan running for about 10 seconds after AC power is removed x Quickly remove the power supply assembly Obser...

Page 244: ...put souce must be brought in via variac to the power supply AC input terminal block with the on off switch in off position on the variac x Electronic load is recommended instead of resistive load x The AC input terminal blocks can be configured for 240VAC 1P or 480VAC 1P See sections 5 and 8 for I O connections x See Picture below for hook up DB25 DC Voltmeter AC Input Source With a Voltmeter AC I...

Page 245: ...d go to step 4 If still noisy go to section 11 to replace the fan assembly If the problem persist go to section 13 4 Apply 10A load to DC output using an Electronic or Resistive load 5 Check the DC voltmeter for output voltage If zero then apply 7 5VDC using an external DC source between pin 8 and pin 9 on the DB25 option connector Verify that the output is enabled and the fan is on If the output ...

Page 246: ...ons The screws marked 1 and 6 are covered by the Warranty labels Remove these screws w o removing the labels Remove screw 7 This will allow pulling the front panel out in step 4 Note screw size and locations Step 2 Remove screws on other side as indicated Top Cover 8 7 6 5 4 2 3 1 Remove the seven screws on the other side at the marked locations The screws marked 1 and 7 are covered by the Warrant...

Page 247: ...onal Manual Rev 3 4 23 2007 17 Step 3 Lift the top cover and remove it Step 4 To pull Front Panel out follow the instructions as shown below Remove the two AC wires from the top AC terminal block only Remove both vertical bus bars by removing the four bolts Pull out the front panel carefully as shown Do not detach or remove any wire assemblies ...

Page 248: ...ne not provided See section 12 for order information Fuse F1 on the Master Board 20A 250V 3AB Normal Blo Fuse Step 6 Looking from the front to access the fuse F1 on the Slave Board hold the bead done as shown in the picture Remove the fuse and replace it with the spare one not provided See section 12 for ordering information Fuse F1 on the Slave Board 20A 250V 3AB Normal Blo Fuse Step 7 Follow ste...

Page 249: ...e instructions below Top Cover 6 5 4 2 3 1 Remove the six screws on one side at the marked locations The screws marked 1 and 6 are covered by the Warranty labels Remove these screws w o removing the labels Note screw size and locations Remove the seven screws on other side at the marked locations The screws marked 1 and 7 are covered by the Warranty labels Remove these screws w o removing the labe...

Page 250: ...PM33215F 8 5kW Instructional manual Rev 2 3 26 2007 20 Step 1 To remove the fan panel follow the instruction below Remove this screw holding the fan panel to the bottom chassis on the other side Note screw size and location Remove this screw holding the fan panel to the bottom chassis on one side Note screw size and location ...

Page 251: ... 2 3 26 2007 21 Step 2 Unplug the fan cable assembly as shown Fan wire assembly Unplug the fan wire assembly here Step 3 Remove the fan assembly by pulling it out and replace it with the spare One following steps 2 and 1 in the reverse order See section 12 for order information Step 4 Remove the two product labels from the old panel and put them on the new panel ...

Page 252: ...ete Fan Assembly Including Labor 124203 Fan Panel 429006 Fan Guard 4 5 8 ring 466044 0075 Screw Pan Hd Phil 4 40X3 4 471115 Nut Shakeproof 4 40 476111 0004 Washer Flat 4 122480 6 Wire Assembly J1 to Fan 6 510047 Fan Muffin 140CFM 24VDC Ball Bearing 442000 0125 Heat shrink sleeving blk 1 8 1 Fuse F1 specification on next page 2 Price and availability provided on request Contact Information to order...

Page 253: ...3 6 08 888 2463 001 C 25 WARNING Disconnect primary power prior to servicing Appendix C Pioneer Power Supply Diamond Series ...

Page 254: ...mation to return unit Customer Service Manager Tel 310 883 6210 Fax 310 829 1026 E mail mneff pioneermagnetics com Step 1 Call Customer Service and request a RMA Step 2 If serial number available provide at the time of getting of requesting the RMA Step 3 Release PO for repair charges if out of warranty Step 4 Return unit to the following address Pioneer Magnetics Inc Customer Service 1745 Berkele...

Page 255: ... Approved Components Inspect Inspect Inspect Ensures High Workmanship Standards Ensures High Workmanship Standards Ensures High Workmanship Standards Functional Test Functional Test Functional Test Electrically Verifies That Work Meets Customer Specifications Electrically Verifies That Work Meets Customer Specifications Electrically Verifies That Work Meets Customer Specifications Burn In Burn In ...

Page 256: ...C 28 888 2463 001 3 6 08 WARNING Disconnect primary power prior to servicing Diamond Series Appendix C Pioneer Power Supply ...

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