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1-18

888-2629-200

10/6/10

WARNING: Disconnect primary power prior to servicing.

Section 1 Introduction

Maxiva ULX COFDM Series

1.2.8.2

Pump Module/Heat Exchanger

The control panel/pump module and heat exchanger are separate units (each in a rack).
The control panel and pump module are self-contained in one rack and include a PID
(programmable logic controller), an expansion tank, air purger, pressure gauges, a
strainer and optional dual pumps operating in main/standby mode. The control panel/
pump module is designed for outdoor operation (some older models were suitable only
for indoor use). If used indoors the pump module and control panel should be located
near the transmitter if possible. The heat exchanger assembly is designed for outdoor
mounting.

Figure 1-10 Pump Module/Heat Exchanger

Pump Module Front

Pump Module Side

(Outdoor rated model shown. Indoor rated models

will not have full cowling over motors )

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Summary of Contents for Maxiva ULX

Page 1: ...is manual applies to the following modulation types DVB T H ISDB T H FLO CTTB CMMB TECHNICAL MANUAL 888 2629 200 Maxiva ULX COFDM Series Digital Transmitter Oct 5 2010 Rev B T M No 888 2629 200 Copyright Harris Corporation 2010 All rights reserved ...

Page 2: ...ii 888 2629 200 10 6 10 WARNING Disconnect primary power prior to servicing ...

Page 3: ...le Parts Service Replacement parts are available from HARRIS Service Parts Department 7 00 AM to 7 00 PM Central Time Monday through Friday and 8 00 AM to 1 00 PM Central Time on Saturday Telephone 1 217 222 8200 or email servicepartsreq harris com to contact the Service Parts Dept Emergency replacement parts are available by telephone only 24 hours a day seven days a week by calling 1 217 222 820...

Page 4: ...iv 888 2629 200 10 6 10 WARNING Disconnect primary power prior to servicing ...

Page 5: ...onnect primary power prior to servicing Manual Revision History Maxiva ULX COFDM Series Digital Transmitter Manual REV DATE ECN Pages Affected A 2010 Mar 15 Created B 2010 Oct 5 59529 Update multiple sections Corrected PS numbering in Sec 5 ...

Page 6: ...MRH 2 888 2629 200 10 6 10 WARNING Disconnect primary power prior to servicing ...

Page 7: ...TIONS 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 equiva lent 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 NOTE Inside the individual tables some standard conventions are used A symbol in front o...

Page 8: ...viii 888 2629 200 10 6 10 WARNING Disconnect primary power prior to servicing ...

Page 9: ...10 6 10 888 2629 200 ix WARNING Disconnect primary power prior to servicing ...

Page 10: ...x 888 2629 200 10 6 10 WARNING Disconnect primary power prior to servicing ...

Page 11: ...otection 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 GROUNDIN...

Page 12: ...xii 888 2629 200 10 6 10 WARNING Disconnect primary power prior to servicing ...

Page 13: ...portation 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 ha...

Page 14: ...xiv 888 2629 200 10 6 10 WARNING Disconnect primary power prior to servicing ...

Page 15: ...dure 2 22 Checking AC Configuration 2 24 TB1 TB2 Jumpers 1 Cabinet 10 16 Modules 2 24 TB1 TB2 Jumpers 1 Cabinet 1 8 Modules 2 24 Signal and Ground Connections 2 29 Intercabinet Connections 2 32 External Interlock Connections 2 32 Interlock Connector on Customer I O Panel 2 32 Fault Off Interlocks Safety Interlocks 2 32 RF Mute External Interlock Connections J2 2 33 3 Port Patch Panel Connections 2...

Page 16: ...her Card 4 16 PS Monitor Card 4 18 CPLD Complex Programmable Logic Device 4 22 Life Support Functions 4 22 Controller Area Network CAN Bus 4 24 System Bus 4 25 Cabinet Bus 4 26 Parallel Control Lines 4 27 Customer I O Board 4 28 Transmitter RF System 4 29 Apex M2X Exciter s 4 29 Predriver 4 29 IPA driver and PA Module 4 33 AC Distribution Board 4 35 AC DC Converter Interface Board 4 35 PA PS AC DC...

Page 17: ...ernate Pumps 5 34 Pump Module Strainer Cleaning 5 34 Coolant Level Management 5 36 Cooling System Maintenance Notes 5 37 Coolant Checks 5 37 Changing Pumps 5 37 Pump Module Operation Without Transmitter 5 38 Air Filter Replacement 5 38 LCD Screen Adjustments 5 39 LCD Screen Contrast 5 39 Touch Screen Calibration 5 39 Date and Time Settings 5 40 Changing the Battery on the PCM Card 5 40 PCM Battery...

Page 18: ...Table of Contents Continued 4 ...

Page 19: ... electrical installation procedures for the transmitter cooling and RF systems and basic remote control con nections Section 3 Operation provides operation and navigation information for the Graphi cal User Interface or GUI as well as identification and functions of all external panel controls and indicators Section 4 Theory of Operation provides detailed theory of operation for the trans mitter a...

Page 20: ...ies COFDM digital television transmitters Included in this section will be descriptions of the control system power amplifier block diagrams of the different models and system specifications Figure 1 1 ULX 8700 Front View Redundant Drivers Redundant Pre Driver A Apex M2X Exciter B PA Slots 11 18 Apex M2X Exciter A Redundant Pre Driver B PA Slots 1 8 TCU System Controller IPA A slot 10 11 18 A B 8 ...

Page 21: ...ion 1 Introduction Maxiva ULX COFDM Series Figure 1 2 ULX 8700 Rear View Upper 8 Way Combiner 3dB Combiner Coolant Hoses In Out Main Breakers Final Reject Load Redundant Cabinet RF Output Line Control Breakers Lower 8 Way Combiner Blowers 2 Upper 8 Way Splitter Lower 8 Way Splitter ...

Page 22: ...H FLO CTTB CMMB 1 2 2 System Block Diagram Figure 1 3 on page 1 5 contains a system block diagram showing the basic signal flow and configuration for a Model ULX 8700 Maxiva COFDM transmitter The block diagram shows the 8 7 kW single cabinet liquid cooled system with 2 pre amp Table 1 1 Maxiva COFDM Series Transmitter Models Tx Models Cabinets PA Modules Output Power Primary Cooling ULX1100 1 2 11...

Page 23: ...TCU will contain the GUI display for the transmitter Additional PA cabinets do not contain GUI screens The system bus originates in MCM master controller module inside the cabinet 1 TCU and goes to the TCU located in each amplifier cabinet The system bus is used to transfer telemetry information in between the TCU s The cabinet bus is similar to the system bus but it connects the cabinet TCU MCM c...

Page 24: ...h adjustable trip points via EPOTS It has pump control and interlocks on one D25 pin connector Customer I O Provides parallel remote control status and meter outputs Connector A has all inputs and Connector B has all outputs Exciter Switch Contains PWB relay 2 RMS detectors with adjustable trips via EPOTs for power monitoring and a control status interface for Exciters A and B PS Monitor Monitors ...

Page 25: ... Mode In this mode the automatic level control is disabled 1 2 4 1 Graphical User Interface The TCU front panel in the control PA cabinet on multi cabinet transmitters contains the graphical user interface which is a 5 25 1 4 VGA LCD touchscreen display The touchscreen display uses software buttons to monitor and control the transmitter Hardware buttons for the primary transmitter functions such a...

Page 26: ...mitter also allows updating of the software used in each transmitter sub system via a serial port connection to an external computer NOTE Software does not need to be loaded into the transmitter unless new components are installed or an update is sent from Harris The transmitter as shipped from the factory is preloaded and ready to run 1 2 5 2 Remote Control The Maxiva Series COFDM transmitter has...

Page 27: ...Table 1 1 page1 4 A simplified block diagram of the PA module is shown in Figure 1 5 on page 1 9 The amplifier and driver modules are interchangeable and do not contain microcontrollers but instead use a CPLD based monitor board in each PA to report faults to the TCU and to take appropriate self protective action if needed Figure 1 5 PA Module Simplified Block Diagram ...

Page 28: ...nnect directly to the PA module with a handheld device and obtain PS voltages fault status FWD and REF RF power levels and internal temperatures The diagnostic port can also be used to reprogram the CPLD as required The part number for the handheld diagnostics unit kit is 971 0040 081 The Harris part number for the diagnostics unit technical manual is 888 2765 001 8 AC DC Converter Modules 4 RF Pa...

Page 29: ...udes a single hybrid connector on one side and five 5 connectors on the other side The large hybrid connector interfaces with mating connector on the back plane board It contains seven 7 AC contacts twenty four 24 small signal contacts and a sin gle RF coaxial connector c AC Distribution Board The AC distribution board provides three phase AC to the eight power supply boards It also provides AC li...

Page 30: ...Pallet failure The combiner contains Forward and Reflected signal directional couplers at its output Detector circuits deliver the forward and reflected output samples to the Monitor Board which indicates the forward power level in dBm and uses the reflected signal for VSWR monitoring and VSWR fault protection for the mod ule Another directional coupler provides an attenuated sample of output RF s...

Page 31: ...ribution board There it is applied to eight AC DC converters two per pallet Depending on the operating frequency the AC DC converter output can be switched between 44 46 48 or 50 VDC which is supplied to each of the eight FET s in the module There are two FET s on each of the four pallets in each module The control system in the transmitter is powered by two low voltage power supply LVPS modules i...

Page 32: ...ust be properly prepared for operation and bled to remove trapped air Instructions for cooling system preparation can be found in Section 2 The heat exchanger and pump module unit operates on either 208 240 VAC 50 60 Hz or 380 415 VAC 50 60 Hz The operating voltages and frequencies should be provided at time of order The number of heat exchanger fans will vary with model number Figure 1 8 Simplifi...

Page 33: ...ribed below 12 Vdc Voltage supplied by Pump Control Unit PUMP_INTLK Output active high When high the transmitter s RF output is muted and the pumps are forced to OFF regardless of the LOCAL REMOTE setting in the pump cooling control panel If this interlock is active the pumps can t be turned ON even locally This interlock is driven by the transmitter or PA cabinet leak detector If a leak is detect...

Page 34: ... hysteresis window This means Fan 1 turns ON at 34 5 C and shuts off at 29 5 C Fan 2 set point will be set at 37 5 C also with a 5 degree hysteresis window This means Fan 2 turns ON at 40 C and shuts off at 35 C e SYSTEM CONTROL LOCAL REMOTE Allows local control or remote con trol via transmitter f HEAT EXCHANGER TEMP CONTROL PID controller used to set fan ON and OFF temperatures The control panel...

Page 35: ... system including ON OFF manual pump selection and automatic pump switching in the case of a failure Placing the control panel in Local mode allows manual switching of the pumps The red selector at the top of the control panel labeled ON OFF is the AC isolation switch which disconnects AC power from the pump module as well as the control circuitry in the control panel itself In the local mode with...

Page 36: ...ller an expansion tank air purger pressure gauges a strainer and optional dual pumps operating in main standby mode The control panel pump module is designed for outdoor operation some older models were suitable only for indoor use If used indoors the pump module and control panel should be located near the transmitter if possible The heat exchanger assembly is designed for outdoor mounting Figure...

Page 37: ...control panel pump module per PA cabinet The fans are controlled electronically The fans are enabled whenever the pump module is activated Factory settings are Fan 1 set point will be set at 32 C with a 5 degree hysteresis window This means Fan 1 turns ON at 34 5 C and shuts off at 29 5 C Fan 2 set point will be set at 37 5 C also with a 5 degree hysteresis window This means Fan 2 turns ON at 40 C...

Page 38: ...id cooled cold plate which connects to the cooling system with quick release connectors There are also cold plates inside the combiner and the splitter to which all of the internal combiner reject loads are attached See Figure 1 12 for cabinet coolant routing and module slot numbering NOTE The module slot numbering should not be confused with the IPA and PA module numbering Module numbering and sl...

Page 39: ...10 6 10 888 2629 200 1 21 WARNING Disconnect primary power prior to servicing Section 1 Introduction Maxiva ULX COFDM Series Figure 1 12 ULX 8700 Liquid Cooling System Internal ...

Page 40: ... Ethernet ports provided with the exciter Figure 1 13 M2X Exciter Front A single exciter unit drives the Maxiva ULX transmitter The excellent quality and stability of COFDM UHF signal output maximizes the TV transmitter efficiency improving performance and helping to reduce operating costs Figure 1 14 M2X Exciter Block Diagram Video Audio A D A D DVB ASI SMPTE 310 Rcvr Cable Equalizer Modulator FP...

Page 41: ...ervicing Section 1 Introduction Maxiva ULX COFDM Series 1 3 General Specifications NOTE Specifications subject to change without notice Unless otherwise noted specifi cations apply at the output of the Harris supplied mask filter Specifications continue on following page ...

Page 42: ...1 24 888 2629 200 10 6 10 WARNING Disconnect primary power prior to servicing Section 1 Introduction Maxiva ULX COFDM Series End of specifications ...

Page 43: ...dels have similar installation and testing procedures 2 2 Documentation The last two letters in the transmitter model number indicate modulation types For simplicity the model numbers noted in this manual will be noted as ULX 0000 NOTE The table below denotes the suffix with the modulation type The 0000 val ues in the table indicate power output in kW for the various models Table 2 1 Model Number ...

Page 44: ...ics for the transmitter system 2 2 1 Installation Drawings It is recommended that you look through the drawing package to familiarize yourself with the information available Although drawings are provided for most assemblies in the transmitter most of the installation and planning information is given in the following drawings see Table 2 2 below for model specific numbers a Outline Drawing Shows ...

Page 45: ...ws basic plumbing component locations and connections flow rate and pressure information as well as simplified cooling diagrams i Cooling System Electrical Diagram Shows the internal workings of the Cooling Control Panel and all interconnects with transmitter pump module and heat exchanger including AC connections Table 2 2 Maxiva ULX System Drawings System Drawings ULX 1100 ULX 1700 ULX 2300 ULX ...

Page 46: ...ms containing up to 4 modules 843 5601 281 is for systems containing 6 to 16 modules 2 Pump Module Heat Exchanger Outline 843 5601 289 is for cabinets containing up to 8 modules 843 5601 285 is for cabinets containing 10 to 16 modules 3 Pump Module Heat Exchanger Wiring Diagram 843 5601 290 is for cabinets containing up to 8 modules 843 5601 286 is for cabinets containing 10 to 16 modules ...

Page 47: ... that rigid coax runs must be installed with minimum elbows If the RF runs encounter obstacles such as liquid coolant lines conduit and duct work more elbows are required The RF lines should have a minimum number of elbows for best performance The liquid cooling system plumbing should installed next Avoid excessive 45 and 90 degree elbows especially back to back elbows as they will restrict the fl...

Page 48: ... set aside in a safe place for the rest of the installation process MULTI CABINET MODELS STEP 3 Place cabinets in position and carefully align ALL MODELS STEP 4 Use levelling shims under transmitter cabinet as required to make sure the transmitter is level and solid not rocking STEP 5 Install Drip Tray The aluminum drip tray slides under the transmitter just below the rear door panel The drip tray...

Page 49: ...e before setting the heat exchanger module in place Plan to unload the heat exchanger module unit directly to its final location Allow extra space for the concrete in front of beside and behind the unit to avoid dirt being blown around by the fans and to allow walking and working space for maintenance and inspection of the unit When mounting on a roof install unit such that building columns or loa...

Page 50: ...eatly restrict coolant flow Hoses will require more support than copper lines If hoses are to be used lay them in a tray if possible or plan hose supports a MINIMUM of 1 meter apart b Any turbulence causing device in the coolant plumbing system can restrict flow and increase the dynamic head pressure of the pump If two turbulence causing devices are connected back to back the flow restriction and ...

Page 51: ...ystem friction pressure loss determines optimum pipeline size For closed loop systems do not include the static head pressure of the system piping as equal and opposite forces cancel out upward and downward flow All elbows tees valves and system component pressure drops must be considered when determining pipe hose size Pump selection at rated flow is based on 150 feet total length Refer to instal...

Page 52: ...roximate the volume of interconnection plumbing line use Table 2 5 on page 2 11 to determine the corresponding factor needed Then multiply total of all line lengths by factor to derive tubing volume Add this volume to the corresponding volumes given in Table 2 3 and Table 2 4 to determine approximate Total System Coolant Capacity Table 2 4 Heat Exchanger Pump Module Capacities Table 2 3 PA Cabinet...

Page 53: ...its permanent place on its concrete pad or on the roof The pump module with control panel should immediately be moved to an indoor location Refer to the section Figure 2 5 5 for heat exchanger pump placement information If required complete any required assembly of the unit See paragraph 2 5 5 Placement of Heat Exchanger and Pump Module 2 5 4 Initial Inspection When the equipment and accessories a...

Page 54: ...SSIVE AMOUNTS OF PIPE JOINT COMPOUND OR JOINT TAPE APPLY PIPE JOINT COMPOUND ONLY TO EXTERIOR THREADS TO PREVENT INTERIOR BUILDUP AND CONTAMINATION OF THE PLUMBING SYSTEM STEP 2 The heat exchanger unit should be installed outside It should be oriented so that plumbing elbows are minimized and complex plumbing assemblies like back to back elbows are not required If hoses are used in the coolant sys...

Page 55: ...Y STEP 4 Lift the heat exchanger unit and set it into the required position vertical or horizontally oriented heat exchangers may be encountered Follow manufacturer s assembly and lifting recommendations They will vary depending on heat exchanger style Set into position using manufacturer s recommended lifting points Use of spreader bars is recommended to keep loads vertical and to prevent damage ...

Page 56: ...system to allow the system to be fully drained A closed expansion tank is provided in the pump module unit utilizing a rubber diaphragm to compensate for surges in the system The diaphragm is actuated by air pressure approximately 12 PSI charged a valve is located on the top of the tank for changing the air charge Charging the expansion tank is not normally required in the field The tank is pressu...

Page 57: ...LBOWS Once all piping and accessory installation has been completed the system is ready to leak test CAUTION ISOLATE THE BLADDER PRESSURE TANK PRIOR TO PRESSURE TESTING BY CLOSING THE BALL VALVE AT THE TANK INPUT CLOSING THE VALVE PROTECTS THE BLADDER FROM DAMAGE DURING THE PRESSURE TESTING CAUTION DO NOT PRESSURE TEST THE PIPING OR HOSE SYSTEM TO HIGHER THAN 20 PSI STEP 5 Charge system with 15 PS...

Page 58: ...AUTION IF THE SYSTEM IS INITIALLY CHARGED WITH WATER DO NOT ALLOW THE SYSTEM TO BE EXPOSED TO TEMPERATURES BELOW FREEZING FREEZING WATER IN THE COOLING SYSTEM MAY RESULT IN DAMAGE TO THE SYSTEM COMPONENTS 2 5 7 Pump Module Heat Exchanger Electrical The electrical installation of the heat exchanger and pump module unit should be in accordance with the National Electrical Code and any local codes an...

Page 59: ...UIPMENT STEP 1 Install conduit and route AC mains cabling to the pump module and from the pump module control panel to the heat exchanger isolator switches Install and wire according to the Harris Electrical Schematic Diagram and follow local wiring codes STEP 2 Install another conduit and route wiring for status and control lines between the pump module and transmitter cabinet Install and wire ac...

Page 60: ...hes on the heat exchanger unit They will be turned ON later in the procedure to check for wiring problems STEP 4 Connect the control and status wires on the cooling control panel with the supplied multi conductor cable These connections are described on the Electrical Installation Drawing These low level signals connect the terminals in the pump module control panel to the transmitter cabinet Tabl...

Page 61: ...on the customer I O panel located at the top of the transmitter with the supplied multi conductor cable These low level signals outlined in Table 2 6 connect from terminals inside the pump module control panel to J1 1 through J1 12 see Figure 2 3 on the pump module connector at the customer I O panel on top of the transmitter Table 2 6 Transmitter to Pump Module Control and Status Connections J1 C...

Page 62: ...ine Drawing Top View for details on AC inputs to top of cabinet NOTE AC Connections will be similar across all cabinets in multi cabinet transmitter models Be sure to verify all connections using the correct schematic drawings WARNING DISABLE AND LOCK OUT STATION PRIMARY POWER BEFORE PRIMARY POWER CABLES ARE CONNECTED TO THE EQUIPMENT CAUTION WHEN CONNECTED TO A 380 415VAC 3 PHASE WYE POWER CONFIG...

Page 63: ...e connected to the copper ground stud shown in Figure 2 4 The grounding stud on this panel is directly attached to the ground strap that runs from the grounding block located on the cabinet top to the ground block located inside the rear of the cabinet on the floor Figure 2 4 Safety Ground Connections Inside Cabinet rear The Maxiva ULX Series transmitters require 3 phase 208 220 240Vac or 3 phase ...

Page 64: ... NOTE For the following two steps the access cover at the top of the transmitter and the panel surrounding the circuit breakers in the top rear of the transmitter should be removed to facilitate connection of the AC mains to the transmitter STEP 2 Connect the AC wires to the primary AC terminal blocks CB23 and CB24 for higher power levels two AC inputs are required Refer to the wiring diagram for ...

Page 65: ...e IPA and PA backplanes on TB1 and TB2 on the AC distribution panel on the MOV boards and by including a neutral connection from the AC service disconnect to CB23 and CB24 for 380 to 415 VAC WYE connections Make sure that the transmitter is setup for the same AC power configuration that is used at the site Check the on site measured AC voltages against the factory test data sheet or the metal ID p...

Page 66: ...ngs of TB1 and TB2 with black boxes representing the jumpers between segments The critical jumpers are indicated by the dashed boxes around them 2 6 3 1 TB1 TB2 Jumpers 1 Cabinet 10 16 Modules For 208 to 240 VAC connections in Delta or WYE TB1 and TB2 have a jumper between terminals 5 and 6 and none between 6 and 7 see Figure 2 7 top For 380 to 415 VAC connection must be WYE and the jumper is remo...

Page 67: ...vice entrance to CB23 and CB24 if used for the 380 to 415 volt WYE connection but no neutral connection is required for the 208 to 240 volt Delta or WYE connections 440 to 480 VAC Delta or WYE connections require a step down transformer Figure 2 6 is a photo of the TB1 and the MOV board on the left These terminal boards need to be properly jumpered depending on the AC mains voltage Figure 2 7 and ...

Page 68: ...ies Figure 2 6 Photo of MOV TB1 Figure 2 6 shows an AC distribution panel removed from the transmitter TB1 in this case is for an amplifier cabinet with 8 modules or less NOTE The dashed rectangles in Figure 2 7 and 2 8 indicate jumpers that need to be moved to change between 208 240V and 380 415V operation TB1 MOV Jumper ...

Page 69: ...Back of PA Cabinet Jumpered for 208 to 240 VAC Delta or WYE TB1 TB2 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 Ground Block AC Power Entrance AC Power Entrance Top View of Back of PA Cabinet Jumpered for 380 to 415 VAC WYE TB1 TB2 1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11 Ground Block AC Power Entrance AC Power Entrance MOV Board MOV Board MOV Board MOV Board L1 L2 N L3 L1 L2 N L3 L1 L2...

Page 70: ... Cabinet With 1 to 8 PA Modules Top View of Back of PA Cabinet Jumpered for 208 to 240 VAC Delta or WYE TB1 1 2 3 4 5 6 7 8 9 10 11 Ground Block AC Power Entrance AC Power Entrance MOV Board 12 Top View of Back of PA Cabinet Jumpered for 380 to 415 VAC WYE TB1 1 2 3 4 5 6 7 8 9 10 11 Ground Block AC Power Entrance AC Power Entrance MOV Board 12 L3 N L2 L1 L3 N L2 L1 ...

Page 71: ...TE Control and signal wires should never be run in the same conduit with any AC wiring A separate conduit should be used for control signal cables STEP 1 Connect the RF Inputs to the customer I O panel at the top of the transmitter see Figure 2 9 Figure 2 9 Customer I O Panel top of transmitter NOTE Refer to the Apex M2X technical manual for RTAC sample levels ...

Page 72: ...es will be calibrated using the GUI after initial turn on see 5 8 Power Calibrations on page 5 15 These sample cables are not supplied since the required length is determined at each site NOTE Refer to the Apex M2X technical manual for RTAC sample levels Table 2 7 Customer I O panel Connections for Exciter A Jack Connector Label J1 SMA 50Ω GPS antenna J2 BNC 50Ω 1PPS J3 BNC 50Ω 10 MHZ J4 BNC 75Ω A...

Page 73: ...transmitter Roll this strap out and attach it beneath the cabinet ground block in the cabinet and to station ground on the other If any additional copper strap is needed it must be at least 5cm wide and 0 5mm thick There is an additional E1 block located on top of each cabinet see Figure 2 9 for additional grounding as needed Figure 2 10 Cabinet Ground Connection Block Table 2 9 RF Samples Connect...

Page 74: ...om the factory with jumpers in the external interlock positions which will allow the transmitter to operate without external interlock connections The Electrical Installation drawing shows that Interlock 1 J2 2 to J2 3 is used by a 3 Port Patch Panel or possibly a motorized switch The External Interlock circuits requires a closed connection on the following interlock connector terminals to allow t...

Page 75: ... unmute when the interlock is restored to a close condition These are J2 5 to J2 6 for test load thermal interlock J2 11 to J2 12 WARNING RF MUTE INTERLOCKS SHOULD NOT TO BE USED IN ANY SITUATION WHERE PROTECTION OF PERSONNEL IS DESIRED Table 2 10 J2 Interlock Connector on Customer I O Board Pin Number Description 1 NC 2 System Safety Interlock 3 System Safety Interlock Return 4 NC 5 System RF Mut...

Page 76: ...NT POSSIBLE DAMAGE TO THE CONTACTS 2 11 Initial Cooling System Turn ON The liquid cooling system external to the transmitter consists of a one or two fan air cooled heat exchanger depending on model two pumps and an integrated electrical control system Typically cabinets with eight PA modules or more will use a two fan heat exchanger unit Cabinets with less than eight modules would use a single fa...

Page 77: ...egral derivative There are two modes of pump operation Local and Remote The PID controller interfaces with the transmitter s Pump Control Interface PCI The controller receives signals from the PCI and sends signals to the PCI NOTE For additional Cooling System start up information see the pump module heat exchanger manufacturer s technical manuals one for the pump module heat exchanger and another...

Page 78: ...he initial power up of the pump module and heat exchanger Verification of pump and fan rotation is outlined in Section 2 11 1 1 on page 2 38 CAUTION INCORRECT REVERSE ROTATION OF THE PUMPS OR FANS WILL CAUSE POOR COOLANT OR AIR FLOW AND DAMAGE TO THE PUMPS CORRECT PUMP OR FAN ROTATION BY SWITCHING ANY TWO INCOMING AC PHASES DO NOT ALTER ANY PANEL WIRING TO CHANGE PUMP OR FAN DIRECTION Fans and mot...

Page 79: ...stem Once air bubbles stop forming in the sight glass and the sight glass is full of liquid turn off the charge pump a Record the amount of liquid required to initially fill the system including the make up water required when the pumps have been run and the remainder of air is bled from the system This information will be used later during flushing to determine the amount of trapped water remaini...

Page 80: ...PUMP A MIXTURE OF GLYCOL WATER INTO OUTSIDE EQUIPMENT TO PREVENT DAMAGE CAUTION THE USE OF DISTILLED WATER IS SUGGESTED ONLY FOR VERY SHORT TERM TESTING THE SYSTEM IS DESIGNED TO OPERATE ON A 50 50 MIXTURE OF DISTILLED WATER AND PROPYLENE OR ETHYLENE GLYCOL THE 50 50 MIXTURE IS REQUIRED FOR PROPER SYSTEM PERFORMANCE THE GLYCOL WATER RATIO SHOULD BE VERIFIED PREFERABLY WITH AN OPTICAL REFRACTOMETER...

Page 81: ...ump the selected pump will run when the AC Isolator switch in the front of the cooling control panel is set to ON 1 When active the pump interlock will deenergize the pumps in either the local or remote modes The pump interlock is acti vated by the transmitter leak detector when it senses a cooling system leak in the transmitter cabinet d While in Local the operating pump is selected on the coolin...

Page 82: ...ng system will not cool properly STEP 1 The proper rotation of both pumps should be confirmed prior to checking fan rotation See 2 11 1 1 STEP 2 Energize the AC mains supply to the Cooling Control Panel STEP 3 Turn the Local OFF Remote switch on the Cooling Control Panel to Local STEP 4 Turn the heat exchanger fans switch to Manual STEP 5 Turn ON the AC isolator switch on the cooling control panel...

Page 83: ...t tube which is located atop the system air purger Low coolant level or the presence of bubbles in the sight tube indicates air in the system and a need for recharging the system with additional coolant STEP 1 Turn on pump A for several minutes Upon the establishment of a steady no air bursts volume of water throughout the system begin visual check for leaks Turn off Pump A after thorough leak che...

Page 84: ...e system open all of the system and cabinet drain and vent valves Once draining is complete close all cabinet drain valves The charge pump can be reversed to aid in draining the system NOTE To facilitate draining one or more vent valves at high points in the system must be opened STEP 3 Use a marker to note the level of the liquid in the container The difference between this level and the previous...

Page 85: ... and draining the system two to four or more if needed times using distilled water The following steps outline the flushing process NOTE The length of flushing time and number of fill drain cycles needed to achieve desired water quality will vary with system size and the amount of residual trapped liquid in the system Residual liquid is trapped in the system and cannot be removed when the system i...

Page 86: ...f coolant may be less than the specified 50 50 mixture Extra glycol equal to the amount of trapped water in the system must be added in order to achieve the proper glycol water mixture STEP 2 Run pumps for several minutes and open vent valves to remove all air from the system Alternate pumps A and B STEP 3 During the final system fill with the coolant water mixture frequently check the static pres...

Page 87: ...he hydrometer should be capable of measuring specific gravity in the 1 02 to 1 08 range Information regarding specific gravity measurement is given in Appendix B 2 12 Install PA Modules STEP 1 Be sure the PA power supply breakers in rear of cabinet as shown in Figure 2 11 are in the OFF position Figure 2 11 PA IPA driver Module Circuit Breakers ...

Page 88: ...r than lifting the modules with one hand on each side of the module it may be easier to place one arm beneath the module supporting it with that arm while holding the side of the module with your other hand NOTE The IPA driver and PA Modules can be placed into any of the IPA driver or PA module slots but it is advisable to place them in the same location as they were tested in The module location ...

Page 89: ... and lack of air bubbles NOTE Each PA module that is installed may introduce air into the system The system will likely need to be recharged after modules are installed The site glass should be checked for fluid level and for air bubbles prior to turning on the transmitter RF Low coolant level or bubbles in the sight glass indicate that the cooling sys tem needs to be recharged 2 13 Initial Turn O...

Page 90: ...eries Figure 2 12 Home Page STEP 4 Turn on Exciter circuit breakers CB21 CB22 STEP 5 Check the TCU Low Voltage power supplies and AC Mains voltages Press the PS power supply button to view the PS screen shown in Figure 2 13 Check for 5 3 3 5 and VA levels The AC Mains readings should be close to the measured AC voltages ...

Page 91: ... see Section 6 Diagnostics for more information This screen is shown in Figure 2 14 NOTE A COMMON FAULT IS A 3 PHASE SEQUENCE FAULT INDICATING THE 3 PHASES HAVE BEEN CONNECTED IN THE WRONG SEQUENCE IF THIS IS PRESENT REMOVE ALL PRIMARY POWER TO THE TRANS MITTER AND SWITCH ANY 2 WIRES ON TRANSMITTER TERMINAL BLOCK CB23 CB24 The 3 phase AC sequence fault can be displayed for either AC1 or AC2 inputs...

Page 92: ... of Cabinets and System Setup Entry Touch the screen at each field to enter the data pertinent to the setting Once all the correct information in this screen has been entered press the CONFIG button This screen is shown in Figure 3 22 on page 3 26 STEP 8 Customize the cabinet Setup Press SYSTEM SERVICE SYSTEM SETUP CABINET SETUP on the GUI Touch the screen at each field to enter the correct data f...

Page 93: ...low rate must be above the trip point level in order to prevent frequent faults and pump switches Refer to the Outline drawing and Plumbing layout drawing for more details Table 2 11 Cooling System Flow Rates MODEL NOMINAL TRANSMITTER FLOW RATE Trip Point LPM PA Modules ULX 1100 38 liters per minute 15 2 ULX 1700 45 liters per minute 19 3 ULX 2300 53 liters per minute 23 4 ULX 3400 65 liters per m...

Page 94: ...nd instruction table in the manufacturers cooling system manual that ships with each unit The controller automatically turns fans on and off according to temperature sensed in the heat exchanger return line The fans can also be turned off with isolator switches on the heat exchanger to allow for maintenance Factory settings are Fan 1 set point set value SV at 32o C with a 5o degree hysteresis wind...

Page 95: ...hose The pump should switch as the flow limit is reached when flow remains low the pumps should shut down STEP 9 After verification of pump switching performance and flow protection restore the globe or ball valve to it s previous condition to restore flow 2 14 1 3 Normal Pump and Fan Operation In normal operation Cooling Control Panel System Control set to REMOTE and Heat Exchanger Fans set to AU...

Page 96: ... STEP 2 Set Cab Fwd Power Reference W on Ouptut screen to zero by entering the value or by entering the zero value or by holding the lower button with ALC on for at least 20 seconds STEP 3 Turn down the transmitter ALC voltage level prior to initial start up Press MAN button on the TCU control panel for at least for at least 5 seconds Then hold down the LOWER button on the TCU control panel for at...

Page 97: ...servicing Section 2 Installation Maxiva ULX COFDM Series Figure 2 15 Power Amps Screen Figure 2 16 IPA Screen STEP 8 See Figure 2 15 and Figure 2 16 All IPA s and PA s should show a green OK or yellow indicating low drive status indication on the GUI Power Amps screens ...

Page 98: ...e cabinet combiner reject loads Inter cabinet phasing is accomplished via the GUI to adjust the preamplifier modules in each cabinet relative to the other cabinets to reduce reflected power to the common reject loads STEP 11 Verify that the transmitter meter readings are close to the factory test data meter readings especially all of the current and voltage readings NOTE Rebias of the FET s in the...

Page 99: ...ed then remote control connections can be made The following tables list the connectors and their corresponding signal names and functions NOTE The Customer I O board connections can be found at the top of the transmitter near the front See Figure 2 18 for connector locations Figure 2 18 Parallel Remote Control Connections External Parallel remote control units can interface at the Customer I O Bo...

Page 100: ...l transmitter control functions except Remote RF Mute RF Switch Position A and RF Switch Position B which are active LOW or HIGH level input states are momentary ground switching and require the remote control equipment to sink at least 15mA to activate the function The Pinouts of J3 J4 and J5 are listed in Table 2 12 Table 2 12 J3 J4 J5 Customer I O Board Remote Control Connectors Connector and p...

Page 101: ...status output connections are listed in Table 2 13 J4 4 IPA_AUTO_SELECT Pulsed LOW J4 5 IPA_MANUAL_SELECT Pulsed LOW J4 6 GROUND GNDA J4 7 PUMP_SWITCH_COMMAND Pulsed LOW J4 8 SPARE J4 9 PUMP_AUTO_SELECT Pulsed LOW J4 10 PUMP_MANUAL_SELECT Pulsed LOW J4 11 GROUND GNDA J4 12 GROUND GNDA J5 1 GROUND J5 2 POWER_CONTROL_AUTO_SELECT Pulsed LOW J5 3 POWER_CONTROL_MANUAL_SELECT Pulsed LOW J5 4 GROUND J5 5...

Page 102: ...CITER_AUTO MANUAL_STATUS L AUTO H MANUAL J6 5 GROUND J6 6 IPA_A B_ACTIVE_STATUS L B ON H A ON J6 7 IPA_AUTO MANUAL_STATUS L AUTO H MANUAL J6 8 GROUND J6 9 PUMP_A_B_ACTIVE_STATUS L A ON H B ON J6 10 PUMP_AUTO MANUAL_STATUS L AUTO H MANUAL J6 11 GROUND J6 12 GROUND J7 1 GROUND J7 2 REMOTE_CONTROL_ENABLED DISABLED_STATUS L Remote ENABLED H Remote DISABLED J7 3 RF SWITCH_A B_ACTIVE_STATUS L B ON H A O...

Page 103: ...ING_FAULTt L FAULT H OK J8 7 POWER_SUPPLY_FAULT L FAULT H OK J8 8 GROUND J8 9 SUMMARY_FAULT L FAULT H OK J8 10 CUSTOMER_SUPPLIED_VCC1 voltage for digital output opto couplers and pull ups JP1 in the TCU customer I O card must be set correctly to use this output J8 11 CUSTOMER_SUPPLIED_VCC2 voltage for digital output opto couplers and pull ups JP1 in the TCU customer I O card must be set correctly ...

Page 104: ...External RF Switch The external RF switch connector is a 12 pin connector provided to allow control of motorized switch that is external to the transmitter The connections for J10 are listed in Table 2 15 Table 2 14 J9 External I O Board Remote Power Metering Connection Metered Parameter J9 1 SYSTEM_FORWARD_POWER J9 2 SYSTEM_REFLECTED_POWER J9 3 GROUND J9 4 CABINET_FORWARD_POWER J9 5 CABINET_REFLE...

Page 105: ... PCM card This battery maintains the time and date when the transmitter loses AC power Refer to 5 11 4 Changing the Battery on the PCM Card on page 5 40 The battery can be found inside a plastic bag that also contains battery installation instructions Connection Metered Parameter J9 1 SWITCH_COMMON J9 2 GROUND J9 3 RF_SWITCH_POSITION_A_SELECT J9 4 RF_SWITCH_POSITION_B_SELECT J9 5 GROUND J9 6 RF_SW...

Page 106: ...2 64 888 2629 200 10 6 10 WARNING Disconnect primary power prior to servicing Section 2 Installation Maxiva ULX COFDM Series ...

Page 107: ...hips with the transmitter 3 2 Transmitter Control Panel The front panel user interface is a 5 25 1 4 VGA LCD touchscreen display This touchscreen display uses software buttons to monitor the transmitter Hardware buttons for the primary transmitter functions such as ON OFF RAISE LOWER and Remote Enable Disable are provided on the overlay panel next to the display as shown in Figure 3 1 NOTE When tr...

Page 108: ...ons which are part of the front panel overlay Located to the left of the buttons are Status LED s which are green under normal no fault conditions The hardware buttons provide immediate control of 6 main transmitter functions a Power Control Auto Manual b Remote Enable Disable c Power Raise Lower d Exciter A B e Drive A B f Transmitter On Off The Status LED s light amber yellow for a warning and r...

Page 109: ...rol module the 2nd board is the PCM processor control module the 3rd board is the RF detector the 4th is the customer I O board the 5th is the exciter switcher 6th is PS monitor the 7th 8th are PA interface digital I O boards The 8th card PA interface is only present in transmitters with more than 8 PA modules The two power supplies on the left are redundant To gain access to the internal boards s...

Page 110: ...f the air for a short time Just above the MCM Reset button is a removable memory card containing system software This card should be installed in any replacement MCM card that is installed 3 3 Graphical User Interface GUI The GUI Gooey was designed to provide an intuitive interface into the transmitter control system Once you become familiar with content finding information is simply a matter of f...

Page 111: ...d and the transmitter repaired see Section 6 for fault log listings PS MUTE A temporary fault condition caused by a power supply related fault If underlying fault clears the mute condition will be lifted and the transmitter returned to normal operating mode If the mute continues the underlying fault will need to be determined and the transmitter repaired see Section 6 for fault log listings RF MUT...

Page 112: ...e filter c Transmitter Forward power output reading in a Bargraph format The 100 mark is based on the nominal power level or TPO Transmitter Power Output entered into the configuration screen The bargraph will also turn yellow if the power level is more than 10 higher or lower than the nominal 100 level NOTE Indications on the global display header in Figure 3 3 should be all green under normal no...

Page 113: ...4 ULX 8700 Home Screen It also has the global status and operation information at the top of the screen which shows the transmitter status power output and any faults present The HOME button shown to the right is a software button located in the upper left quadrant of all 5 main menu screens for quick navigation to the HOME screen If a submenu screen is displayed on the GUI see Figure 3 4 the lowe...

Page 114: ...s can also act as status indicators and turn red if a fault condition is detected There is a navigation button shown to the right to allow access to information specific to the PA cabinet Pressing this button will take you to the Power Amp screen shown in Figure 3 8 on page 3 13 This button is also a status indicator for the PA cabinet as it will change from green to red if a problem is detected i...

Page 115: ...tor to select exciters and pre driver IPA s It also allows selection of AUTO or MANUAL switching mode for the drive chain when the optional dual exciter system is installed Specifically it includes a The operational and on air status of 1 or 2 exciters the second exciter is optional pre drivers and IPA s NOTE The standard M2X exciter comes with a main and aux input b The status of Exciters and Dri...

Page 116: ...he bottom of the screen on the right This dual driver has 2 switches 1 Auto Manual This toggle button should always be in the Auto position for normal operation Placing it in Manual mode prevents an autoswitch to the alternate IPA Preamp Driver In AUTO mode if the on air predriver IPA drops below 50 of nominal power the controller will automatically switch to the backup pre driver IPA Manual mode ...

Page 117: ... The optional exciter B is installed immediately above the TCU and below the top exciter unit see layout photo Figure 1 1 on page 1 2 3 5 2 Drive Chain Meters When the Meters button in Figure 3 6 is pressed it will bring up the screen shown in Figure 3 6 This screen displays input and output information for exciters and pre driver IPA units Current values for the pre driver and IPA s are also give...

Page 118: ...3 12 888 2629 200 10 6 10 WARNING Disconnect primary power prior to servicing Section 3 Operation Maxiva ULX COFDM Series Figure 3 7 Drive Chain Meters Screen To Figure 3 6 To Figure 3 5 ...

Page 119: ...g the PA s 1 8 or 11 18 buttons in the lower left portion of the bottom of the screen The PA Input and On Off indications on the screen are also status indicators with 3 possible states indicated a OK Green background b Fault Red background c OFF The background is gray The On Off field will can be used to toggle individual amplifier modules on or off as needed NOTE For multi cabinet Maxiva Series ...

Page 120: ...ally a list of all faults monitored in each PA Module An active fault will be highlighted in RED A warning condition will be highlighted in YELLOW The PA Faults screen in Figure 3 9 shows that PA Module 1 in PA Cabinet 1 has no faults and 1 temperature warning It also shows a power supply fault on module 3 and an input power warning on module 4 NOTE For a detailed explanation of all PA Faults in F...

Page 121: ...ackgrounds that are red for fault or yellow for warning A VSWR fault is indicated when the system VSWR is 1 9 1 Foldback warning is indicated when system VSWR is 1 4 1 NOTE Both VSWR fault and foldback levels are adjustable via software Power Amplifier Cabinet Amplifier cabinet icons triangle give a status indication of OK green or Fault red along with cabinet Forward and Reflected power before th...

Page 122: ...r on the customer I O panel must be jumpered For more information see 2 9 External Interlock Connec tions on page 2 32 3 7 1 Output Faults This screen shows faults which are considered Cabinet or System level such as VSWR Power High foldback etc An active fault will be highlighted in RED A warning condition will be highlighted in YELLOW A detailed explanation of each of these faults is given in Se...

Page 123: ... the screen shown in Figure 3 12 The Power Supply Menu structure is shown in Figure 3 26 on page 3 30 This is the power supply metering screen for both the low voltage power supply units in the TCU and the AC Mains It also allows access to Power Supply Fault screens PS Faults Fault list and status Next Cabinet Access to PS screens on other cabinets if applicable Figure 3 12 Power Supply Screen To ...

Page 124: ... PS power supply Faults screen which lists of all of the monitored power supply faults for the AC mains and low voltage power supplies An active fault will be highlighted in RED while a warning condition will be highlighted in YELLOW For a detailed explanation of these faults refer to Section 6 Diagnostics Figure 3 13 PS Faults Screen To Figure 3 12 ...

Page 125: ...ump icon has a green background color if no faults are present or a red background color if faults are active For more information on faults press Faults c Pump Control Pump A Pump B for dual pump systems are indicated This panel would be grayed out inactive for single pump systems The active pump will have a green background Pumps can be switched from this screen by pressing A or B only if the pu...

Page 126: ... on page 3 19 It is a complete listing of all transmitter and system faults in the order in which they occurred It can hold up to 99 faults and then becomes a FIFO First IN First Out memory buffer with the latest fault entry on top Active Faults will be highlighted and cannot be reset All other faults will be cleared when the RESET button is pressed Use the NEXT and PREVious buttons to view the en...

Page 127: ...s List on page 6 12 These tables are a quick reference list and in most cases is all that is required for an advanced user to diagnose the problem However detailed information on each of these faults is also given in context with the fault page where it originated also in Section 6 Figure 3 16 System Fault Log Screen To Figure 3 14 Note Date format is DD MM YY Press to clear all faults ...

Page 128: ... chosen must match the transmitter name plate It is used to gray out portions of the GUI screens which are not used by some models Serial Number This is entered at the factory Refer to this number if calling for sup port Figure 3 17 System Service Screen Remote The System Service screen varies depending on whether it is viewed on the local GUI screen or remotely via web browser The local screen sh...

Page 129: ... viewing and operational adjustments Expert allows viewing operational and maintenance adjustments Local GUI login is admin Web browser login is admin Password Allows user password entry There are different login and passwords for local and web browser GUI usage The default logins and password from the factory are Local GUI password is harris Web browser password is harris2009 Expire Sets the expi...

Page 130: ...o servicing Section 3 Operation Maxiva ULX COFDM Series Reboot This button will reboot the TCU The transmitter will stay on the air Reboot takes about 2 minutes Figure 3 19 System Admin Screen local Figure 3 20 System Admin Screen remote To Figure 3 22 To Figure 3 21 ...

Page 131: ...GO OFF AIR WHEN THE SOFTWARE IS UPDATED 3 9 3 2 System Setup Sys Pwr Out W Set this value to the system nominal power output This value determines the 100 level on the GUI power out bar Center Freq MHz Enter the center frequency for the desired operational channel In early software versions this is only sets the frequency display In later software versions it also sets the exciter frequency CAUTIO...

Page 132: ... set up the transmitter for CH29 and store it in entry 3 you enter 3 in the Sys tem Setup Entry This will recall the data for entry 3 If no data is there defaults will be loaded Once all the calibrations for channel 29 are done you press SAVE SETUP This will save the data to entry 3 Figure 3 22 System Setup Screen NOTE The Save Setup button allows storage of up to eight setups for the purpose of N...

Page 133: ...0 over this value Number of PA s Enter the number of PA modules in the selected cabinet This needs to be set for each cabinet Number of IPA s Enter the number of IPA modules in the selected cabinet This needs to be set for each cabinet Cooling Pumps Set this to either 1 or 2 depending on how many pumps are in pump module for this cabinet This needs to be set for each cabinet Figure 3 23 Cabinet Se...

Page 134: ...stem Version Screen This screen shows the software revision for the TCU controllers This information should be known before calling for technical support Figure 3 24 System Version Screen 3 9 3 6 System Network Screen This screen provides information about network settings MAC IP Netmask and Gateway settings are given To Figure 3 17 ...

Page 135: ...twork system so the change is made permanent and the new parameters become active 3 10 GUI Menu Structures Figure 3 26 on page 3 30 shows the menus which can be accessed on the GUI This menu tree may be helpful when learning to navigate the screens The blocks on the left represent the main menus which can accessed using one of the 5 software buttons on the right side of the GUI HOME Page Each succ...

Page 136: ...ction 3 Operation Maxiva ULX COFDM Series Figure 3 26 GUI Menu Tree Drive Chain Faults Meters Meters Amps Power Faults Output Power Supply Faults Logs Faults System Service Version Network Log Faults Log Clear Setup System Cabinet Setup Save Setup Calibrate Trips Calibrate Cabinet ...

Page 137: ...oling System 4 1 1 Active Logic Symbols Each logic signal has an active and inactive state and a unique name within the system To differentiate between active high or active low logic states on the schematics a forward slash is placed in front of an active LOW signal name such as RF_MUTE This means that if this logic line is pulled low the transmitter RF will be muted By the same logic the signal ...

Page 138: ...rs and configurations Using the model ULX 2300 as an example the model number breaks down as follows U stands for UHF band L stands for Liquid Cooled X stands for Transmitter 2300 stands for 2300 watts average power at the transmitter output before the band pass filter stands for the type of modulation See Table 2 1 on page 2 1 Table 4 1 Maxiva ULX COFDM Series Transmitter Models Tx Models Cabinet...

Page 139: ...n sheet 8 of the PA Cabinet Main Wiring Diagram drawing number 843 5601 001 Driver and PA backplane boards On the IPA and PA backplane boards drawing numbers 801 0222 131 and 801 0222 101 respectively the jumpers on TB1 TB2 and TB3 are connected between terminals 2 and 3 for 208 to 240 VAC Delta or WYE and connected between terminals 1 and 2 for 380 to 415 VAC WYE connections EX 1 EX 2 MOV AC SAMP...

Page 140: ...N STBY command is issued from the UCP In multi cabinet systems there is a TCU in each cabinet and the main cabinet no 1 TCU contains a GUI graphical user interface screen and assumes the role of the master controller for the system The TCUs in the other PA cabinets are considered slaves they don t have GUI screens and do not require all of the cards used in the main cabinet TCU For additional info...

Page 141: ...e transmitter power as commanded by the end user This signal is sent via CAN messages Figure 4 2 on page 4 6 illustrates the power control functionality If the Main TCU is down all cabinets maintain their current power output In each cabinet the system power reference is compared to the detected cabinet RF power sample and the resultant error voltage cabinet ALC is produced The error voltage is us...

Page 142: ... a detected sync pulse from the cabinet or system RF output sample which adjusts the predriver level to negate the effects of compression or expansion due to changing average picture level Figure 4 2 Control System Simplified Block Diagram MA IN UCP System Power R eference From System Bus S 16 PAs Cabinet 1 A LC S 16 PAs Cabinet 2 ALC S 16 PAs Cabinet 3 A LC PA C AB UC P PA CA B U CP CA BIN ET CO ...

Page 143: ...r control unit Each cabinet contains a TCU The main cabinet cabinet 1 in multi cabinet systems contains an enhanced TCU with a GUI screen while additional PA cabinets contain a basic TCU without GUI screen The basic TCU will not be equipped with all of the same components as the enhanced unit The cabinet 1 TCU assumes the role of master controller in multi cabinet systems TCUs in added PA cabinets...

Page 144: ...ange of control and status information between the main cabinet TCU and additional PA cabinets The MCM is responsible for maintaining life support operation when the PCM card is not operational The system bus connector J6 connections are provided in Table 4 11 on page 4 26 The cabinet bus connector J5 has limited use in this transmitter Pin 7 is the only signal used in the cabinet bus It sends the...

Page 145: ...odule card The PCM card contains the Harris Coldfire based micro module running embedded Linux OS The PCM allows use of an optional 5 25 color 1 4 VGA GUI touch screen for enhanced monitoring and control It also provides exciter and multi cabinet data collection fault logs web remote connectivity via TCP IP connection SNMP error trap reporting and configuration and setup interface Figure 4 4 PCM B...

Page 146: ...S detectors with adjustable trips set by EPOTS electronic potentiometers Pump control and interlock wiring is combined on one D25 pin connector J3 For analog transmitters the card also serves as an interface to the analog down converter board via another D25 connector J2 Figure 4 5 on page 4 10 shows the RF Detector Pump Control Interlocks card connectors on the rear of the TCU and how the board i...

Page 147: ...e 5 PUMP_ON_CMD Output Active high to turn on selected pump 6 PUMP_SWITCH_CMD Output Pulsed active high to switch between pumps A and B 7 PUMP_INTLK Output active high 8 COOLANT_FAULT Input connect to open drain or relay contacts Active low 20mA sink 9 COOLANT_WARN Input connect to open drain or relay contacts Active low 20mA sink 10 PUMP_A_STATUS Input connect to open drain or relay contacts Acti...

Page 148: ...Cabinet forward sample from directional coupler DC1 at combiner output 2 CAB REF Cabinet reflected sample from directional coupler DC1 at combiner output 3 SYS FWD System forward sample from customer I board J16 at top of transmitter 4 SYS REFL System reflected sample from customer I O board J16 at top of transmitter 5 REJ 1 Reject sample from on customer I O board J19 at top of transmitter 6 REJ ...

Page 149: ...dules and receives fault information and status from them Figure 4 6 shows how the PA interface boards connect to the IPA driver and PA backplanes Figure 4 6 PA Interface Card Connection to Backplane Boards 4 4 3 4 1 Predriver and IPA Drive A and B Busses The Drive A and Drive B busses provide control and monitoring of the predriver and IPA modules A and B These busses run from connectors J3A and ...

Page 150: ...ve 50 conductors Table 4 5 provides the connections for these busses Table 4 4 Predriver and IPA Drive A and Drive B Control Busses Predriver Assembly Connectors J1 and J2 and IPA Backplane Connectors J1 and J5 Pin Function Pin Function Pin Function Pin Function 1 15V from TCU 14 N C 27 N C 40 Gnd 2 IPA A or B Fault 1 15 N C 28 N C 41 N C 3 IPA A or B Fault 2 16 Gnd 29 N C 42 N C 4 IPA A or B Faul...

Page 151: ...5 PA Backplane Board BP 1 through BP 4 Control Busses Pin Function Pin Function Pin Function Pin Function 1 VA 14 PA 3 Fault 3 27 Digital Output 5 40 Gnd 2 PA 1 Fault 1 15 PA 3 Present 28 Digital Output 6 41 PA 2 Output Power 3 PA 1 Fault 2 16 Gnd 29 Digital Output 7 42 PA 2 Sum Current 4 PA 1 Fault 3 17 PA 4 Fault 1 30 Digital Output 8 43 Gnd 5 PA 1 Present 18 PA 41 Fault 2 31 Gnd 44 PA 3 Output ...

Page 152: ...xciter switching with a board mounted relay It includes 2 RMS detectors with adjustable trip points that use EPOT s to monitor exciter power There are control and status interface connectors J1A and J1B that go to exciters A and B respectively Table 4 6 shows the signals on the pins of connector J1A The simplified block diagram for the exciter switcher card is given in Figure 4 7 Figure 4 7 Excite...

Page 153: ...m pull up to 5V TVS protection Active 0 state to command exciter equalizer to hold 3 EXC_A_ACTIVE_CMD Open collector output Exciter A active command 100mA sink capability 0 8Vdc max 1K ohm pull up to 5V TVS protection Active 0 state to command exciter equalizer to on air 4 NC No connection 5 GND Ground 6 GND Ground 7 EXC_A_MUTE_STATUS CMOS input Exciter A mute status 0 on this line indicates excit...

Page 154: ...VS protection Active 0 state to command exciter mute 2 EXC_B_EQUALIZER_HOLD_CMD Open collector output Exciter B equalizer hold command 100mA sink capability 0 8Vdc max 1K ohm pull up to 5V TVS protection Active 0 state to command exciter equalizer to hold 3 EXC_B_ACTIVE_CMD Open collector output Exciter B active command 100mA sink capability 0 8Vdc max 1K ohm pull up to 5V TVS protection Active 0 ...

Page 155: ...10 6 10 888 2629 200 4 19 WARNING Disconnect primary power prior to servicing Section 4 Theory of Operation Maxiva ULX COFDM Series Figure 4 8 PS Monitor Card Block Diagram ...

Page 156: ..._SAMPLE Analog input AC phase BC sample sine wave input scaled to 2Vrms 245VAC 6 PH_AC_SAMPLE Analog input AC phase AC sample sine wave input scaled to 2Vrms 245VAC 7 FUSE1 Open CMOS input MOV board sense status 1 on this line indicates the fuse is ok TVS protection 1M pull down 8 FUSE2 Open CMOS input MOV board sense status 1 on this line indicates the fuse is ok TVS protection 1M pull down 9 FUS...

Page 157: ..._SAMPLE Analog input AC phase BC sample sine wave input scaled to 2Vrms 245VAC 6 PH_AC_SAMPLE Analog input AC phase AC sample sine wave input scaled to 2Vrms 245VAC 7 FUSE1 Open CMOS input MOV board sense status 1 on this line indicates the fuse is ok TVS protection 1M pull down 8 FUSE2 Open CMOS input MOV board sense status 1 on this line indicates the fuse is ok TVS protection 1M pull down 9 FUS...

Page 158: ...MCM card in the main TCU Table 4 10 Life Support Functionality System Function Description Available in Life Support Mode TX On Transmitter ON command via front panel or parallel remote interface YES TX Off Transmitter OFF command via front panel or by parallel remote interface YES Power Raise Transmitter power raise command via front panel or by parallel remote interface YES Power Lower Transmitt...

Page 159: ...c level control if in AUTO YES VSWR Protection YES Fold Back Operation YES PA Module Summary Fault Monitoring YES PA Module Deep Fault Monitoring YES PA Module Meter Readings Not available due to loss of GUI display NO AC Faults Monitoring YES Liquid Inlet Outlet Temperature Faults YES Flow and Temperature Meter Readings Not available due to loss of GUI display NO Cabinet Summary Fault YES Safety ...

Page 160: ...node on a CAN bus do not contain addresses of either the transmitting node or of any intended receiving node Instead the content of each Message Frame e g ON OFF PS 1 Voltage Coolant Flow OK etc is labeled by an identifier that is unique throughout the network All other nodes on the network receive the message and each performs an acceptance test on the identifier to determine if the message and t...

Page 161: ...to the MCM Transmitter control signals are also sent via CAN but are also sent over hardwired parallel control lines 4 4 7 System Bus The system control bus is a twenty five conductor ribbon cable which distributes the CAN Controller Area Network bus and parallel control lines from the MCM card in cabinet one to other MCM controllers in a multi cabinet system If system bus communications with the ...

Page 162: ...gh 2 CAB_AC_LOW 3 3V CMOS Input 3 SYS_OFF_CMD 3 3V CMOS I O 4 SYS_RF_MUTE 3 3V CMOS I O 5 SYS_ALC 0 4 095V Analog I O 6 SYS_PS_ADJUST 0 4 095V Analog I O 7 SYS_FAULT_OFF 3 3V CMOS I O 8 SYS_SPARE1 3 3V CMOS I O 9 SYS_RESTRIKE 3 3V CMOS I O 10 SYS_SPARE2 3 3V CMOS I O 11 SYS_CTRLR_OK 3 3V CMOS I O 12 SYS_FAULT 3 3V CMOS I O 13 SYS_SPARE3 3 3V CMOS I O 14 SYS_CAN_L CAN 5V pass through 15 25 GND Tabl...

Page 163: ... CAN messages The following is a brief explanation of each of the parallel control lines included in the system control bus a SYS_ON_CMD This command corresponds to the transmitter operator pushing the ON button This signal is high for ON and produced by the MCM card in the TCU b SYS_OFF_CMD This command corresponds to the transmitter operator pushing the OFF button The signal is low for OFF and p...

Page 164: ...output and is normally sent digitally over the CAN bus This line carries an analog voltage from the MCM to the predriver modules The analog signal is an alternate version of the digital ALC signal sent over the CAN bus It is a backup signal only used if the PCM card in main cabinet cabinet one in multi cabinet systems fails If the PCU and it s associated CAN bus is operational this signal is not u...

Page 165: ...are two exciters the output of the exciters are connected to the exciter switch card in the main cabinet TCU In cases where there is a single exciter it s output goes directly to the pre driver For additional information on the M2X exciter see the exciter technical manual which ships with each transmitter 4 6 2 Predriver The Maxiva predriver provides redundant power and phase adjustment of the RF ...

Page 166: ...ich drives its own IPA The RF input to the predriver assembly feeds a two way splitter the output of which feed the two predriver trays The assembly is designed so that one predriver tray can be removed for servicing while the transmitter operates from the other predriver tray It should be noted here that only one IPA drives the PA the other is terminated in a load The IPA outputs feed a coax swit...

Page 167: ...e Connectors J5 J3 and J1 Interconnect to Interface Boards View From Rear of Predriver Assembly Interface Board 801 0222 261 J1 28 Volt Power Supply J2 J4 AC Predriver Tray B LED Assembly J3 J5 Phase Gain Board 801 0222 221 J3 DC and Control RF In RF Out J2 J1 CD2007 Amplifier RF In RF Out DC DC and Control Interface Board 801 0222 261 J1 28 Volt Power Supply J2 J4 AC Predriver Tray A LED Assembly...

Page 168: ...e and gain board is used by the transmitter to control cabinet power by driving the PA modules with more or less input power and cabinet phasing Figure 4 12 gives a block diagram of the phase and gain board Figure 4 12 Phase and Gain Board Block Diagram The CD2007 output amplifier has a peak rating of 35 watts and is generally operated over a 0 3 to 4 0 watt average range for digital to allow adeq...

Page 169: ...13 through A16 The RF signal enters each PA pallet through E1 and the amplifier signal leaves the pallet through E2 From the PA pallets the four RF signals enter the combiner board via ports 1 through 4 The combined output leaves the combiner board and the PA module through a blind mate RF connector Blind mate connector J1 is a combination RF and control connector A discussion of the connector pin...

Page 170: ...S Board A10 AC Distribution Board A2 801 0222 021 J10 J11 J12 AC Power J1 J2 J3 J4 J5 J6 J7 J8 J9 Monitor Board A18 This is the PA Control Board but it uses a CPLD instead of a microprocessor J2 J1 J3 J4 801 0222 051 J3 is the Test Jack Output Refer To Drawing 843 5601 012 For Greater Detail PA Pallet A13 801 0222 081 Splitter Board A11 801 0222 071 Signal Distribution Board A12 J1 E2 RF Out E1 RF...

Page 171: ...fore minimum Line N voltage is 187Vrms Three wire Delta WYE line to line power system Maxiva ULX power amplifier module employs a total of 8 power supply converters This presents an unbalanced load to the three phase power line grid 4 6 3 2 AC DC Converter Interface Board AC DC Converter Interface board is a 500W output AC to DC switching power supply It accepts universal AC input voltage from 85 ...

Page 172: ...n page 4 37 The PA voltage select path from the MCM board in the TCU to the IPA and PA backplanes shown with bold lines in figure Figure 4 14 is carried on pin 7 of the 25 conductor Cabinet Bus This represents the only use of the cabinet bus in the Maxiva transmitter Table 4 14 PS Connector Pin Assignments Pin Signal Description 1 AC1 Input 3 4A 240VAC fused at 5A 2 NC Not connected 3 AC2 Input 3 ...

Page 173: ...TCU J1 B5 J2 8 System Distribution Board Monitor Board AC Distribution Board J4 8 J1 8 J1 8 J2 1 J9 1 J1 8 J8 8 J2 7 IPA Backplane Board J3 B5 J4 B5 J1 8 PS 1 J1 8 PS 8 801 0222 131 801 0222 061 801 0222 051 801 0222 021 801 0221 031 801 0221 011 801 0222 101 801 0222 041 801 0222 081 801 0222 081 The IPA Modules are the same as the PA Modules therefore the voltage select signal path is the same a...

Page 174: ...d delivered to the UCP in the Maxiva ULX transmitter via individual separate wires The overall control logic is done via a CPLD device and there is no microprocessor on board and there is no serial communication designed into the PA monitor board Only one fault can be detected at a time If two or more fault conditions are detected simultaneously only the highest priority fault is shown through the...

Page 175: ...tor board communicates with all of the other boards in the PA module via its connectors J1 J2 and J4 Connector J3 on the Monitor board is a test output used by engineering 4 6 3 5 J1 PA or IPA Connector I O Board Refer to Figure 4 16 The pins of sections A through D of the connector are in horizontal rows of six pins with pin 1 to the left and pin 6 shown to the right The pins of sections A throug...

Page 176: ...L1 respectively If a 380 to 415 volt wye connection is used connector sections F H and K are connected to the 3 phase neutral The line or neutral choice is made by connecting jumpers between terminals 1 and 2 for neutral and between 2 and 3 for line inputs in the following listed IPA and PA backplane connectors In the IPA backplane use TB1 through TB6 In the PA backplane use TB3 through TB8 TB10 t...

Page 177: ...al that is applied on the input of the splitter between 4 power amplifier pallets The splitter has a broad band response that covers the entire TV Band IV V frequency range and requires no tuning Insertion phase of the signals at each of the outputs is configured to provide minimum loss re combining by the power combiner The splitter contains two splitting stages Each stage equally distributes the...

Page 178: ...tected signal to the Monitor Board p n 9010222051G The sampled base band signal amplitude indicates power level in dBm The third directional coupler serves to deliver a scaled down sample of output RF signal to a specially designated coaxial port at the front panel of the PA Module 4 6 3 10 RF Pallets The PA pallet serves as the single stage of amplification in the Triton module There are 4 PA pal...

Page 179: ... for each FET is set at the factory to approximately 1 amp Variations between FET idle currents should be less than 10 4 6 4 Module Combiner The module combiner is a compact water cooled hybrid combiner optimized to work across the entire UHF frequency band from 470MHz to 860MHz There are several combiner configurations depending on the number of PA modules used in the cabinet Figure 1 2 on page 1...

Page 180: ...ger Pump Module Diagrams Figure 4 18 is a block diagram that shows the major components in the heat exchanger pump module system The diagram shows the transmitter as the heat source but does not give details of the plumbing external to the heat exchanger pump module Figure 4 19 on page 4 46 shows the schematic diagram of the heat exchanger pump module control panel Information on interconnect wiri...

Page 181: ...10 6 10 888 2629 200 4 45 WARNING Disconnect primary power prior to servicing Section 4 Theory of Operation Maxiva ULX COFDM Series Figure 4 18 Heat Exchanger Pump Module Block Diagram ...

Page 182: ...4 46 888 2629 200 10 6 10 WARNING Disconnect primary power prior to servicing Section 4 Theory of Operation Maxiva ULX COFDM Series Figure 4 19 Heat Exchanger Pump Module Schematic ...

Page 183: ...10 6 10 888 2629 200 4 47 WARNING Disconnect primary power prior to servicing Section 4 Theory of Operation Maxiva ULX COFDM Series Figure 4 20 Heat Exchanger Pump Module Schematic_Part 1 ...

Page 184: ...ak detector to alert the system should a leak occur A leak detection will cause the transmitter and the pump to be shut off by activating the pump interlock signal In order to reset the leak detector the float must be removed and a drain plug removed Removing the drain plug allows the reservoir to drain into the drip pan at the bottom of the cabinet The cabinet can be emptied of coolant by opening...

Page 185: ...A modules are the same The predriver assembly features an RF splitter and two predriver modules It therefore has one input and three outputs The predriver assembly is discussed in greater detail 4 6 2 on page 4 29 and its block diagram is shown in Figure 4 11 on page 4 31 The two RF output signals from the predriver are applied to the IPA backplane where they drive two IPA modules The two IPA outp...

Page 186: ...axiva ULX COFDM Series Sync required for analog TV transmitters only The outputs from the PA modules are combined as follows PA Slots 1 through 8 are combined in 8 Way combiner A13 PA Slots 11 through 18 are combined in 8 Way combiner A12 The outputs of the two 8 Way combiners are joined in 2 Way combiner A14 ...

Page 187: ...12 PA Backplane A6 801 0222 101 PA Module 14 843 5601 012 PA Module 13 843 5601 012 PA Module 12 843 5601 012 PA Module 11 843 5601 012 PA Backplane A8 801 0222 101 PA Module 8 843 5601 012 PA Module 7 843 5601 012 PA Module 6 843 5601 012 PA Module 5 843 5601 012 PA Backplane A9 801 0222 101 PA Module 4 843 5601 012 PA Module 3 843 5601 012 PA Module 2 843 5601 012 PA Module 1 843 5601 012 4 4 4 ...

Page 188: ...4 52 888 2629 200 10 6 10 WARNING Disconnect primary power prior to servicing Section 4 Theory of Operation Maxiva ULX COFDM Series ...

Page 189: ...THIS LIMITS MODULE REPAIR TO A MODULAR LEVEL CONSISTING OF PALLETS AND PC BOARDS ONLY HOT SURFACE THE MAXIVA PA MODULES ARE DESIGNED TO HANDLE VERY HIGH TEMPERATURES AND MAY BE EXTREMELY HOT UP TO 90O F 32O C ABOVE ROOM TEMPERATURE DO NOT TOUCH THE MODULES WITH BARE HANDS AFTER THE TRANSMITTER HAS BEEN RUNNING ESPECIALLY IN HIGH AMBIENT TEMPERATURE ENVIRONMENTS SPECIAL GLOVES CAN BE OBTAINED FROM ...

Page 190: ...iguration The Slot No identifies the PA as it is displayed on the GUI screen Table 5 1 PA Slot Allocations for Single Cabinet Models Slot No 16PA Models 12 PA Models 10 PA Models 8 PA Models 6 PA Models 4 PA Models 3 PA Models 2 PA Models 18 PA PA PA x x x x x 17 PA PA PA x x x x x 16 PA PA PA x x x x x 15 PA PA PA x x x x x 14 PA PA PA x x x x x 13 PA PA PA x x x x x 12 PA x x x x x x x 11 PA x x...

Page 191: ... 5 1 on page 5 3 to identify module numbers and their locations in the cabinet PA and IPA driver modules can be removed or installed while the transmitter is operating but the following steps should be followed Redundant Drivers Redundant Pre Driver A Apex M2X Exciter B PA Slots 11 18 Apex M2X Exciter A Redundant Pre Driver B PA Slots 1 8 TCU System Controller IPA A slot 10 11 18 A B 8 1 IPA B slo...

Page 192: ...ull the module halfway out of the rack then reposition hands to the sides of the module to better support the weight 26 5kG Remove the module from the rack CAUTION DO NOT LET THE MODULE SWING DOWN WHEN PULLING THE MODULE OUT OF THE RACK THIS COULD CAUSE SEVERE DAMAGE TO THE CONNECTORS ON THE BACK OF THE MODULE 5 2 3 PA Module Installation To install a PA Module STEP 1 Inspect the connectors on the...

Page 193: ...low the module to cool sufficiently before reinserting Check the coolant connectors on the back of the PA module and on the coolant manifold The manifold connector has an O ring seal Figure 5 2 which must be in good condition to prevent leaks If there is evidence of a mechanical interference or misalignment of the coolant connectors on all the modules then a rack re alignment may be required This ...

Page 194: ... on how many modules are removed 5 2 5 PA Module Rack Alignment If difficulty installing modules is encountered and misalignment of the rack is encountered an alignment of the rack may be needed The following steps outline the alignment procedure STEP 1 Disconnect power from transmitter Turn off breakers AC1 and AC2 on the cabinet being aligned STEP 2 Drain system of coolant STEP 3 Remove all PA a...

Page 195: ... Rack Alignment STEP 5 Loosen hoses between upper and lower manifolds If more than 8 PA s NOTE The system was drained to avoid leaking at this connection when the clamp is loosened Loosening the clamp allows the upper and lower manifolds to move relative to each other Manifold Clamps Upper Manifold Clamps Lower Interconnect Hoses Manifold Drain Hoses Cabinet ...

Page 196: ...old connectors are a little higher than the module connectors STEP 7 Insert the module slowly and carefully until fully inserted onto the manifold connectors NOTE The manifold may have to be moved slightly to allow proper alignment between module connectors and manifold connectors Do not aggressively insert or dam age to the connectors may result STEP 8 Once the two modules are fully inserted and ...

Page 197: ... is required in the field PA modules and IPA driver modules can be used in any location without re phasing NOTE Phasing between cabinets is required to minimize cabinet combiner reject power and it is accomplished via the GUI screen Cabinet phase and gain is controlled by adusting the relative phase and level values of each cabinet using the pream plifiers 5 5 PA Module Component ID Before attempt...

Page 198: ...al Pin Signal Pin Signal Pin Signal 1 ON OFF STATUS 0V 4 9V 2 PS8 VOLTAGE 3 8V 27 P3 FET 1 CURRENT 3V 28 GND 3 PS VOLT SEL TB 44 5 15V 46 4 12V 48 2 49V 50 87V 4 GND 29 P3 FET 2 CURRENT 3V 30 CANH 3 2V 5 AVG INPUT POWER 012V 6 12V 11 9V 31 P4 FET 1 CURRENT 3V 32 CANL 0V 7 GND 8 12V 11 9V 33 P4 FET 2 CURRENT 3V 34 GND 9 OUTPUT POWER 023V 10 PALLET 1 TEMP 2 0V 35 PA SUM CURRENT 3V 36 SPI CS TMS 3 2V...

Page 199: ...module STEP 1 Turn off PA module breaker WARNING MODULE MAY BE HOT ALLOW THE MODULE TO COOL BEFORE REMOVAL STEP 2 Wait 30 seconds for the module to cool STEP 3 Unscrew retaining screws and remove PA module STEP 4 Remove PA module cover STEP 5 Remove four 4 center pallet hold down screws Allen head STEP 6 Remove five 5 additional pallet hold down screws Phillips head Allen Screws torque Jumper Jump...

Page 200: ... Use the screwdriver to gently pry upward without placing stress on adjacent boards Repeat this process along the edges of the board in several places until it loosens up STEP 9 Reapply heat transfer compound Use a small roller or brush to apply even thin coat STEP 10 Install pallet and all hold down screws STEP 11 Torque four 4 allen screws to 30 in lbs STEP 12 Solder two jumpers and the blue gra...

Page 201: ... NOTE PS board fuse is 5A 250V fast blow STEP 1 Turn off PA module breaker WARNING MODULE MAY BE HOT ALLOW THE MODULE TO COOL BEFORE REMOVAL STEP 2 Allow the module to cool for 30 seconds STEP 3 Unscrew retaining screws and remove PA module STEP 4 Remove PA module cover STEP 5 Remove four 4 PS hold down screws Phillips screws STEP 6 Remove supply wire from WAGO block STEP 7 Remove board from conne...

Page 202: ...ry on each board prior to installation into a module or shipment as a replacement part The output voltage can also be set in the field if a module test system is available The optional PA module test system part number is 971 0040 080 5 7 2 1 Setting Voltage STEP 1 Follow the PS board replacement steps outlined in Section 5 7 1 on page 5 13 stopping at step 10 STEP 2 Place the module in the module...

Page 203: ... before filters e Exciter Forward Power f PDU Forward Power NOTE Forward and Reflected power calibrations should only be done while operating the transmitter into a known good load or a low VSWR antenna system 5 8 1 Forward Power Calibration Equipment Used Maxiva Series precision directional couplers precision meaning that the coupling ratio has been measured at the exact operating frequency Avera...

Page 204: ...low d Connect the power meter probe to the Total Forward directional coupler port e Hold in power LOWER button for 20 seconds or navigate to Output screen and set Cab Ref Pwr to zero Either of these steps will insure that the transmitter does not produce large amounts of RF power at turn on f Turn on and adjust the Maxiva COFDM transmitter to licensed nominal power as programmed in the System Setu...

Page 205: ... kW detector voltage level should be between 3 0 and 3 4V at full rated power Operating in this range insures measurement accuracy in detector s linear region If the detected levels are too high attenuation will need to be added at the coupler port to reduce the detected voltage level k To access the Calibration screen press SYSTEM SERVICE SYSTEM SETUP CALIBRATE shown in Figure 5 8 on page 5 17 Fi...

Page 206: ...upler s offset into the power meter Dif ferent couplers will have different coupling values Figure 5 9 Cabinet Coupler 5 8 2 Reflected Power Calibrate This procedure establishes the values used to calculate the VSWR protection thresholds for Foldback and Fault events These values are based on the Nominal Power Output value entered into the System Setup screen in Figure 3 22 on page 3 26 The foldba...

Page 207: ... the user A 1 9 1 VSWR corresponds to 9 63 reflected power NOTE The cabinet fault threshold is set to 1 9 1 at the factory Contact Harris service if these values need to be changed 5 8 2 1 Calibrate Reflected Total Power NOTE Before attempting reflected calibration Forward calibration must be verified a Turn on and adjust Maxiva Series transmitter to 100 rated average peak power according to the b...

Page 208: ...reflected detector voltage for later use in setting thresholds NOTE At this time the VSWR protection could be verified by pressing the Enable VSWR button CALIBRATE screen The transmitter should fault off i Remove the 10 dB pad and return the reflected cable to the reflected port on the coupler Reconnect the forward cable to the forward coupler port j Turn on the transmitter and adjust Maxiva ULX S...

Page 209: ...d on the exciter web browser screens 5 8 4 PDU Calibration The predriver unit PDU has a forward power directional coupler for each preamp module to measure input power This power reading shows up on the SYSTEM SERVICE SYSTEM SETUP CALIBRATE CABINET CALIBRATE screen shown in Figure 5 10 Calibration Procedure NOTE This value is preset at the factory Should it need to be reset in the field use this p...

Page 210: ...an exciter issue and disables ALC STEP 5 Press the window of the active PDU input to be calibrated and enter the values determined in STEP 5 The value entered should be in uW micro Watts STEP 6 Press DONE to store the changes or CANCEL to discard the changes STEP 7 Select the other predriver and repeat the procedure to calibrate the other predriver power output Figure 5 10 Cab Pwr Calibrate Screen...

Page 211: ...ing the following steps STEP 1 Set the exciter to nominal output 100 mW average STEP 2 Lower exciter output power to 50 mW using the web browser STEP 3 Press the threshold Cal window and adjust the Cal value higher in 1 V increments until the red fault LED on the TCU exciter switcher card lights NOTE To view the LED on the exciter switcher card the front panel of the TCU must be pivoted downward S...

Page 212: ...8 5 3 System Reflected Thresholds System reflected threshold voltage should be set to approximately 100 mV less than the detector voltage level noted in 5 8 2 1 Calibrate Reflected Total Power on page 5 19 Approximately 2 4V is typical For a 6kW digital transmitter this corresponds to a reflected power level of 168W 5 8 5 4 System Foldback Power System foldback power Watts can be set as needed to ...

Page 213: ...whenever the transmitter is on The fans are redundant either of the fans can be removed while the transmitter continues operating with one remaining operational fan The cabinet cooling fans supply air to the PA modules IPA driver modules and the predrivers Exhaust air from the fans exits the cabinet at the top 5 9 1 Cabinet Fan Removal STEP 1 Open the rear cabinet door STEP 2 Disconnect connectors...

Page 214: ... and Alignments Maxiva ULX COFDM Series Figure 5 13 Fan Bracket Hardware STEP 4 Fan enclosure can now be removed from the cabinet angling the rear of the unit toward the center of the cabinet and pulling it out through the door opening NOTE The fan capacitor is located inside the fan enclosure REMOVE ...

Page 215: ...TEP 1 Turn off the transmitter Remove all power and turn of main breakers AC1 and AC2 Disable remote operation to prevent transmitter from being reactivated STEP 2 Remove the cabinet fan assemblies The fan removal sequence is described in section 5 9 on page 5 25 STEP 3 Loosen the clamp that holds the output coax in the flange see Figure 5 15 on page 5 28 STEP 4 Lift the output coax and inner cond...

Page 216: ... Section 5 Maintenance and Alignments Maxiva ULX COFDM Series Figure 5 15 RF Output Plate STEP 6 Loosen the clamp on the outer conductor flange coupling that is located the cabinet output directional coupler see Figure 5 16 on page 5 29 Plate Screws 4 places RF Output Coax Clamp ...

Page 217: ... section in a safe location STEP 8 Loosen the clamp that holds the hybrid combiner reject port elbow in place while supporting the back to back elbow assembly and the reject load Lower the elbow see Figure 5 19 on page 5 31 to disconnect the inner conductor bullet Lift the back to back elbows and reject load with attached coolant hoses up and out of the way It can be temporarily tied up out of the...

Page 218: ...cing Section 5 Maintenance and Alignments Maxiva ULX COFDM Series Figure 5 17 RF Support Bracket Lower STEP 10 Use a 13 mm wrench to remove the two bolts from the center of the RF support bracket see Figure 5 18 on page 5 30 Figure 5 18 RF Support Bracket Lower Remove Remove ...

Page 219: ...es from the directional coupler at the output of the hybrid combiner STEP 12 While supporting the weight of the hybrid combiner coax RF system loosen the clamps on outer conductor sleeves at the output of the lower and then the upper module combiners Slide the coaxial sleeves to the right to expos the inner conductor The loosened upper clamp is show in Figure 5 20 on page 5 32 Clamp Elbow Reject L...

Page 220: ... are loose the hybrid coupler and coaxial assembly can be supported and then pulled away from the module combiners The hybrid combiner coaxial RF system can then be removed from the cabinet and stored in a safe location The hybrid combiner coaxial output assembly is shown in Figure 5 21 on page 5 32 The cabinet with the RF system removed is shown in Figure 5 22 on page 5 33 Figure 5 21 Hybrid Comb...

Page 221: ...isconnect primary power prior to servicing Section 5 Maintenance and Alignments Maxiva ULX COFDM Series Figure 5 22 Cabinet with RF System Removed STEP 14 Reverse the procedure to reinstall the cabinet RF system STEP 15 End of procedure ...

Page 222: ...p both pumps in a proper working state Switching the pumps can be accomplished via the GUI screen with pump module in REMOTE mode by pressing SYSTEM then press the button for the inactive pump This can also be done with the pump module in LOCAL mode by pressing the Pump Select button This may also be a good time to manually operate open and close them several times all valves to assure proper move...

Page 223: ...mbled and cleaned when the transmitter is off the air since the coolant flow must be disrupted prior to opening the strainer assembly Follow the steps that follow to clean the strainer a Turn off the transmitter and pump module b Close the ball valves on either side of the strainer CAUTION WEAR SUITABLE PROTECTIVE GLOVES AND EYE PROTECTION WHEN REMOVING THE STRAINER CAP LOOSEN THE CAP SLOWLY SINCE...

Page 224: ... 5 11 1 4 Coolant Level Management The Maxiva cooling system is a closed pressurized system The system contains a pressurized expansion tank with a bladder that separates the system coolant from pressurized air The expansion tank is pressurized at the factory and should not need pressurization on site The coolant level is checked by viewing the coolant passing through the sight glass located on th...

Page 225: ...at 3 month intervals as well 5 11 1 5 2 Changing Pumps a Turn off the transmitter and pump module b Close the ball isolation valves on either side of the pump that is to be changed c Disconnect the fittings on either side of the pump NOTE A small amount of liquid will still be present in the pipe and pump housing and a receptacle bucket will be necessary to contain the spillage WARNING WEAR SUITAB...

Page 226: ...ithout Transmitter The pump module can be operated independently without being attached to the transmitter by selecting the LOCAL mode on the pump module heat exchanger cooling control panel CAUTION SELECTION OF LOCAL WILL ALSO ALLOW THE PUMP MODULE HEAT EXCHANGER TO BE OPERATED FROM THE CONTROL PANEL AS LONG AS THE PUMP INTERLOCK IS NOT ACTIVE 5 11 2 Air Filter Replacement Monthly inspection and ...

Page 227: ...ith compressed air wash with detergent water or replace as necessary h Reinstall dry filter by reversing the order of the above steps 5 11 3 LCD Screen Adjustments 5 11 3 1 LCD Screen Contrast The LCD display contrast can be adjusted by accessing the GUI SYSTEM SERVICE ADMIN screen Press the white text box for the LCD Contrast and a pop up window will appear to allow the setting to be adjusted 5 1...

Page 228: ...ferent Harris transmitter models The TCU will contain different printed circuit cards depending on the transmitter application TCU s that have GUI graphical user interface touch screen displays will contain a PCM card The PCM card is the second card from the right when looking at the front of the TCU Figure 5 26 TCU with front panel lowered Maxiva transmitter shown The PCM card contains a battery ...

Page 229: ...tains battery replacement instructions Once the transmitter is installed and AC power has been connected the clock battery should be installed in the PCM card 5 11 4 1 PCM Battery Installation Instructions STEP 1 Turn off the transmitter and disconnect power from the transmitter cabinet or disconnect the AC plug s from the rear of the TCU Figure 5 27 Rear of TCU cards removed STEP 2 Use the cut ou...

Page 230: ...kets STEP 3 On Maxiva ULX transmitters the entire TCU unit can be pivoted downward for easier access to the cards This is done by removing the front screw shown in figure 5 28 on either side of the TCU slide brackets CAUTION THE TCU MUST BE SUPPORTED WHILE REMOVING THESE SCREWS TO KEEP IT FROM FALLING DOWNWARD RAPIDLY Remove 1 screw from each side to pivot TCU down ...

Page 231: ...ivoted Downward NOTE In other types of transmitters like LAX and HPX the TCU can t be pivoted down ward In these cases a stool or ladder may be used to gain easier access to the top of the TCU unit STEP 4 Remove the top cover from the TCU to gain easier access to the PCM card STEP 5 Locate the battery holder on the PCM card Location is shown in figure 5 30 ...

Page 232: ...STEP 6 Use a small flat blade screw driver to gently pry open the battery hold down clip while sliding the battery under the clip The side of the battery must installed closest to the battery clip i e the side must point away from the board in the holder The installed battery is shown in figure 5 31 CAUTION SEE FIGURE 5 31 NOTE THAT THE SIDE OF THE BATTERY SHOWS NEAR THE CLIP PCM battery holder ...

Page 233: ...a network the system time and date will reset automatically after the TCU is restarted If not connected to a network set the TCU system time date using the Home System System Service screen on the GUI STEP 12 End of procedure 5 11 5 TCU Card Replacement Should it become necessary to change cards in the TCU use the following procedure STEP 1 Go to the System Service Version screen and note the revi...

Page 234: ... easier access to the top of the TCU unit STEP 5 Remove the top cover from the TCU to gain easier access to the TCU cards STEP 6 Remove connectors from the rear of the card that is being changed STEP 7 Lift the board out of the slot and replace with new board NOTE If the MCM card is changed the flash drive card should be removed from the old board and installed in the new board This will allow the...

Page 235: ...to VT100 if VT100 is connected to RS 232 port NOTE If the MCM card is changed the flash drive card should be removed from the old board and installed in the new board This will allow the system to retain previ ously stored calibration values 5 12 Typical Test Equipment Table 5 3 Recommended Test Equipment Equipment Type Manufacturer Model Number Options Harris Part No if applicable TV Spectrum Ana...

Page 236: ...04 000 BNC barrel male to male 620 0564 000 SMA to BNC male to female 620 2611 000 SMA to N male to female 620 2562 000 SMB push on to BNC 620 0628 000 SMC to BNC screw on jack to plug 620 2563 000 BNC to TNC jack to plug 620 2821 000 BNC to TNC jack to jack 620 2823 000 TNC to N plug to jack 620 2824 000 TNC to N jack to plug 620 2822 000 Attenuator 10 dB attenuator type N male to female 556 0074...

Page 237: ...n then be easily exchanged The GUI buttons and icons use a symbol and color code system Some examples using the triangle shape are given below The other shapes operate similarly a Green with a 1 ON and operating normally b Green symbol ON and operating normally c Light Gray Grayed Out Not communicating or not available d Yellow Warning A non critical sub system or parameter is out of tolerance and...

Page 238: ...press SYSTEM then SYSTEM LOG This will bring up the screen in Figure 6 2 The System Log gives the following information a This gives the number of the fault There can be up to 99 faults in the log then it is FIFO First IN First Out b Fault Type This is simply the name of the fault c Time and Date This gives the exact time and date that the fault occurred d Active or Inactive If the fault is highli...

Page 239: ... Screen 6 3 Maxiva Three Strike Fault Actions 6 3 1 Reflected Power Faults The TCU monitors reflected power at the Cabinet output and at the System output When the reflected power level typically 10 of the rated power or a 1 9 1 VSWR is exceeded the TCU generates an RF MUTE If after three attempts to restart three strikes subsequent faults occur the transmitter will turn OFF and operator intervent...

Page 240: ...N Command There is a 3 second delay between restart attempts The fault strike restart process is the same as the system restart command all of the module faults will be reset During the 10 second three strike window any of the nuisance faults will be reported to the Main Controller These are the module faults which will be allowed three strikes Over Voltage Pallet Under Voltage Pallet Over Tempera...

Page 241: ...PA if in Auto Mode YES YES IPA B Fault Power Supply LDMOS VSWR Power Overload Tempera ture Input Power The IPA can report upto 6 faults via their parallel con trol pins Any one fault active IPA Switch to alternate IPA if in Auto Mode YES YES PDU Predriver A Fault The Predriver cur rent is monitored inside the PDU A fault is sent if it is below the normal minimum current Predriver current is below ...

Page 242: ...cted Exciter Switch to alternate Exciter if in Auto Mode NO NO EXCB NO COMMU NICATIONS Exciter B not com municating with transmitter main controller No serial communica tions traffic detected Exciter Switch to alternate Exciter if in Auto Mode NO NO EXCA Summary Fault Exciter A reports a summary fault Exciter Switch to alter nate Exciter if in Auto Mode NO YES EXCB Summary Fault Exciter B reports ...

Page 243: ...va ULX COFDM Series Table 6 2 PA and IPA Module Fault List TYPE Description Fault Level or Threshold Transmitter Action Three Strike Available in Life Support Temperature Fault YES YES VSWR Fault YES YES Power Overload including Input Power Overdrive YES LD MOSFET Failure YES YES Input Power Low YES YES ...

Page 244: ...ltage Failure Value is more than 15 of normal reading WARNING NO YES 3 3 VDC FLT 3 3V Voltage Fail ure WARNING WARNING NO YES AC Mains High AC Mains voltage has exceeded 10 above nominal WARNING NO YES AC Mains Low AC Mains voltage has exceeded 15 below nominal Any phase is greater than 5 of the average of all three phases NO YES AC Phase Imbalance AC line imbalance phase to phase Wrong sequence W...

Page 245: ...Fuse failed on MOV board FUSE OPEN WARNING NO YES MOV Fuse 3 Fuse failed on MOV board FUSE OPEN WARNING NO YES MOV Fuse 4 Fuse failed on MOV board Value is more than 15 of normal reading WARNING NO YES Table 6 3 Power Supply Faults List TYPE Description Fault Level or Threshold Transmitter Action Three Strike Available in Life Support ...

Page 246: ...ed Power has exceeded 10 of rated power Trip point is set at VSWR 1 9 1 Foldback starts at 1 4 1 Trip point adjustable by epot Foldback set point adjustable by soft ware RF MUTE Fault OFF after 3 strike The Time interval between strikes should be about 3 senconds YES YES for trip NO for Fold back Fold back routine requires PCM action Cabinet For ward Power Fault Visual Power in Analog TV Cabinet F...

Page 247: ...VSWR Trip point is set at VSWR 1 4 1 This is a software trip point which depends on the transmitter nomi nal power WARNING NO NO Reject 1 Fault Reject power threshold exceeded WARNING NO YES YES Reject 2 Fault Reject power threshold exceeded WARNING NO YES YES Reject 3 Fault Reject power threshold exceeded WARNING NO YES YES Table 6 4 Output Faults List TYPE Description Fault Level or Threshold Tr...

Page 248: ...s less than the minimum Liters per minute flow rate for the number of PAs present Depends on transmitter model RF MUTE followed by pump switcho ver If still insuffi cient flow RF MUTE stays active until proper flow is restored Transmit ter returns to ON state automatically when fault clears NO YES Coolant Leak Coolant leak detected inside transmitter cabinet N A Transmitter Fault OFF A manual turn...

Page 249: ... empty Open circuit from level detector inside tank Transmitter Fault OFF A manual turn ON is required for recovery NO YES Coolant Warning The coolant in the tank is low Open circuit from level detector inside tank WARNING NO YES Fan 1 Fault Fan AC current too low or too high Fault levels LOW 100 mA HIGH 800 mA WARNING NO YES Fan 2 Fault WARNING NO YES System Safety Inter lock Open circuit Transmi...

Page 250: ...utomatically when the interlock is closed NO YES Cabinet Safety Inter lock Open circuit Cabinet Fault OFF A manual turn ON is required for recovery NO YES Cabinet RF Mute Inter lock Open circuit Cabinet RF MUTE Cabinet returns to ON state automati cally when the interlock is closed NO YES Table 6 5 System Faults List TYPE Description Fault Level or Threshold Transmitter Action Three Strike Availab...

Page 251: ...PA MODULE 971 0040 004 P 7 4 Table 7 10 DUAL CIRCUIT BREAKER ASSEMBLY 208 240V 971 0040 033 J 7 4 Table 7 11 ANALOG PKG 16PA 971 0040 059 B 7 5 Table 7 12 CABLE ANALOG EXCITER A I O 952 9253 057 A 7 5 Table 7 13 CABLE ANALOG RF 952 9253 063 C 7 5 Table 7 14 CUSTOMER I O ASSEMBLY ANALOG 971 0040 022 D 7 5 Table 7 15 MAXIVA 16PA BASIC TRANSMITTER 981 0418 001 AB 7 6 Table 7 16 ASM TOP UCP TRITON SYS...

Page 252: ...RITON PA MODULE 0 EA 971 0040 004 ASSEMBLY MAXIVA ULX PA MODULE 18 EA 971 0040 020 CUSTOMER I O ASSEMBLY DIGITAL 0 EA A1 971 0040 033 DUAL CIRCUIT BREAKER ASSEMBLY 208 240V 0 EA 971 0040 037 DUAL CIRCUIT BREAKER ASSEMBLY 380 415V 0 EA 971 0040 059 ANALOG PKG 16PA 0 EA 971 0040 075 KIT CE DIGITAL MAXIVA ULX 0 EA 971 0040 080 UNIT PA DIAGNOSTICS 0 EA 971 0040 095 KIT SINGLE EXCITER 0 EA 981 0222 012...

Page 253: ...HEX 3 8 16 25 EA 310 0011 000 WASHER FLAT 3 8 SST ANSI REGULAR 25 EA 314 0011 000 LOCKWASHER SPLIT 3 8 SST ANSI 25 EA 358 1131 000 NUT W SPRING 3 8 16 15 EA 359 1933 000 ADAPTER M M GARDEN HOSE 1 EA 843 5601 562 LAYOUT PLUMBING MAXIVA 1PA DRYCOOLER 0 DWG 217510003 HOSE RUBBER 1 500 ID 100 FT 359 1573 000 HOSE BARB 1 1 2 6 EA 943 5585 257 ASSY MANIFOLD SUPPLY RETURN MAXIVA 1 EA 358 3493 000 HOSE BA...

Page 254: ...AY IN 6 EA Table 7 5 MAXIVA ULX SYSTEM WIRING KIT 943 5276 184 B P Harris PN Description Qty UM Reference Designators 34010082 CU STRAP 0 020 X 2 X 50 1 EA 250 0443 000 CABLE 12C 20AWG STRD 50 FT 253 0059 000 CABLE 2C 22AWG AUDIO 50 FT 618 0511 100 COAX CABLE RG 223 U 100 FT REEL 1 RL 620 0818 000 PLUG BNC STRAIGHT CABLE 4 EA 620 2174 000 N PLUG CRIMP ST 4 EA Table 7 6 ASSEMBLY MAXIVA ULX PA MODUL...

Page 255: ...EADER 1 EA A17 922 1300 019 CABLE RF INPUT 1 EA 943 5601 009 RING TEFLON 7 8 RF RECPTACLE 1 EA 943 5601 011 INSULATION AC DISTRIBUTION PWA 1 EA 943 5601 046 FENCE PALLET SHIELD 3 EA 943 5601 047 FENCE RF DIVIDER 1 EA 943 5601 048 COVER PA MODULE 1 EA 943 5601 061 WASHER SHOULDER 4 EA 943 5601 101 FENCE PALLET SHIELD 1 EA 943 5601 122 PA COLDPLATE ASSEMBLY TRITON PA MODULE1 EA 943 5601 125 PANEL SI...

Page 256: ...11 KIT CE DIGITAL MAXIVA ULX 971 0040 075 A P Harris PN Description Qty UM Reference Designators 302 0972 000 SCREW SKT HD CAP M5 X 18 4 EA 344 0248 000 SCREW 8 X 3 4L SHEET METAL 12 EA 358 0498 000 HOSE CLAMP SST SAE 48 22 EA 448 1082 000 GASKET EMI RFI SHIELDING 27 15 FT 448 1383 000 LATCH FLUSH MOUNT BLACK 2 EA 448 1399 000 HINGE METAL LIFT OFF 2 EA 943 5601 553 WINDOW CE DOOR 1 EA 943 5601 555...

Page 257: ... ADAPTER 7 8 TO 7 16 1 EA 843 5601 612 BLOCK DIAGRAM AC DISTRIBUTION 1 DWG 943 5601 600 CHASSIS MODULE TEST FIXTURE 1 EA 943 5601 602 COVER MODULE TEST FIXTURE 1 EA 943 5601 603 COVER MTG TEST FIXTURE 1 EA 943 5601 604 HINGE STOP TEST FIXTURE 1 EA 943 5601 605 ANGLE STOP MODULE TEST FIXTURE 1 EA 943 5601 606 GUIDE MODULE TEST FIXTURE 1 EA 943 5601 608 AC PANEL INTERFACE MODULE TEST FIXTURE 1 EA 97...

Page 258: ...000 NAMEPLATE HARRIS LOGO 1 EA 646 1701 000 NAMEPLATE MAXIVA 1 EA 700 1422 042 RF LOAD 10KW 3 1 8 WATER COOL 1 EA 792 0207 000 3 01DB HYBRID 20KW AVE OUTPUT POWER 1 EA A14 9010222101G PWA 4PA BACKPLANE BOARD 4 EA A5 A6 A8 A9 917 2558 099 STANDOFF M F M4 X 25 16 EA 917 2567 017 DIN RAIL CUT LENGTH 612MM 1 EA 943 5560 052 PANEL FRONT BLANK 2U 1 EA 943 5601 049 CABLE BACKPLANE AC 8 EA 943 5601 088 OU...

Page 259: ...0 PIN PULL 3 16 OD X 3 0 LG 1 EA 358 2589 000 MOUNT RIBBON CABLE 2 10 EA 358 2628 000 CABLE PUSH MOUNT 2 EA 358 3197 000 SLIDES 10 PAIR 1 PR 359 1268 000 VALVE 3 8 MINI BALL 2 EA 359 1273 000 HOSE END 3 8 BARBED 2 EA 359 1874 000 FTG 1 25 HOSE BARB X 1 MIPT BRASS 2 EA 359 1922 000 HOSE BARB 3 8 HOSE X 3 8 FIPT 2 EA 424 0502 000 BUMPER 5 8 DIA X 1 4 THK 1 EA 448 0868 000 AIR FILTER 14 X 20 X 88 1 E...

Page 260: ...TRACTOR 1 EA 943 5601 328 PLATE ANGLED COVER 1 EA 943 5601 330 COVER ACCESS 1 EA 943 5601 332 SHIELD I O BOARD 1 EA 943 5601 398 INSULATOR IPA BACKPLANE 1 EA 943 5601 432 PANEL UCP M2X MOUNTING 2 EA 943 5601 433 RAIL M2X MOUNTING 2 EA 943 5601 434 RAIL UCP CABLE MOUNTING 1 EA 943 5601 435 RETRACTOR CABLE 1 EA 943 5601 436 CLAMP LOAD MANIFOLD 2 EA 943 5601 437 ANGLE FRONT TRIM 2 EA 943 5601 532 PLA...

Page 261: ...4 0 7 X 8 SEMS 8 EA 303 4104 016 SCREW MACH M4 0 7 X 16 1 EA 303 4203 006 SCREW MACH M3 0 5 X 6 4 EA 303 4204 035 SCREW MACH M4 0 7 X 35 4 EA 304 0174 000 NUT JAM BRASS 1 2 28 7 EA 306 0028 000 NUT HEX KEPS M4 ZINC 10 EA 307 0001 040 NUT STD HEX M4 0 7 X 8H 2 EA 314 0014 000 WASHER INT LOCK 1 2 7 EA 315 0023 040 WASHER EXT LOCK M4 3 EA 33 351 EMI CLIP SMALL SINGLE 19 EA 336 1330 000 STDOFF M F 4 5...

Page 262: ...1 0274 001 EXCITER APEX M2X BASIC 1 EA 971 0035 014 ASM SUB BLANK PANEL B 1 EA 971 0035 015 ASM SUB BLANK PANEL C 0 EA 971 0035 013 ASM SUB BLANK PANEL A 1 EA Table 7 19 FORMAT EXCITER APEX M2X ATV 995 0063 005 G 5 Harris PN Description Qty UM Reference Designators 971 0035 003 KIT BATTERY BACKUP 0 EA 9710035011G ASM SUB TX IO INTERFACE MODULE 0 EA 9710035020G ASSY ATV INPUT OPTION 1 EA 981 0274 0...

Page 263: ...d brass ball PTFE seats seals 9303 Type J MGO Thermocouple with jack 0 250 OD X 4 long 304SS sheath ungrounded junction 1 4 NPTM brass compression FTG STD male 6419 Ft of Type J Thermocouple Extension Wire 20Ga red white with solid duplex parallel extruded PVC jacket insulation 221F insulation 14862 1 25 Terminator Ball Valve union end No PT C x M copper X male NPT 14861 1 5 Terminator Ball Calve ...

Page 264: ...or Mounted Disconnect OT16 25 32ET3 Black UL NEMA type 1 3R 12 IP65 14855 Transformer 150VA 13841 Fuse Holder Cover Kit for Sola XFMR 6603 Fuse 2A 600V Class CC Time Delay Rejection Type 2197 Fuse 3 2A 600V Class CC Time Delay Rejection Type 14726 Power Supply 15W 12VDC 1 2A Output 14850 Socket Base for ABB Alternating Relay 11 Pin 14848 Alternating Relay 120VAC DPDT with rotary switch 11 pin octa...

Page 265: ...MP commoning link B frame B 9300 IDEC Momentary Pushbutton 1NC Contact black flush type 14825 IDEC Selector Switch 2 Position 1NC contact 7902 IDEC Contact Block 1NC 7883 IDEC Pilot Light Green LED 120VAC round flush type 10535 Cage Clamp Term Block RED 2L 10538 Cage Clamp Term Block WHITE 2L 10536 Cage Clamp Term Block BLUE 2L 14779 Cage Clamp Term Block ORANGE 2L 10543 Cage Clamp End Plate GREY ...

Page 266: ...7 16 888 2629 200 10 6 10 WARNING Disconnect primary power prior to servicing Section 7 Parts List Maxiva ULX COFDM Series ...

Page 267: ... Table A 1 Tools and Materials Needed For RF Feed Line Construction Welding Torch Set Hacksaw and Extra Blades Oxygen and Acetylene Tanks Plumb Bob Welder s Mask or Goggles Chalk Line Power Band Saw can be rented and Extra Blades Wrenches Silver Solder 1 16 inch diameter 30 45 Hard Stay Silv 45 Aladdin 45 HARRIS part number 086 0004 060 Crowbar Paste flux Engelhard Ultra Flux 1 lb jar HARRIS part ...

Page 268: ... deburred 5 Using the suggested techniques for installing the flanges given in Section A 4 solder a flange to each end of the outer conductor 6 Measure the flange face to flange face dimension after soldering to confirm the prop er length and to determine the initial length of the inner conductor 7 Determine the length of the inner conductor by using the flange face to flange face dimension of the...

Page 269: ...ction Below Cut Length Outer Conductor Flange to Flange Length Flange Silver Solder Ring some suppliers may not provide this grove Outer Conductor Cut Back For Each Flange Groove For O ring Mating Surface Teflon Portion of Bullet Note The cutback will vary for different transmission line manufacturers Cutback for inner conductor The amount of cutback vary for different transmission line manufactur...

Page 270: ...hem If the saw has an au tomatic feed cut slowly It is critical that the support saw horses be made level with the saw Test cuts should first be made using scrap pipe or a wood 4x4 to verify that the blade is not 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 4 Method 4 Tub...

Page 271: ...s Figure A 5 Cutting With a Hand Band Saw Correct Depth Cut Too Deep Start Cut Stop Cut Turn Line Approximately 45 Degrees Finish cut on second pass Keeping the blade from falling too far below the surface keeps the cut smooth On the first pass score the cut Do not let the blade go below the surface ...

Page 272: ...A 6 888 2629 200 10 6 10 WARNING Disconnect primary power prior to servicing Maxiva ULX COFDM Series Figure A 6 Swing Arm Band Saw Cutting Tips ...

Page 273: ... of flux to the line and to the flange 5 Slide the flange onto the end of the outer conductor Warning SKIN BURN HAZARD TEMPERATURE OF THE HEATED LINE IN THE FOLLOWING STEPS IS QUITE HIGH AND PRECAUTIONS MUST BE TAKEN TO AVOID CONTACT WITH EXPOSED SKIN 6 Stand the line on end vertical for soldering flange to be soldered pointing down Ensure that the flange remains square with the outer conductor 7 ...

Page 274: ...el wool will remove torch black with good results In addition cleaning with an acid solution can make this job easier The procedure is as follows Warning MURIATIC ACID USED IN THE FOLLOWING PROCEDURE IS HAZARDOUS USE EYE AND SKIN PROTECTION WHEN HANDLING OR MIXING KEEP AN EXTRA BOX OF BAKING SODA HANDY FOR FIRST AID OR TO NEUTRALIZE SPILLS PERFORM THE PROCEDURES OUTDOORS IF POSSIBLE IF THE WORK MU...

Page 275: ... the line into the soda solution This will stop the action of the ac id 5 Use a Scotch Bright pad or steel wool to scrub off the remaining torch black 6 If the flux scale is particularly stubborn repeat the process 7 When finished rinse thoroughly when done with water and dry the line before assem bling A 5 1 Alternate Cleaning Method The following is an alternate procedure to clean the soldered t...

Page 276: ...set from 10 to 20 min utes 3 Scrub the line with Scotch Brite or the BBQ Grill pad to loosen the torch black and flux scale 4 Flush with water until the Naval Jelly residue is gone 5 Repeat the process until all the torch black and flux scale is removed The first application of the Naval Jelly will remove the torch black and some of the flux scale Normally if vigorous scrubbing is done repeating t...

Page 277: ...t must be obtained from the manufacturer in order to calculate the transmitter power output calorimetrically Caution DO NOT USE AUTOMOTIVE GRADE ANTI FREEZE AS A SUBSTITUTION FOR INDUSTRIAL GRADE GLYCOL IT DOES NOT CONTAIN THE PROPER INHIBITORS FOR THIS APPLICATION AND WILL LEAD TO EVENTUAL DAMAGE OF THE SYSTEM Table B 1 Recommended Coolants Description Part Numbers Ucartherm Cooling Fluid ethylen...

Page 278: ...N 200K OHMS The quality of water mixed with glycol concentrate can impact system performance Poor quality water can cause scale sediment deposits or sludge throughout the cooling which will reduce heat transfer efficiency Poor quality water can also cause damage to the system by depleting the corrosion inhibitor and can lead to the creation of a number of corrosions including general and acidic at...

Page 279: ...angle iron or channel and hangers needed to support the plumbing Tubing cutter or a hack saw always de bur the line remove any rough points or flared in edges at the cut after cutting Warning TEMPERATURE OF THE HEATED LINE IN THE FOLLOWING STEPS IS QUITE HIGH PRECAUTIONS MUST BE TAKEN TO AVOID CONTACT WITH EXPOSED SKIN B 2 2 Pipe Sizing and Routing If a typical system layout is not used the typica...

Page 280: ...ipe sections Any improperly cleaned and poorly fluxed surfaces either one or both will not allow the solder to flow properly for continuous adherence of the solder to the two surfaces being soldered After cleaning and fluxing a continuous and evenly distributed application of heat without overheating will result in an evenly distributed flow of solder between the surfaces being soldered for a plum...

Page 281: ...he installation process centers around the need for the discipline of personnel in and around the cooling system installation area Under no circumstances should anyone cooling system installer and or workers in other disciplines and areas walk on pipes and fittings that have or have not been positioned and soldered Although probably convenient for passage between adjacent work areas walking on alr...

Page 282: ...bundance of vegetation is present this inspection will be required weekly c To achieve even usage time per unit and ascertain that back up integrity exists it is recommended that the pumps in the pump module are operated alternately one month at a time a Check the pump module pressure gauge to ensure that a consistant stable pressure is indicated b Inspect and clean the filtration loop c Check flo...

Page 283: ...gital refractometer to verify the 50 50 mixture The hydrometer should be capable of measuring specific gravity in the 1 02 to 1 08 range Extract a sample of the coolant being used and cool it to 60oF Note this is the temperature to which your hydrometer has been calibrated Read the specific gravity as accurately as possible With this number the concentration or per cent of glycol in the solution c...

Page 284: ...096 50 0 98807 61 682 12 0 99952 62 3969 52 0 98715 61624 14 0 99927 62 3811 54 0 98621 61 566 16 0 99897 62 3623 56 0 98524 61 505 18 0 99862 62 3407 58 0 98425 61 443 20 0 99823 62 3164 60 0 98324 61 380 22 0 99780 62 2894 62 0 98220 61 315 24 0 99732 62 2598 64 0 98113 61 249 26 0 99681 62 2278 66 0 98005 61 181 28 0 99626 62 1934 68 0 97894 61 112 30 0 99567 62 1568 70 0 97781 61 041 32 0 9950...

Page 285: ...uid portion of the cooling system Ucartherm can be purchased from Harris in 55 Gallon lots using the following part numbers 051 1010 021 Ucartherm 50 50 solution 051 1010 001 Ucartherm 100 concentrate Automotive grade antifreeze is not recommended due to the silicon additives which can cause incompatibility problems with pump seals and other components within a system Due to a tendency of the glyc...

Page 286: ...B 10 888 2629 200 10 6 10 WARNING Disconnect primary power prior to servicing Maxiva ULX COFDM Series Figure B 1 Ucartherm Operating Practices ...

Page 287: ...10 6 10 888 2629 200 B 11 WARNING Disconnect primary power prior to servicing Maxiva ULX COFDM Series Figure B 2 Ucartherm Maintenance and Freeze Protection ...

Page 288: ...B 12 888 2629 200 10 6 10 WARNING Disconnect primary power prior to servicing Maxiva ULX COFDM Series Figure B 3 Ucartherm Freezing Point ...

Page 289: ...10 6 10 888 2629 200 B 13 WARNING Disconnect primary power prior to servicing Maxiva ULX COFDM Series Figure B 4 Ucartherm Physical Properties ...

Page 290: ...B 14 888 2629 200 10 6 10 WARNING Disconnect primary power prior to servicing Maxiva ULX COFDM Series Figure B 5 Specific Gravity of Ucartherm Water Solution ...

Page 291: ...10 6 10 888 2629 200 B 15 WARNING Disconnect primary power prior to servicing Maxiva ULX COFDM Series Boiling Point of Ucartherm Water Solution Figure B 6 Boiling Point of Ucartherm Water Solution ...

Page 292: ...B 16 888 2629 200 10 6 10 WARNING Disconnect primary power prior to servicing Maxiva ULX COFDM Series Figure B 7 Thermal Conductivity of Ucartherm Water Solution ...

Page 293: ...10 6 10 888 2629 200 B 17 WARNING Disconnect primary power prior to servicing Maxiva ULX COFDM Series Figure B 8 Specific Heat of Ucartherm Water Solution ...

Page 294: ...B 18 888 2629 200 10 6 10 WARNING Disconnect primary power prior to servicing Maxiva ULX COFDM Series Figure B 9 Ucartherm Shipping Data ...

Page 295: ...10 6 10 888 2629 200 B 19 WARNING Disconnect primary power prior to servicing Maxiva ULX COFDM Series Figure B 10 Eucartherm Handling Storage and Emergency Assitance ...

Page 296: ...B 20 888 2629 200 10 6 10 WARNING Disconnect primary power prior to servicing Maxiva ULX COFDM Series ...

Page 297: ...tically When operated within specifications a surge protector does not require testing adjustment or replacement All parts are permanently enclosed to provide maximum safety and flexibility of installation To assure the safety of equipment and personnel primary power line transformers must be protected by lightning arrestors at the service entrance to the building This will reduce the possibility ...

Page 298: ...ound wires which are physically separated from each other but terminate at earth ground The green ground wire from the AC power input must connect to the power panel and the ground straps of the equipment cabinets The primary electrostatic shield of the isolation transformer if used connects to the AC neutral wire white so that in the event of a transformer primary fault fault current is returned ...

Page 299: ...e a one inch metal rod driven 20 feet into moist earth will have a resistance of approximately 20 ohms and a large ground counterpoise buried in moist earth will exhibit a resistance on the order of 1 to 5 ohms The resistance of an electrode to ground is a function of soil resistivity soil chemistry and moisture content Typical resistivity of unprepared soil can vary from approximately 500 ohms to...

Page 300: ...pper clad steel meshes and wires are available Each crossover point must be brazed to ensure good electrical continuity Equipotential planes for existing facilities may be installed at or near the ceiling above the equipment Each individual piece of equipment must be bonded to its rack or cabinet or have its case or chassis bonded to the nearest point of the equipotential plane Racks and cabinets ...

Page 301: ...destructive to electronic equipment because it contains huge amounts of high frequency energy Here are some examples of this damage Melted ball and horn gaps Ground straps burned loose H V rectifier stacks shorted Massive arc marks in the output circuit of AM transmitters Ball lightning traveling into building on outer conductor of transmission line Figure D 1 is a map of the United States that sh...

Page 302: ...connected See Figure D 3 2 Single phasing This is where one leg of the three phase service is open Remedy Protection afforded by a loss of phase detector Without protection power transformers and 3 phase motors over heat 3 Radio frequency interference RFI This is something we must design into all trans mitters however equipment may be purchased that is susceptible is not protected and may develop ...

Page 303: ...uried power and transmission lines will reduce the amount of coupled energy to a great extent This does not totally eliminate the prob lem because there are currents traveling in the earth which prefer to travel on the metal conductors when lightning strikes close to the station 5 Surge A rapid increase in voltage on the power lines usually caused by lightning The duration is less than 1 2 cycle a...

Page 304: ...D 4 888 2629 200 10 6 10 WARNING Disconnect primary power prior to servicing Maxiva ULX COFDM Series Figure D 3 Regulators for Delta and 4 Wire WYE systems Figure D 4 EM Flux Field ...

Page 305: ... prior to servicing Maxiva ULX COFDM Series Figure D 5 Sample Surge Voltage as a Function of Distance From Stroke to Line Voltage kV 2400 2000 1600 1200 800 0 1 2 3 4 5 6 Time in usec A B C A 1 2 mile from station B 1 mile from station C 2 miles from station ...

Page 306: ... coax can be buried below the antenna ground plane to still further reduce the RF current coupled to it In medium and short wave installations the antenna ground plane is very important as it is of the radiating element RF current leaving the antenna must return via the ground path ground wave For this reason the antenna coupling unit must be close to the base of the tower and securely connected t...

Page 307: ...ector The surge protector must be connected to the building ground system by short direct connections see Figure D 6 A surge protector is a solid state device that has a high impedance until the voltage across it reaches its rated clamping voltage at which time its impedance suddenly decreases The protector will then conduct hundreds to thousands of amperes to ground All protectors are rated for m...

Page 308: ...nts sized accordingly All coaxial lines should have the shield connected to the system ground at the point of entrance and in addition have a ferrite choke around it located between the entrance point and the equipment rack This will provide a high impedance for current flowing in the shield but does not affect the signal currents D 5 Conclusion The 1 chance of a major lightning strike probably ca...

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