Harris Platinum Z16HD+ Preliminary Manual Download Page 1

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Platinum Z16HD+

IBOC FM Transmitter

T.M. No. 888-2586-001

PRELIMINARY MANUAL

888-2586-001

Platinum Z16HD+

IBOC FM Transmitter

Printed: May 2006

Rev A

Summary of Contents for Platinum Z16HD+

Page 1: ...Platinum Z16HD IBOC FM Transmitter T M No 888 2586 001 Copyright Harris Corporation 2006 All rights reserved PRELIMINARY MANUAL 888 2586 001 Platinum Z16HD IBOC FM Transmitter Printed May 2006 Rev A ...

Page 2: ...d Locate and retain all PACKING CHECK LISTs Use the PACKING CHECK LIST to help locate and identify any components or assemblies which are removed for shipping and must be reinstalled Also remove any shipping supports straps and packing materials prior to initial turn on Technical Assistance HARRIS Technical and Troubleshooting assistance is available from HARRIS Field Service during normal busines...

Page 3: ...9 15 06 888 2586 001 MRH 1 WARNING Disconnect primary power prior to servicing Manual Revision History Platinum Z16HD Technical Manual REV DATE ECN Pages Affected Preliminary 2 03 2006 Created ...

Page 4: ...MRH 2 888 2586 001 9 15 06 WARNING Disconnect primary power prior to servicing ...

Page 5: ...NATIONS 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 Inside the individual tables some standard conventions are used A symbol in front of a...

Page 6: ...9 15 06 888 2586 001 MRH 1 WARNING Disconnect primary power prior to servicing ...

Page 7: ... fire protection standards must be observed The following National Fire Protection Association NFPA standards are recommended as reference Automatic Fire Detectors No 72E Installation Maintenance and Use of Portable Fire Extinguishers No 10 Halogenated Fire Extinguishing Agent Systems No 12A WARNING ALWAYS DISCONNECT POWER BEFORE OPENING COVERS DOORS ENCLO SURES GATES PANELS OR SHIELDS ALWAYS USE ...

Page 8: ...viii 888 2586 001 9 15 06 WARNING Disconnect primary power prior to servicing ...

Page 9: ...ortation 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 hal...

Page 10: ...x 888 2586 001 9 15 06 WARNING Disconnect primary power prior to servicing ...

Page 11: ...S4 2 14 Installing PS1 and PS2 2 16 Auxiliary Cabinet 2 18 Transmitter AC Connections 2 18 Information concerning some 360 to 416 volt systems 2 19 Three Phase AC Connection 2 20 Single Phase AC Connection 2 20 Grounding 2 20 Low Voltage Power Supply and Blower 2 22 Audio Input Connections 2 22 External and Failsafe Interlock Connections 2 22 External Interlock Connection 2 22 Failsafe Interlock C...

Page 12: ...te IPA Switching 4 13 IPA Monitoring 4 13 Air Flow Sensing 4 14 IPA Interlocking 4 14 IPA Power Divider 3dB Hybrid 4 14 Z Plane Combiner Divider Boards 4 14 8 Way Divider 4 15 PA Modules 4 17 Power Amplifier PA 4 17 8 Way Combiner 4 19 Isolation Boards 4 19 5kW 3 dB Hybrid Combiners 4 20 10kW Final Hybrid Combiner 4 21 Harmonic Filter 4 21 Directional Coupler Assembly 4 21 Power Supply Block Diagr...

Page 13: ...Typical Coupling Ratios 5 12 Maximum Power Settings 5 13 Setting FWD PWR to Display 100 5 14 Setting Life Support Power Level 5 14 Forward Power Calibration 5 15 Reflected Power Calibration 5 18 PC Board Replacement Procedures 5 22 Replacement of the Life Support Board 5 22 Replacing the Power Supply Controller Board 5 23 Replacing a PA Controller Board 5 24 Replacing the Master Controller Board 5...

Page 14: ...t Temperature Fault 6 30 ISO_ System ISO Over Temperature 6 30 System ISO Foldback 6 30 System ISO Overload Fault 6 31 RFSOURCE _LOW Fault 6 31 RFSOURCE _AFC Fault 6 31 RFSOURCE Fault 6 32 PA Signal Tracing 6 32 PA Controller Faults 6 33 General PA Troubleshooting 6 33 A B C or D _OC PA Over Current Fault 6 33 A B C or D _UC PA Under Current Fault 6 33 A B C or D _MUTE_FLT PA Mute Fault 6 34 A B C...

Page 15: ...peration also known as Modulation Formats that may be used in a typical IBOC system including a backup mode The four Modulation Formats are FM Analog RF only This could be the analog backup mode in the event of a digital failure HD Digital RF only Used for Separate Combining with a separate analog transmitter FM HD Analog digital RF with the digital signal being 20dB below the analog also known as...

Page 16: ...itter for use up through the initial turn on of the equipment Section 3 Operators Guide describes operation of the equipment and is intended to be the primary section referenced by operating personnel Section 4 Overall System Theory is included to help service personnel to understand the inner workings of the transmitter Section 5 Maintenance Alignments lists and explains alignments and adjustment...

Page 17: ...at reduced power Hot Pluggable modules Redundant power supplies to keep the transmitter on the air Broadband design to eliminate tuning adjustments from 87 through 108MHz High performance air cooling design using an internal blower Independant power settings based on 4 four modulation formats including corre sponding alternate power settings for use with a UPS or generator backup system Directiona...

Page 18: ...e may be times when text discussing certain circuitry may still use the original term exciter Also there may be certain pieces of hardware that still contain the word exciter in the part description on its silkscreen labeling or as part of the schematic representation 1 3 1 1 Harris HDx FM Exciter Reliable DSP platform The HDx FM utilizes an embedded DSP based hardware platform and with direct to ...

Page 19: ...to appropriate levels for the IPA stage 1 3 1 3 Redundant Exciters Depending upon the exact configuration of your Z16HD system a 2nd HDx FM exciter or DIGIT CD FM operation only exciter may be used for backup purposes 1 3 1 4 Backup DIGIT CD FM Exciter The DIGIT CD with its digital input module generates the complete stereo FM waveform in the digital domain using a digital signal processor DSP as ...

Page 20: ...for the RF modules and tends to absorb power received by the antenna This can reduce the amount of RF intermodulation generated by the transmitter when co sited with other FM transmitters 1 3 4 Control System A microprocessor based controller monitors over 100 operating functions of the transmitter and makes intelligent operating decisions based on operating conditions Detailed system information ...

Page 21: ...tap switching techniques non switching design This approach provides high conversion efficiency and excellent power factor with very low line harmonics in an easy to service design The power supplies are mounted on a roll out mounting plate for complete accessibility The multiple supply concept protects against total loss of service due to loss of a single supply NOTE For the Z16HD Single Phase ve...

Page 22: ...1 8 888 2586 001 9 15 06 WARNING Disconnect primary power prior to servicing Section 1 Introduction Specifications Platinum Z16HD NOTE Specifications subject to change without notice ...

Page 23: ...as incurred during shipment Retain the shipping materials until it has been determined that the unit is not damaged The contents of the shipment should be as indicated on the packing list If the contents are incomplete or if the unit is damaged electrically or mechanically notify the carrier and HARRIS CORPORATION Broadcast Systems 2 2 1 Factory Test Data Locate and retain the FACTORY TEST DATA Du...

Page 24: ...he customer When communicating with HARRIS CORPORATION Broadcast Systems specify the HARRIS Order Number or Invoice Number 2 4 Air Cooling Requirements Harris transmitters are designed to operate in an unobstructed environment with a maximum inlet air temperature of 45 C This means that the transmitter air system is designed to supply sufficient air at the required static pressure to cool the tran...

Page 25: ...ly Installation 4 Transmitter wiring 5 Initial checkout 6 Remote Control Connections 2 5 1 Transmitter Placement NOTE State County and Local Electrical Code may require more distance but a mini mum clearance of 36 inches is recommended for front and rear access to system equipment Set the transmitter in place on a level surface near power and signal cables Either or both sidewalls of the FM Transm...

Page 26: ...r of the power supply tray After the transmitter is off the pallet it is also a good idea to remove the shipping screws holding the rear of the power supply tray This will allow the power supply to be rolled out the front of the transmitter at a later date without having to take off the fan assembly 2 5 1 2 Single Phase Cabinets The 3 phase version of the transmitter has only one cabinet however t...

Page 27: ...be times when text discussing cer tain circuitry may still use the original term exciter Also there may be certain pieces of hardware that still contain the word exciter in the part description on its silkscreen labeling or as part of the schematic representation The exciters may or may not be removed from the ZHD cabinet depending on the shipping considerations If the exciters were not removed fo...

Page 28: ... should be visible next to the AC power cord connection on the rear of the exciter For information on setting the exciter voltage refer to the exciter techni cal manual 2 5 4 BoostPro Mechanical Installation If shipped separately or added to the system at a later date the following section discusses the steps necessary to install this unit Refer to 5 3 Adding a BoostPro on page 5 5 for setup infor...

Page 29: ...n Installation STEP 1 If being installed as an addition remove blank panels of the Z transmitter cabinet STEP 2 Install rack rail frame STEP 3 Slide unit onto rack rail guides STEP 4 Refer to 2 5 4 4 BoostPro Connections on page 2 7 Figure 2 1 BoostPro Rear Panel 2 5 4 4 BoostPro Connections IMPORTANT Refer to System Configuration drawings in the FlexStar System technical manual 888 2587 001 for c...

Page 30: ...low custom routing of all CAN cables between DB 9 connectors These adaptors allow you to route the CAN circuit any way you like The only limitation is that only two cables can be attached to any one connector adaptor cable length should not be an issue as maximum cable length for a CAN connection is 200 feet STEP 1 Determine best circuit path refer to to System Configuration and Cable Layout drawi...

Page 31: ...see STEP 4 below STEP 4 Set Jumper J3 as follows When a single CAN cable is connected to a device the adaptor will require a termination at that end Set J3 across IN pins When two CAN cables connect to a single device the adaptor will NOT require a termination for that connection Set J3 across OUT pins however the opposite end of either of these cables will most likely connect singly to another de...

Page 32: ...pply installed depending on where and how it is shipped If the power supply was shipped installed in the transmitter skip to 2 5 7 Transmitter AC Connections on page 2 19 Before installing the power supply check the primary AC tapping on the power transformers as outlined below WARNING DISCONNECT AND LOCKOUT PRIMARY POWER AT THE AC SOURCE PRIOR TO PERFORMING ANY CONNECTIONS REPAIRS OR MAINTENANCE ...

Page 33: ...rst remove the front cover panel from the power supply compartment at the bottom of the transmitter The power supply connection cables are either tied up in the power supply compartment in the bottom of the transmitter or tied up with the power transformers The power supply should be rolled into position in front of the transmitter Do not roll it in yet There are four separate power supplies on th...

Page 34: ...ards while the power cable W21 gray with the orange connector con nects to J6 on the PS1 Rectifier Board 1 First with the power supply rolled just up to the front of the transmitter connect the ribbon cable marked W12 to J4 on PS2 NOTE This is a good time to get the AC input wires 1 2 and 3 large orange cables on the left side of the power supply compartment and A1P2 gray connector with discrete w...

Page 35: ...connect to the feed through capacitors C3 C4 C7 and C8 at the top of the power supply compartment See Figure 2 4 The connections are as follows 1 Wire 45 connects to C3 wire 80 already connected 2 Wire 52 connects to C4 wire 81 already connected 3 Wire 245 connects to C7 wire 280 already connected 4 Wire 252 connects to C8 wire 281 already connected Figure 2 4 DC and Ground Connections for 3 Phase...

Page 36: ...to the ground studs at the top front edge of the power supply compartment The cable numbers are 46 60 246 and 260 The studs are located under the shelf which separates the power supply from the PA compartment see Figure 2 4 f Connect the safety ground wire to the stud on the front of the power supply tray g Tighten the two hold down nuts located on the bottom front corners of the power supply comp...

Page 37: ...t is shown on the Overall System Block Diagram along with the transformer schematic Verification and or re tapping will require opening the power supply access panels on the front of the transmitter cabinets and rolling out the power supply trays 2 5 6 2 Installing PS3 and PS4 First remove the front cover panel from the power supply compartment at the bottom of each cabinet The power supply connec...

Page 38: ...xtend the assem bly number For example PS1 is labeled 1A17A1 while PS3 is labeled 2A17A1 The PS3 PS4 tray should be rolled into position in front of the right hand cabinet Do not roll it in yet The following cables will need to be connected a Ribbon Cables W211 and W212 will be tied up in a plastic bag inside the PA left hand Cabinet Route them through the grommet hole between the cabinets See Fig...

Page 39: ...behind the wire hole and then carefully push toward the rear of the transmitter This will open the contact inside the Wago block and the wire can be inserted Be very careful not to let the wire ends fray as the connectors are very close together and could cause a short The wire insulation should actually extend just inside the Wago block hole Release the screwdriver to clamp the wire e The 52Vdc o...

Page 40: ... connec tions to A17TB1 c A1J2 the large gray connector near the front of PS2 can now be connected to A1P2 See Figure 2 5 d Connect the PS3 PS4 to PS1 PS2 interconnect cable The cable is a small bundle of wires that connects from J6 on PS2 in the left hand cabinet to J6 on PS3 in the right hand cabinet see Figure 2 5 The bundle also has wire 210 bundled with it Wire 210 connects to 2A17A1TB1 a sma...

Page 41: ...ce at the end of this section Refer to the Z16HD Outline Drawing in the drawing package for current ratings nominal fuse sizes and wire gauge for the 3 phase 3 wire delta or wye 4 wire wye or single phase input voltage combinations The AC input wiring should be in agreement with local electrical codes and capable of supplying the transmitter power requirements A customer supplied AC primary power ...

Page 42: ...In a typical 380 volt system that has a connection to earth ground each AC phase will measure about 220 volts to ground The phase to phase and phase to ground voltages should be balanced within a few percent However in a system which has no direct connection to earth ground each AC phase will measure a voltage which follows no particular pattern In such a case the MOV protection may need to be mod...

Page 43: ...onnection is NOT required for 208 220VAC 4 wire WYE source voltage and should not be run to the transmitter There is no connec tion in the transmitter for the neutral connection for this application and it should not be connected to chassis ground The power supply transformers in the transmitter will be configured as delta for this application 2 5 7 3 Single Phase AC Connection The single phase Z1...

Page 44: ...and or a buried copper ground screen with copper strap used to connect the tower base to earth ground A low impedance will help carry lightning current directly into the ground instead of into your building Additionally coax shield s should be electrically connected to and exit the tower as near to the bottom as practical to minimize the lightning voltage potential carried by the coax into your bu...

Page 45: ...transmitter is shipped with two jumpers installed on TB1 the Remote Control Interface terminal strip TB1 7 to TB1 6 GND is for External Interlock and TB1 8 to TB1 10 GND is for Failsafe 2 5 9 1 External Interlock Connection To use the External Interlock connection remove the jumper between terminals TB1 7 to TB1 6 GND then connect external interlock wires A contact closure allows the transmitter t...

Page 46: ...gh the IPA and exciter are muted The failsafe interlock wires can also be connected directly to the Life Support Board at J4 7 and J4 8 if it is desired to have the failsafe interlock completely separate from the remote control interface The TB1 and J4 connections are in parallel Only one or the other is to be used NOTE The transmitter will transmit when the failsafe interlock connection is restor...

Page 47: ... fully operational Refer to the Factory Test Data Sheets supplied with the transmitter for typical meter readings The transmitter was checked into a 50 ohm resistive load at the Factory The Transmitter ON OFF sequence is controlled by three separate buttons HIGH LOW OFF These buttons are located on the front panel of the Controller STEP 1 Activate the STATION AC POWER source to the transmitter STE...

Page 48: ...front PA compartment STEP 6 If the PA VOLTS reading appears okay then shut the transmitter off and insert the PA and IPA Modules as directed below See Figure 2 9 and Figure 2 10 STEP 7 PA Module installation Eight PA modules and 2 IPA modules are inserted in the front of the cabinet and eight in the back of the cabinet The PA and IPA modules are identical and symmetrical which means they can be in...

Page 49: ...ule serial number tag should be on top of the module when inserted into the transmitter CAUTION EACH MODULE HAS TWO CAPTIVE THUMBSCREWS WHICH MUST BE TIGHTENED TO ASSURE PROPER MODULE OPERATION THEY SHOULD BE FINGER TIGHT IF A SMALL SCREWDRIVER IS USED BE SURE NOT TO OVERTIGHTEN Figure 2 9 PA Compartment Front View D1 C1 IPA_CD1 IPA_CD2 B1 A1 C2 D2 D3 C3 D4 C4 B2 A2 B3 A3 B4 A4 IPA_AB2 IPA_AB1 ...

Page 50: ... the right side of the heatsink This places the amplifier in the IPA_AB1 position on the lower IPA and in the IPA_CD2 position for the upper IPA the default for the controller If the IPA is on the left side of the heatsink when inserted then IPA_AB2 and IPA_CD1 will have to be selected in the Configuration Menus before operating the transmitter STEP 9 With all of the modules installed the Fault LE...

Page 51: ...following HDx FM settings on the Output Setup page 1 4 must be made for normal HD operation HD Carriers ENABLED Exgine Input EXPORTER Exgine Output NORMAL STEP 10 Turn the transmitter back ON at LOW power Verify that the RF source s power is the same as the factory test data sheet This can affect performance NOTE The fan will run at high speed for 1 minute then will automatically switch to low spe...

Page 52: ...y a Set the power to the desired TPO using the raise and lower buttons b Go to the 100 TPO SET screen HOME MORE CONFIGURA TION B B then select your desired modulation format and set the power level to your TPO Press BACK to update and store the new information Repeat this step for all possible desired modulation for mats c The front panel FWD PWR reading should be 100 You may also want change the ...

Page 53: ...latinum Z16HD IBOC Transmitter allow remote control of the transmitter functions by connection to terminals on terminal board A1TB1 TB1 is a 40 pin Terminal strip with a ribbon connection on the back which connects to J20 on the controller Table 2 1 on page 2 38 contains a complete listing and explanation of connections for TB1 Figure 2 11 shows TB1 pinout and connections TB1 is located in the upp...

Page 54: ...hing See Figure 2 12 Grounds are provided on TB1 for use as common Figure 2 12 Ground Switching for Remote Control The status output lines on TB1 are transistor type open collector Figure 2 13 A illustrates how to interface TB1 outputs with TTL logic circuits Figure 2 13 B illustrates how to interface TB1 with an external relay A series resistor and LED can also be used for extended status indicat...

Page 55: ...drive a small printed circuit board type relay check current requirements for relay coil and be sure to install a circuit protection diode across the coil A 1N4004 or equivalent will work Figure 2 14 shows typical remote extended control and status connections Figure 2 14 Typical Remote Extended Control and Status Connections NOTE TB1 38 is not used for HD Transmitters Not Used for HD Transmitters...

Page 56: ...figure the input using the Diagnostics Display Menu press HOME MORE CONFIGURATION A A This should bring up the screen shown in Figure 2 16 The default setting is shown as UPS This means the input is ready to be used as the UPS Mode select To use TB1 9 as a Remote RF source select input press C This will switch the display to read EXC This re configures the TB1 9 input so that when it is pulled low...

Page 57: ...r to the preset UPS power level which is factory set for rated power via software in the Diagnostics Display System However if the transmitter is operating in LOW power when the UPS mode is activated then the transmitter will stay at the LOW power level unless the UPS level is set lower For example if LOW power is set for 3kW and UPS is set for 3500W the transmitter will stay at the LOW power leve...

Page 58: ...u to the screen in Figure 2 18 Set the power level at which you want the alarm to become active and press BACK to save changes For a complete listing of all configurable parameters see System Configuration and Calibration in Section VI Troubleshooting Figure 2 18 Remote Low Power Alarm Set HOME MORE CONFIGURATION B A C 2 10 Jumper Settings for Installation of a Harris Exciter The following is for ...

Page 59: ...8 2586 001 2 37 WARNING Disconnect primary power prior to servicing Section 2 Installation Initial Turn On Platinum Z16HD DIGIT CD Exciter with 994 XXXX 004 part number DIGIT Exciter with 994 XXXX 002 part number ...

Page 60: ...2 38 888 2586 001 9 15 06 WARNING Disconnect primary power prior to servicing Platinum Z16HD Section 2 Installation Initial Turn On Table 2 1 TB1 Remote Control Interface Connections ...

Page 61: ...9 15 06 888 2586 001 2 39 WARNING Disconnect primary power prior to servicing Section 2 Installation Initial Turn On Platinum Z16HD Table 2 2 TB1 Remote Control Interface Connections continued ...

Page 62: ...2 40 888 2586 001 9 15 06 WARNING Disconnect primary power prior to servicing Platinum Z16HD Section 2 Installation Initial Turn On Table 2 3 Jumper Settings for Installing a Harris Exciter ...

Page 63: ... Transition from 1 to 0 will lower the power by 0 5W when biased in FM mode and 50mW in HD mode If this input is held in the 0 state for greater then 1 second the Boost Pro will decrement power every 125ms by the same step size as defined above until the input is released 4 RFLD_PWR_SAMPLE Analog output 0 to 4Vdc corresponds to 0 to 10W reflected power 17 5 GND Ground 18 6 MUTE_STAT Open collector...

Page 64: ...the cabinet of your transmitter Transformers and motors can be designed with extra safety features where thermal rise is limited to acceptable levels however in this case other transmitter parameters cannot be made acceptable at a reasonable cost 2 11 2 Transmitter Noise Performance The most difficult parameter to meet with power line unbalance is transmitter noise performance Most large transmitt...

Page 65: ...ir satisfactory operation of the overall transmitter may result For this reason along with their inherent susceptibility to transients Harris does not recommend the use of open delta systems Figure 2 19 3 Phase Closed Delta vs Open Delta The only advantage of the open delta is lower initial cost and this is partially offset by the fact that when only two transformers are used they must be larger t...

Page 66: ...not many things will It has been reported by engineers that installation of a third transformer and transient protection devices have eliminated the difficulty 2 11 5 3 Phase Wye Distribution Transformers The WYE connected system is also considered a symmetrical form of three phase power distribution All impedances are balanced as seen from each terminal see Figure 2 20 It is important when using ...

Page 67: ...tages that are available with this configuration In summary both symmetrical power distribution systems are satisfactory because of their balanced impedances Use either a closed delta or a four wire WYE system for maximum transmitter performance Never use an open delta system just to cut costs it could cost dearly in the long run Table 2 5 Typical Line Voltages Delta or WYE Delta Connected Transfo...

Page 68: ...2 46 888 2586 001 9 15 06 WARNING Disconnect primary power prior to servicing Platinum Z16HD Section 2 Installation Initial Turn On ...

Page 69: ...dware configurations there are many possi bilities of RF signal origination within the transmitter The RF chain may begin with either an HDx FM exciter or a BoostPro amplifier output Or in FM backup mode it may begin with any one of several Harris FM exciters To simplify termi nology this RF origination will be called RF Source by the controller and throughout this manual However there may be time...

Page 70: ...omatically due for instance to high VSWR pressing the LOW button will return the transmitter to the normal low power level provided the cause of the foldback is gone POWER up down arrows used to raise and lower the transmitter power REMOTE DISABLE Located on the left side of the controller used to disable any remote control system which is connected to the transmitter When the LED is lit the remot...

Page 71: ...dback Interlock LED Indications NOTE For Emergency conditions refer to 3 6 Emergency Operating Procedures on page 3 12 Front panel LEDs can indicate normal and abnormal conditions Typically GREEN is good and RED is bad A continuously lit Fault LED indicates an active fault If the LED is blinking it is an indication of a previous fault conidition that is no longer present and the tranmsitter should...

Page 72: ... The diagnostic system consists of the LCD Diagnostic display and 6 function keys HOME BACK and the four selection keys on the right side of the LCD screen NOTE For all discussions pertaining to the Diagnostic system the four function keys to the right side of the Diagnostic LCD display will be called A B C and D from top to bottom as in Figure 3 2 This figure also shows the default screen which w...

Page 73: ...en As an example if you were to press HOME and then choose STATUS you would now be in layer 2 of the STATUS menu You should see the screen shown in Figure 3 5 If you press MORE you go the second screen in layer 2 Now press the BACK key Notice that it did not take you to the previous screen but back to Layer 1 the HOME layer shown in Figure 3 3 However if instead of pressing BACK you pressed more a...

Page 74: ...code will be used to guide you to the area or screen being discussed The code will have the name of one of the HOME menu items listed above followed by the appropriate A B C or D function key presses required to get to the screen being discussed The code will always be enclosed in brackets x x x NOTE It will be assumed that you always press the HOME key first before entering the key sequences in t...

Page 75: ... change the Maximum High Power setting using the A B C and D function keys Pressing the BACK key updates the change while pressing HOME would cancel any changes Figure 3 7 Max High Power Configuration Screen MORE CONFIGURATION B C then choose the desired modulation format 3 4 5 Asterisk and Pound Signs The asterisk and the pound sign characters are used in some of the metering menus of the Diagnos...

Page 76: ...8 Fault Menu HOME FAULT Pressing D takes you to the Fault Log shown in Figure 3 9 This screen shows the latest of a possible 32 faults as designated by LOG No 1 of N where N would be the total number of faults present Type gives the name of the fault The individual faults and their cause are given in Section VI Troubleshooting Time gives the elapsed time since the fault occurred not the actual tim...

Page 77: ...for extensive metering status information and configurable parameters Once within one of these menus the UP ENTER and DOWN controls are used to maneuver through them See Figure 3 11 on page 3 11 for detailed menu structure NOTE It is normal operation for the Power Meter display to vary 1 3 5 3 UP ENTER DOWN Parameter Controls These are the navigation buttons for selecting and maneuvering through l...

Page 78: ...1 9 15 06 WARNING Disconnect primary power prior to servicing Platinum Z16HD Section 3 Operator Guide 3 5 5 BoostPro Operation The following graphic is the entire menu structure for the front panel GUI on the BoostPro ...

Page 79: ...9 9 9 9 9 9 9 9 5 67 786 087 67 786 67 087 8 7 675 2 2 2 2 087 32 67 087 32 3 02 6 5 9 5 9 2 7 3 96 5 75 3 3 5 75 3 3 7 03 3 855 2 2 2 2 3 29 5 9 3 81 5 9 1 7 3 81 2 9 2 2 2 2 2 9 2 9 2 9 2 9 2 9 2 9 2 9 2 96 5 2 2 3 7 03 51 2 3520 2 3 2 7 7 2 7 1 2 2 21 81 2 087 5 5 6 7 8 7 6 21 7 5 68 7 1 867 7 3 0 32 5 83 2 1 5 7 21 12 12 9 86 21 86 6 5 029 1 1 83 7 1 32 5 1 2 0 7 5 2175 67 02 8 7 21 23 5 02 7 ...

Page 80: ...lt that is no longer active and tranmsitter should be operating normally Navigate through the Diagnostic display to the Fault Log to determine fault Inactive faults can be reset from that menu The operator may refer to the transmitter technical manual Section 3 for specific details on how to view and clear the fault description in the Diagnostic Display s fault log If more troubleshooting is neces...

Page 81: ...loop is open Navigate through the Diagnostic display to the Fault Log to determine which loop is open and causing the LED indication The operator may refer to 3 4 6 Fault Logging on page 3 8 for specific details on how to view and clear the fault description in the Diagnostic Display s fault log If more troubleshooting is necessary a technician can refer to Section 6 of that manual for fault expla...

Page 82: ...ord FAULT Refer to 6 2 1 Boost Pro Fault Indication on page 6 3 To reset the fault press INFO then CONTROL SUBMENU move cursor to point to RESET FAULT Press ENTER to clear the fault status If the fault indication is still present the condition causing the malfuntion will need to be identified and corrected 3 6 8 Manual RF Source Switching Due to the many possible configurations of HDx FM DIGIT Boo...

Page 83: ...ressing D will toggle between the IPA pairs Figure 3 13 IPA Status Screen HOME STATUS A C 3 6 10 Fan Speed The Platinum Z is equipped with a 2 speed blower This normally runs at the LOW speed to reduce ambient noise and increase transmitter efficiency However if any fault occurs the fan will automatically switch to HIGH speed until the fault is no longer active The fan can also be forced to HIGH s...

Page 84: ...3 16 888 2586 001 9 15 06 WARNING Disconnect primary power prior to servicing Platinum Z16HD Section 3 Operator Guide ...

Page 85: ... of operation for the transmitter only For exciter and other peripheral equipment detailed theory please see the corresponding manual The Platinum Z16HD can be configured with a 3 Phase or Single Phase power supply Both supplies are discussed in detail Exciter theory is presented within the appropriate Exciter technical manual Major topics of discussion are listed below in order a RF Flow Block Di...

Page 86: ...4 2 888 2586 001 9 15 06 WARNING Disconnect primary power prior to servicing Platinum Z16HD Section 4 Overall System Theory Figure 4 1 RF Flow Block Diagram Z16HD shown with optional 2nd RF Source ...

Page 87: ...of two separate amplifiers one on each side of the heat sink which are referred to as PAs The term module is reserved for the combination of heatsink and 2 PAs The modules are Hot Pluggable which means they can be removed and replaced while the transmitter is running They are also symmetrical which means that they can be inserted into the transmitter with either side facing up they cannot be inser...

Page 88: ...ted in the front of the transmitter while 5 8 are located in the rear of the transmitter Any four PAs on the same Z Plane labeled 1 4 are considered a FOURSOME because they are connected to the same 4 Way combiner Any PAs labeled 5 8 are also considered a Foursome Here is a list of the 8 Foursomes in the Z16HD See Figure 4 4 and Figure 4 5 for module location A1 A2 A3 and A4 Front Z Plane A B1 B2 ...

Page 89: ...or amplitude between the two Z Plane outputs AB or CD the ISO load absorbs the imbalance An example would be a failed PA causing one Z Plane output to be lower than the other A removed PA module would not cause an imbalance at this point since it would affect Z Planes A and B or C and D the same The greater the imbalance the higher the temperature of the ISO load A temperature sensor on the load m...

Page 90: ...in line with the RF signal The source of the APC voltage can be switched between an external source via the transmitter interface connector or an internal digital to analog converter This APC switch is controlled by the microcontroller The phase of the RF can also be adjusted via the microcontroller or by information entering on the RS232 port GUI or CAN interfaces Communication and internal decis...

Page 91: ...9 15 06 888 2586 001 4 7 WARNING Disconnect primary power prior to servicing Section 4 Overall System Theory Platinum Z16HD Figure 4 2 BoostPro Block Diagram ...

Page 92: ...control the phase of the RF signal RFLD_PWR_TRIP This voltage will set a trip point to mute the PA if the reflected power becomes too great This voltage will change when the modulation mode changes FWD_PWR_TRIP Same concept as RFLD_PWR_TRIP except for forward power is monitored RFLD_PWR_SAMPLE This analog voltage represents the reflected power sampled on the analog to digital converter scaled for ...

Page 93: ... supply at 5Vdc 15Vdc and 15Vdc Both power supplies are capable of 85 264VAC 47 440Hz inputs 4 3 4 Front Panel The front panel uses a 128x64 dot LCD warning LEDs and buttons to interact with the BoostPro The interface to the LCD is on the data bus 4 3 5 Power Amplifier The amplifier contains 3 stages of amplification The first stage uses an LD MOSFET in Class A operation mode Class of operation of...

Page 94: ...he schematic representation 4 4 1 RF Source Switching If a second or backup RF Source is installed and the on air RF Source fails the controller will automatically switch to the backup and log the fault NOTE The controller will wait 40 seconds for the on air exciter to recover before switching to the backup If a backup RF Source is added anytime after factory testing the installer must go into the...

Page 95: ... one of the PA modules This allows a PA module to be used in place of a failed IPA The standard IPA configuration includes 2 dual IPA modules each used in a main alternate configuration in other words only 1 2 of each module is used at a time The IPAs are labeled IPA_AB1 IPA_AB2 IPA_CD1 IPA_CD2 IPA_AB1 and AB2 are the 2 amplifiers on the lower IPA Module with IPA_CD1 and CD2 on the upper module On...

Page 96: ... The gate bias voltage range is about 18V for off and 0V for full on 4 4 2 3 IPA Power Supply The IPA power supply is 52 volts and is diode OR ed from two of the four PA power supplies for redundancy The 52Vdc is connected to the IPAs via the IPA Backplane Boards IPA_AB1 AB2 are powered from PS1 and PS2 while IPA_CD1 CD2 are powered by PS3 and PS4 The supply feeds for the IPAs are diode or ed toge...

Page 97: ...ignal IPA DRIVER SELECT is normally low which places K2 and K3 in the IPA_AB1 position as shown on the schematic If IPA DRIVER SELECT goes high K2 and K3 will be energized and switch to the IPA_AB2 position If the Master Controller detects a loss of RF output from the active IPA it will automatically switch to the second IPA IPA switching can also be done manually via the Diagnostics Display 4 4 2...

Page 98: ...ocking The signals IPA1_PCB_OK and IPA2_PCB_OK are the interlock signals for the IPA boards The interlock connections on the IPA board and the PAs as well are shorter than the other pins This causes the interlock connection to break before the RF contacts when the module is unplugged This gives the controller time to shut off the IPAs via the IPA gate voltage IPA1_GATE so that the connector contac...

Page 99: ... transmitter faults refer to Section VI Troubleshooting The Divider Board is also the interface for interlock temperature sense lines and the PA_GATE voltages for the amplifiers The RF output of the Z Plane board connects directly to the 3dB hybrid where it is combined with the output of its companion Z Plane The Z Plane boards are identical but the outputs connect to opposite ends of the 3dB hybr...

Page 100: ...or to servicing Platinum Z16HD Section 4 Overall System Theory Figure 4 4 PA Compartment Front View Figure 4 5 PA Compartment Rear View D1 C1 IPA_CD1 IPA_CD2 B1 A1 C2 D2 D3 C3 D4 C4 B2 A2 B3 A3 B4 A4 IPA_AB2 IPA_AB1 A5 B5 C5 D5 B6 A6 B7 A7 B8 A8 C6 D6 C7 D7 D8 C8 ...

Page 101: ...e trimmed to a nominal value which allows all modules to combine in phase The RF signal is then sent to T1 a coaxial 9 1 transformer which also splits the phase providing 0 degree and 180 degree outputs to drive a pair of push pull RF power MOSFETs Q1 and Q2 The control signal to Q1 and Q2 labeled Vg for Gate Voltage is connected through the center of the secondary winding of T1 The bias circuit i...

Page 102: ...Drain Voltage from the main power supply enters at location C 1 and is decoupled and filtered by C11 C12 C13 C14 C16 C24 C29 C30 C33 L1 and L2 A special mention to capacitor C11 It is a 100uF electrolytic capacitor that if connected abruptly to the Vd supply it will create some arching to the DC connection that could eventually destroy it To avoid the formation of pitting in the DC connection and ...

Page 103: ...GENERAL OR DOMESTIC WASTE Failed PA boards should be sent in for repair or exchanged mainly due to the minimal cost involved Refer to the Maintenance section of this manual for the RF amplifier replacement procedure 4 4 5 8 Way Combiner Refer to the Combiner schematic for the following Each 8 way combiner consists of two 4 way Wilkinson combiners called Foursomes followed by a 2 way Wilkinson comb...

Page 104: ... characteristics of the 3dB hybrid combiner which tends to ignore minor amplitude and phase imbalances in the two Z Plane outputs The 2 way combiner combines the outputs of the 2 foursomes with the four in the front being one foursome such as A1 A4 and the four in the back being the other such as A5 A8 An imbalance between these 2 foursomes will cause a rise in the temperature of RT9 the ISO load ...

Page 105: ...for monitoring and protection This is considered a System ISO load and its temperature is monitored by both the Master Controller and the PA Controllers The Master Controller monitors for power foldback purposes while the PA Controllers monitor for protection if the Master Controller is not operational 4 4 8 Harmonic Filter The vertical transmission line in the back of the cabinet contains the Har...

Page 106: ...0 Vac The 3 Phase 3 wire and 4 wire supplies have all of the same components but have a different wiring harness The PA power supplies whether 3 Phase or Single Phase are regulated by reliable tap switching techniques which provides excellent efficiency while avoiding the power line harmonic problems associated with switching supplies The regulation range is 48 54Vdc at 2Vdc per tap 4 5 1 1 3 Phas...

Page 107: ...an output ripple frequency of 600 720Hz for 50 60Hz input Each of the secondary windings has 4 possible voltage taps each of which are connected through an SCR to ground The SCRs act as tap switches activating the tap which gives the appropriate DC voltage output as rectifiers and as a way of turning the supply on and off This gives a total of 12 SCRs per secondary 4 per winding but only 3 SCRs pe...

Page 108: ...or to ground instead of the direct ground connection provided with the rest of the SCRs This allows the Soft Start by limiting the maximum surge current while charging the power supplies The soft start lasts for 3 5 seconds during turn on After the 3 5 second soft start the resistor is bypassed by activating the normal run mode SCRs which are also attached to the lowest voltage output tap but conn...

Page 109: ...tart and Discharge 4 5 1 2 Single Phase Power Supply The Z16HD single phase transmitter uses four main power transformers working in groups of two These are designated PS1 PS2 PS3 and PS4 Figure 4 10 shows the placement of each of the 4 power supplies and connection points for installation or removal of the supplies Due to the size of the single phase supplies a second cabinet is required for PS3 ...

Page 110: ...re connected through an SCR to ground The SCRs act as tap switches activating the tap which gives the appropriate DC voltage output as rectifiers and as switches to turn the power supply on and off This gives a total of 8 SCRs per secondary but only 2 SCRs will be activated at any one time providing the ability to regulate the output DC voltage by changing the transformer turns ratio The 4 pairs o...

Page 111: ...ected through a common surge limiting resistor to ground instead of the direct ground connection provided with the rest of the SCRs This allows the Soft Start by limiting the maximum surge current while charging the power supplies The soft start lasts for about 5 seconds during turn on After 5 seconds the soft start resistor is bypassed by activating the normal run mode SCRs which are also attache...

Page 112: ...ng to turn on during a discharge cycle 4 5 1 2 3 16VCT Secondary There is a 16VCT secondary on each transformer whose output goes to the Rectifier Board for that supply It is rectified and used as the drive for the gates of the SCRs This is required due to the large gate drive current needed on the large single phase SCRs The rectified voltage from this secondary is called V SCR on the Rectifier B...

Page 113: ...AC input 3 wire or 4 wire and must be tapped for the proper AC input voltage The tapping chart can be found on the Overall System Block Diagram Each transformer has 2 WYE secondaries with the center connection being the rectified DC output of 52Vdc nominal Note that the secondaries are the same no matter what the AC input voltage or configuration The two secondary outputs are combined via large in...

Page 114: ... in the secondary There are two rectifier boards mounted on the top of each power transformer There is an A side and a B side both of which are shown on the same schematic The left side of the schematic is the B side and the right side is the A side except on sheet 3 which is B side only There is also only one part number for both boards The A Rectifier Board is for the transformer secondary A wit...

Page 115: ...9 15 06 888 2586 001 4 31 WARNING Disconnect primary power prior to servicing Section 4 Overall System Theory Platinum Z16HD Figure 4 13 Simplified 3 Phase Transformer Secondary ...

Page 116: ...for the 48V tap will be explained here as the other three are identical but are attached to different transformer secondary winding taps The DRIVE_1 signal is used to activate the 48Vdc secondary tap This tap is designated TAP 1 in the Diagnostics Display When active HIGH it causes the output of U2 17 to go low This turns on Q28 which applies 10VB SS now called DRIVE_1 to R12 on the B side of the ...

Page 117: ...harge circuit uses R48 to bleed down the supply whenever the transmitter is turned off The DISCHARGE signal is active low and comes from the PS Controller Board When low it causes the output of U2 14 to go high This does two things a First it reverse biases CR31 which allows the gate of Q33 to pull high through R54 shutting Q33 off This removes the 10VB SS used to activate the trans former taps Th...

Page 118: ...pplies are identical Each one supplies 52Vdc for the PAs and IPAs PS1 and PS2 supply power to the AB power block while PS3 and PS4 supply power for the CD power block T1 T2 T3 and T4 primaries must be tapped for the proper AC input voltage The tapping chart can be found on the Overall System Block Diagram Each transformer has one center tapped secondary with the center connection being the rectifi...

Page 119: ...zing a different secondary tap The taps closest to the center will provide the least amount of secondary turns in circuit and will therefore give the lowest DC output voltage This means that the taps which are furthest from the center will give the highest DC output voltage due to more active turns in the secondary The DC voltage range with a nominal AC input voltage is 48 54Vdc 4 6 2 2 Rectifier ...

Page 120: ...fied diagram of the Soft Start and PA Power Supply Discharge circuits in shown in Figure 4 12 Refer to the Rectifier Board schematic for the following The Soft Start control signal is active high and comes directly from the PA Controller Board via J4 8 A high SOFT START signal at J4 8 causes U2 12 to go low This turns on FET switch Q5 which then applies the 20VB SS through R18 to CR28 and CR29 pro...

Page 121: ...c respectively These voltages are sent to the controller where they will be distributed to the individual controller boards Input voltages to these regulators will vary depending on the AC mains voltage 4 6 2 2 6 16VCT V SCR Supply The 16VCT secondary winding is fused by F3 and F4 on the Rectifier Board These are self resetting fuses which physically look like disc capacitors The AC is rectified b...

Page 122: ...s are fused by F3 F4 F5 and F6 and are then full wave rectified for two DC outputs of approximately 10Vdc NOTE Fuses F3 F10 are self resetting circuit breakers which physically look like disc capacitors This voltage will vary depending on what the AC mains voltage is for the site The 10Vdc is filtered by C1 C6 and connected to the rectifier boards on top of the PA power supply transformers in the ...

Page 123: ...position When A19K3 pulls in so does K2 not A19K2 Upon transmitter turn on the fan will run at high speed for one minute then will normally run at the low speed until a fault occurs or there is a significant increase in temperature detected by the controller The blower motor is a 2 speed single phase motor K2 simply directs the AC to the high or low speed windings on the motor The fan speed can al...

Page 124: ...rmware software burned into an EPROM The Controller consists of the following boards Master Controller Board PA Controller 1 PA Controller 2 PA Controller 3 PA Controller 4 Power Supply Controller 1 Power Supply Controller 2 Life Support Board Display Backplane Board motherboard All of these boards are located directly behind the transmitter control panel and plug into the Display Backplane Board ...

Page 125: ...OM non volatile U39 When the low voltage is applied to the controller it loads up the program from ROM to RAM and then goes to the EEPROM for all of the transmitter configuration calibration settings power levels fault limits etc Basically EEPROM U39 stores any settings that can be changed in the Diagnostics Display Any changes made in the Diagnostics Display will be either automatically saved in ...

Page 126: ...put goes down the RF Source output will be increased which will increase the PA RF output to compensate for power fluctuations The APC loop starts at the forward power directional coupler The forward sample is connected to the Life Support Board where it is calibrated with R127 for about 8 9V 100 TPO at TP9 This voltage sample is then sent to the Master Controller schematic sheet 7 where it is squ...

Page 127: ...tionately increase or decrease the output of the PAs EXAMPLE The following is an example of how the entire loop would work For our example the power output of the transmitter goes down due to a failed PA This would decrease the output of the forward power directional coupler and the voltage at the input to the difference amp at U5 6 on the Master Controller Board Since U5 has almost infinite gain ...

Page 128: ... configuration and modulation format of the ZHD transmitter They are factory calibrated or have been field calibrated at the rated transmitter power as detailed in the Maintenance procedures These numbers are stored in EEPROM U39 The actual numbers obtained during the factory calibration are recorded in the Factory Test Data NOTE If the transmitter is calibrated at a power level other than rated p...

Page 129: ... below show default Factors for all ZHD transmitters These may be used for the math calculations in the following section to determine approximate values for your transmitter 4 8 2 1 DAC_APC_REF DAC_APC_REF HOME MORE CONFIGURATION C B is a counter internal to the micro whose output will be between 0 and 900 that is controlled by the RAISE and LOWER buttons on the front panel RAISE increases the co...

Page 130: ...A D converted in the micro for metering This A D value shows up as A D_FWD_PWR HOME MORE CONFIGURATION C B which at 8 9V should be very close to 806 the A D converter is 10 bit for 0 to 1024 range but the input to the A D is not actually 8 9V By setting the FWD PWR CAL screen to 7000W and calibrating we are telling the micro that 806 represents 7000W The micro now calculates the Forward Factor by ...

Page 131: ...librated APC_Factor OP_APC_Factor Operating APC_Factor The Operating APC Factor is frequency compensated based on the slope of the coupler output 1 8dB across the FM Band 88 108MHz If the transmitter is operating at the same frequency at which it was calibrated then the two numbers will be the same If the operating frequency is changed the OP_APC_Factor will be higher or lower depending on whether...

Page 132: ...e DAC_MAX MAX HIGH SET kW APC_Factor For LOW ON mode DAC_MAX MAX LOW SET kW APC_Factor For UPS mode DAC_MAX UPS SET kW APC_Factor DAC_MAX HOME MORE CONFIGURATION C B is the display variable which will contain one of the above numbers depending on which mode the transmitter is in Once these are set the DAC_APC_REF in that mode can never go above the DAC_MAX setting Example If the transmitter is cal...

Page 133: ...linearly track the transmitter power output Power is the square of the voltage VSWR protection is based on this A D reading which is directly proportional to a reflected power level not on a calculated VSWR reading The actual VSWR fault level in the transmitter is set at 1 7 1 which is 470W The Foldback level is set at 1 30 1 which is 115W 4 8 3 VSWR Foldback The Master Controller contains another...

Page 134: ...FL_PWR VSWR greater than 1 5 1 ISO_AZ_OT The predicted temperature of R9 on the A Z Plane Isolation board is greater than 130o C ISO_BZ_OT The predicted temperature of R9 on the B Z Plane Isolation board is greater than 130oC ISO_CZ_OT The predicted temperature of R9 on the C Z Plane Isolation board is greater than 130oC ISO_DZ_OT The predicted temperature of R9 on the D Z Plane Isolation board is...

Page 135: ...ller Boards in the Z16HD transmitter They utilize micro controllers which report to the Master Controller but operate independently of the Master Each controls 8 of the 32 PAs Table 4 1 shows which PAs are controlled by each of the PA Controller Boards The boards are identical except for the programmable ID number which is set with DIP switches on the board to determine which board is PA Controlle...

Page 136: ...he system level imbalance The most likely cause of foldback in this condition will be the temperature of the ISO_ABCD isolation load on the ABCD hybrid NOTE The Power Supplies PS1 PS2 PS3 and PS4 each power the PAs associated with one PA Controller This means that the loss of one power supply will create the same scenario as loss of one PA Controller 4 8 5 3 Metering The PA Controllers are respons...

Page 137: ...PA Controller has what is called a Watchdog Timer The outputs of the watchdog timers are each monitored by the other PA Controller If the pulses from the watchdog timer are interrupted due to either hardware or software problem the other PA Controller will initiate what is called a Crossover or XOVER Basically an operational PA Controller will apply a mute to all of the PAs associated with the def...

Page 138: ...n the transmitter is turned on the Master Controller brings the PS_DISABLE signal low provided the contactor has been activated and the Master Controller is operating normally This will first activate the SOFT_START outputs at J1 8 and J2 8 This allows the supplies to charge slowly limiting the in rush current via the soft start resistor and SCRs on the rectifier boards The supply voltage must rea...

Page 139: ... charge in this manner until the PS_STANDBY signal goes low and the power supplies are fully active again or shut off by the PS_DISABLE signal 4 8 6 4 Discharge Protection Circuit The discharge protection circuit protects the power supply and the discharge circuit components from a failure in the discharge circuit Specifically it protects against a short which would cause the discharge resistor to...

Page 140: ...t is used to detect a loss of a rectifier fuse on the transformer sec ondary a non critical fault The second is a 100 to 120 Hz band pass filter which is used to detect a severe primary phase imbalance or loss of phase Loss of phase is a critical fault which will shut the power supply off momentarily see Power Supply Controller Faults in Section 6 of this manual HEAT SINK THER mistor is the temper...

Page 141: ...ional Mode The following contains all pertinent circuit operation when the Master Controller is functioning properly 4 8 7 1 1 Transmitter Turn On When the transmitter is turned on either HIGH or LOW the Master Controller generates a high TX ON signal which enters the Life Support Board at J1 A55 and is tied to AND gate U26 9 TX ON is generated when either LOW ON or HIGH ON is pressed on the front...

Page 142: ...rlock line going to U33 1 ties the interlock into the OFF command circuit When the Interlock is closed this line is low and U33 1 ignores the input If the Interlock were opened the line would go high which would send a high to the RESET input on relay K4 and the main AC contactor would disengage Contactor Turn On Relay K4 Latching K4 is a latching relay which only needs to be pulsed to make it cha...

Page 143: ...8 as long as the Mas ter Controller is operating normally When the PS DISABLE signal at U30 11 goes high the power supplies will be shut off via the PS Controller c U30 10 ties the CONTACTOR_ON BAR signal into the SYSTEM MUTE line which will mute the exciter and IPA when the contactor is off Remote Low Power ON Command This command should only be used during Life Support Mode and is therefore disc...

Page 144: ... controller front panel This connects to the Life Support Board at J1 A6 In any of the three cases Failsafe is an active low signal which must be pulled low before the transmitter will output any power To use the failsafe the factory jumper must be removed When the failsafe circuit is satisfied it will cause U23 8 and U25 4 to go low and U25 6 will stay low having no effect on transmitter operatio...

Page 145: ... or U28 2 for an active high mute signal If your RF source requires an active low to mute then JP1 and JP2 should be placed in the 2 3 position where the mute signal bypasses the U27 inverters and is inverted to an active low by U28 1 or U28 2 again depending on the position of K1 For proper positioning of these and other related jumpers refer to Jumper Settings for Installation of a Harris Excite...

Page 146: ...K3 IPA_SELECT lines are pulsed signals which will go high to select the appropriate IPAs The IPAs work in the following pairs in the Z16HD AB1 and CD2 AB2 and CD1 This is done for system alignment purposes Therefore if IPA_SELECT_AB1 goes high so will IPA_SELECT_CD2 This will make U14 3 and U14 11 high if the Master Controller is working MSTR_NORMAL 1 will be high This passes through inverter U13 ...

Page 147: ...is working then U5 13 is high and MSTR_IPA_CTL passes through the switch to U5 4 If there is no mute signal present at U5 5 the signal will pass through to CR4 and U15 3 CR4 and R30 basically create a negative gate bias for the IPA which will vary with the MSTR_IPA_CTL signal The IPA requires about 15V to be completely shut off and about 0V to be fully turned on 4 8 7 1 9 IPA Current and Voltage S...

Page 148: ...the board at J3 It is detected by CR10 and buffered by U1 1 The voltage at TP7 is directly proportional to the amount of reflected power coming back to the transmitter from the antenna or transmission line This DC sample voltage is sent to the Master Controller via J1 A19 for VSWR protection and monitoring when the Master Controller is operational The VSWR fault comparator output at U3 2 will only...

Page 149: ...the Master Controller fails MASTER_NORMAL will go low opening the U5 13 switch The MANUAL PWR REF pot R25 now controls the transmitter power output This is factory set for 1 4 of the rated transmitter power output MSTR_NORMAL 1 This signal goes low when the Master Controller fails Its primary responsibility is to disconnect all of the control lines coming from the Master Controller via AND gates I...

Page 150: ...plies AC to the RF Source 2 The high at U26 13 enables the XMTR_ON_LOW pushbutton on the front panel overlay when in Life Support Mode to enable the local transmitter ON LOW command Remote ON LOW REM_ON_LOW is also avail able in Life Support Mode Note that the HIGH ON pushbutton on the front panel overlay has no function when in Life Support Mode f MSTR_NORMAL1 applies a low to all nine AND gates ...

Page 151: ...the Q output to apply a 3 second SOFTSTART_MUTE whenever an on command is given via U35 11 The SOFTSTART_MUTE mutes the exciter RF output to make sure there is no RF applied to the system for 3 5 seconds to allow the supplies to fully charge U8 is only active in Life Support Mode It is cleared by the MASTER_NORMAL BAR signal when the Master Controller is operational The Master Controller normally ...

Page 152: ...itter will be shut off It is important to note that if the Master controller is working then U6 3 would not go high and therefore the LS_SYST_FAULT is not active This is due to the fact that the Master Controller has the primary responsibility for VSWR protection This circuit only has function when the Master Controller has failed and the transmitter is running in the Life Support Mode 4 8 7 2 3 I...

Page 153: ... PA2 PA2 J2 K2 RT2 D8 PA1 PA1 J1 K1 RT1 This chart is meant as an aid in tracking control status and metering signals between the PA Controllers and the individual PAs The first column groups the PAs by Z Plane The second column gives the actual PA designation or location as silk screened on the inside of the PA doors As for columns 3 through 6 each PA Controller is identical and has the ability t...

Page 154: ...4 70 888 2586 001 9 15 06 WARNING Disconnect primary power prior to servicing Platinum Z16HD Section 4 Overall System Theory ...

Page 155: ...afety Precautions WARNING DISCONNECT AND LOCKOUT PRIMARY POWER AT THE AC SOURCE PRIOR TO PERFORMING ANY CONNECTIONS REPAIRS OR MAINTENANCE INSIDE THE TRASNMITTER It is very dangerous to attempt to make measurements or to replace components with power on The design of the transmitter provides safety features such that lethal voltages are shielded behind doors or clear Lexan shields which require a ...

Page 156: ... be monitored using front panel metering and the Diagnostic Display and the results recorded in the transmitter logbook at least once a day 5 2 2 3 Maintenance Logbook The maintenance logbook should contain a complete description of all maintenance activities required to keep the transmitter operational A list of maintenance information to be recorded and analyzed to provide a database for a failu...

Page 157: ... air system filtering humidity etc at least once a year This determination can be made either by visual inspection or by monitoring the module temperatures in the Diagnostics Display WARNING THE PA MODULES ARE DESIGNED TO HANDLE VERY HIGH TEMPERATURES AND MAY BE EXTREMELY HOT DO NOT TOUCH THE MODULES WITH BARE HANDS AFTER THE TRANSMITTER HAS BEEN RUNNING ESPECIALLY IN HIGH AMBIENT TEMPERATURE ENVI...

Page 158: ...with a vacuum cleaner or compressed air or both For example the rectifier heatsinks on top of the transformers should be cleaned with compressed air then after the dust settles the rest of the compartment vacuumed Be very careful when moving cables to clean Anytime a cable or wire is moved there is the possibility of breakage or open connections Therefore cables should always be moved as little as...

Page 159: ...Source to verify RF Source 1 or RF Source 2 see section 2 5 4 4 2 TX INTERFACE on page 2 9 Then press corresponding button to toggle through the choices to select BSTAMP STEP 3 Set the Flexstar HDx FM Exciter Aux Power Level to 0 by accessing page 3 of the Output Setup screen STEP 4 Press the INFO button on BoostPro STEP 5 Select CONTROL SUBMENU then press ENTER STEP 6 Select CONIFG UNLOCK Press t...

Page 160: ... the Output Setup screen STEP 13 Press the FWD PWR meter button on the ZHD transmitter Press HIGH to turn on transmitter and RAISE power to approx 50 TPO STEP 14 Press the APC meter button on the ZHD transmitter STEP 15 Back to the EXT APC GAIN screen on the BoostPro set the gain to a value that maintains a 3 3 volt APC reading on the transmitter STEP 16 Press the RAISE button on transmitter until...

Page 161: ...at the wall breaker Remove a PA module to allow access to the Z Plane connectors Connect the common lead of the meter to the chassis and check pins 14 or 15 on the Z Plane connector The resistance should be 50 ohms 3 ohms for Z Plane B C and D Z Plane A will read as a short via L1 the static drain choke in the hybrid Checking any slot on one Z Plane will test the following reject loads See Overall...

Page 162: ...ault Log the abort screen will read VSWR high During the test the HIGH ON and LOW ON buttons will not work The test can be started at any time and any power level above 50 If a fault is detected during the test it will be aborted and the fault will be noted in the Fault Log Also the user can abort the test at any time by pressing the OFF button or via the test screen on the Diagnostics Display The...

Page 163: ...ITTER If it is determined that one of the Isolation Boards needs repair or replacement then the following procedure should be read and thoroughly understood before beginning The entire Isolation assembly is relatively inexpensive and easy to remove and replace The Isolation resistors and RF switches are critical to the proper operation of the combiner system Replacement of any parts on the Isolati...

Page 164: ...LED STRAIGHT OUT IF BENT THEY WILL HAVE TO BE STRAIGHTENED BEFORE IT WILL BE ABLE TO BE RE INSTALLED IF BENT TOO FAR THE PINS MAY BREAK OFF WHEN STRAIGHTENED d The Isolation assemblies for Z Planes A and D the 2 nearest the sides of the transmitter can be taken out the front of the transmitter The 2 in the middle from Z Planes B and C must be taken out the rear of the transmitter The 2 Isola tion ...

Page 165: ...all the harmonic filter being careful to make sure it is inserted fully into the friction fitting on the hybrid note the mark made during removal and rotated correctly incorrect rotation could cause the doors to hit the directional couplers 5 7 Removing the Harmonic Filter This procedure will only take 5 to 10 minutes to accomplish provided there is adequate room above the transmitter It will take...

Page 166: ...nserted as far as the reflected and have a small gap between the coupler and the base Before removal mark each coupler for the following a Proper position the couplers should go back into the same hole from which they came b Orientation mark the couplers with an arrow pointing up to be sure and replace them correctly Reversing a forward coupler makes it read reflected and vise versa c Cable Number...

Page 167: ...rn the transmitter on at HIGH power and set the power output to a power level which is less than the desired maximum power using the Raise and Lower buttons STEP 2 To enter a new MAX HIGH setting go to the MAX HIGH SET screen HOME MORE CONFIGURATION B C Then choose the desired modulation format to change to the new maximum power level and press BACK to save the changes STEP 3 Press Raise to make s...

Page 168: ...evel to your new TPO Press BACK to update and store the new information The front panel FWD PWR reading should be 100 You may also want to change the MAX HIGH and MAX LOW power settings to something more in line with your new TPO as well MAX HIGH sets the maximum power level when the HIGH ON button is pressed while MAX LOW sets the maximum power level when the LOW ON button is pressed STEP 4 Repea...

Page 169: ...libration procedure requires an external power meter to be used as the calibration reference STEP 1 Shut the transmitter off Press HOME MORE CONFIGURATION D and set your operating frequency STEP 2 Go to the 100 TPO SET screen HOME MORE CONFIGURATION B B Then choose the desired modulation format Set this screen to read the power at which you are going to calibrate your TPO If you wish to restore to...

Page 170: ...or Screen HOME MORE CONFIGURATION C A A D STEP 6 Set R127 ten turn pot on the Life Support Board maximum CW STEP 7 Press and hold the HIGH power button then press the lower button for 30 seconds this will lower the power to zero and also set the APC REF APC value to zero STEP 8 Make sure the RF Source is properly connected powered on and unmuted STEP 9 Press HOME MORE CONFIGURATION C B This will t...

Page 171: ...until the external meter reads the TPO at which you are calibrating STEP 11 Set the power level in Figure 5 6 the FWD POWER CAL screen HOME MORE CONFIGURATION C C to the TPO at which you are calibrating Figure 5 6 Forward Power CAL Screen HOME MORE CONFIGURATION C C STEP 12 Set the Transmitter LCD meter the right hand display to read FWD PWR in kW STEP 13 Calibrating Verify once more that the FWD ...

Page 172: ...ce they may have changed from those noted on the factory test data sheet HOME MORE CONFIGURATION C A FORWARD FACTOR CAL FREQUENCY CAL APC FACTOR Forward power calibration is now complete 5 13 Reflected Power Calibration Reflected power calibration must be performed upon replacement of the Life Support or Master Controller boards or the Directional Coupler To correctly re calibrate your transmitter...

Page 173: ... power directional coupler it should be the one on the left side It is marked with a small tag If necessary trace the wire numbers to determine the correct coupler Be very careful to keep track of the top to bottom orientation Loosen the 2 clamps until the Reflected Coupler can be taken off Now rotate the coupler 180o and re install it This lets the coupler sense forward power Be sure to push the ...

Page 174: ...llowing formula based on your desired TPO for your primary modulation method to determine the A D RFL PWR factor EXAMPLE Desired TPO of primary modulation format 4600W A D RFL PWR factor 474 Figure 5 8 A D RFL PWR Reading HOME MORE CONFIGURATION C B STEP 10 Press HOME MORE CONFIGURATION C D The will take you to the Reflected Power Cal screen and should look like Figure 5 9 Set this screen to the c...

Page 175: ...osition STEP 12 Press HOME MORE CONFIGURATION B A D D This takes you to the VSWR Foldback Set screen Set the VSWR FOLDBACK to 1 30 and press BACK to save the setting STEP 13 Turn the transmitter back on and press the RAISE button on the front panel until you have 100 or desired TPO STEP 14 It is recommended that the REFLECT FACTOR Value be noted for future reference since it may have changed from ...

Page 176: ...There are 7 jumpers on the Life Support Board JP1 and JP2 select the main and alternate exciter mute as active HIGH or LOW Table 2 2 in Section II shows the proper settings for a Harris exciter JP3 should be set from pins 2 3 for a ZHD JP4 JP5 should be set to 1 2 JP6 set to 2 3 for IBOC operation JP7 at 1 2 for single RF Source only For any other configurations set at 2 3 STEP 4 Be careful to mar...

Page 177: ...RATION MUST BE COMPLETE BEFORE RETURNING THE TRANSMITTER TO ON AIR SERVICE STEP 12 Set R25 Maximum CCW STEP 13 Power Calibration complete the Reflected Power Calibration and then the Forward Power Calibration procedures located earlier in this section then return here to finish replacement of the Life Support Board STEP 14 Set switch S1 9 on the Master Controller to the ON position to place the tr...

Page 178: ...all other switches OFF c For PAC 3 S1 2 ON all other switches OFF d For PAC 4 S1 1 and S1 2 ON all other switches OFF NOTE The switches set the board ID Once the ID for the board has been set it must be placed in the proper slot and the correct cables connected to that controller An improper ID or incorrect cabling will generate cable or jumper faults in the Fault Log and the transmitter will not ...

Page 179: ...t RS 232 ID S1 5 ON EEPROM mode select must be ON for any IBOC mode S1 6 OFF Factory Use Only S1 7 OFF Not used S1 8 OFF Factory Use Only S1 9 OFF ON Microcontroller RESET S1 10 ON APC ON OFF STEP 6 Install the new Master Controller Board and apply AC power to the transmitter It is a good idea to verify the transmitter configuration settings in the Diagnostics Display NOTE To verify the most impor...

Page 180: ...FF Factory Use Only S1 7 OFF Not used S1 8 OFF Factory Use Only S1 9 OFF ON Microcontroller RESET S1 10 ON APC ON OFF STEP 6 Turn on the Low Voltage breaker in the rear of the transmitter If the EEPROM is blank the Fault Log will register EEPROM_DEF which means it loaded the default settings for the EEPROM these are listed in Table 5 1 Reset the Fault Log STEP 7 All of the parameters in Table 5 1 ...

Page 181: ...D Mode Default Settings Forward Factor 0 015393 Reflect Factor 0 000613 CAL Frequency Set to your frequency Default 98MHz Operating Frequency Set to your frequency Default 98MHz Cal APC Factor 15 15 100 TPO Set 7000W 3500W Max High Set 7350W 3675W Max Low Set 3500W 1750W UPS Setting 3500W 1750W Low Power Alarm User Configurable VSWR Foldback 1 30 VSWR Fault 1 70 NOTE These are typical values Refer...

Page 182: ...into two sections a Configuration b Calibration 5 15 1 Configuration The transmitter should be turned off but with AC power applied from the wall breaker The REMOTE DISABLED LED should be lit on the front panel of the transmitter For the following setup refer to the Diagnostics Display Menu Tree for more details of how to get to System Calibration and Setup screens referred to below NOTE For the f...

Page 183: ...the High Mode of operation 105 TPO is the MAX setting MAX LOW SET This screen will let you set the upper limit the trans mitter will be allowed to go to in the Low Mode operation Default is 50 TPO When finished press BACK to update Press A B UPS SET This screen will let you set the power output the transmitter will go to in the UPS Mode Default is also 50 TPO When finished press BACK to update Pre...

Page 184: ...ision number for the software c A U component designator to locate the correct socket on the board The fol lowing is a list of the component designators for each of the Firmware IC s 1 Master Controller U18 and U28 2 PA Controllers U23 and U30 3 PS Controller U5 and U8 WARNING BE SURE TO USE AN ANTI STATIC WRIST STRAP WHEN HANDLING PC BOARDS OR IC S TO PREVENT DAMAGE TO THE COMPONENTS 5 16 1 Firmw...

Page 185: ...the IC pry it up just a little Then move to the opposite corner and pry it up a little Work back and forth from one corner to the other until the IC comes out STEP 6 If the IC is going to be re installed and you need to set it down make sure it is placed on an anti static mat or in an anti static bag 5 16 2 Firmware IC installation STEP 1 To install the firmware IC s you first need to match the U ...

Page 186: ...ring Disconnect the connector and then completely remove the assembly from the transmitter STEP 3 Remove the power supply securing hardware STEP 4 Disconnect cable W21 Cable W21 is the gray ribbon cable with orange connector located on the front right rectifier board STEP 5 Locate the large gray Wago block A17TB1 in the lower front center of the power supply chassis A17TB1 numbering is 1 through 8...

Page 187: ...ut STEP 15 Disconnect the output transmission line from the top of transmitter and disconnect J3 J4 J5 from the directional couplers Disconnect the top plate and connector assembly from the transmitter so that the filter can be raised up about 6 inches Loosen the two hose clamps holding the filter in place and slide it up and out of the combiner Then tighten the hose clamps to hold the filter up S...

Page 188: ...he fan assembly Slowly slide the assembly to the side being careful of the interconnect wiring Disconnect the connector then completely remove the assembly from the transmitter STEP 4 Loosen the power supply securing hardware at the front corners of the supply tray STEP 5 Disconnect the interconnect cable which connects to J6 on PS1 at the front right side of the transformer Also disconnect wire 2...

Page 189: ...onnector is socketed there are no hose clamps or hardware that needs to be removed to pull this filter out STEP 14 Disconnect the output transmission line from the top of transmitter and disconnect J3 J4 J5 from the directional couplers Disconnect the top plate and connector from the transmitter so that the filter can be raised up about 6 inches Loosen the two hose clamps holding the filter in pla...

Page 190: ...5 07 88 10 50 FM MAX LOW Set 01 00 01 75 02 50 03 75 05 00 FM UPS Set 01 00 01 75 02 50 03 75 05 00 FM HD SLC 100 TPO Set 01 50 02 50 03 50 05 00 07 00 FM HD SLC MAX HIGH Set 01 58 02 63 03 68 05 25 07 35 FM HD SLC MAX LOW Set 00 75 01 25 01 75 02 50 03 50 FM HD SLC UPS Set 00 75 01 25 01 75 02 50 03 50 HD 100 TPO Set 00 88 01 30 01 75 02 60 03 50 HD MAX HIGH Set 00 92 01 37 01 84 02 73 03 68 HD M...

Page 191: ...9 15 06 888 2586 001 5 37 WARNING Disconnect primary power prior to servicing Section 5 Maintenance and Alignment Platinum Z16HD Table 5 3 Z16HD Recommended Minimum Log Readings ...

Page 192: ...5 38 888 2586 001 9 15 06 WARNING Disconnect primary power prior to servicing Platinum Z16HD Section 5 Maintenance and Alignment ...

Page 193: ...s is not to say that component level troubleshooting is not an option But due to the complexity of the circuitry and the use of surface mount components especially in the controller boards which are multi layer boards as well troubleshooting and field replacement can be very difficult It is relatively easy to damage these boards with improper equipment and soldering techniques due to the size of t...

Page 194: ...ATURE AND OF THE NECESSARY SAFETY PRECAUTIONS AFTER USE DISPOSE OF AS CHEMICAL OR SPECIAL WASTE ACCORDING TO THE REGULATIONS APPLYING AT THE LOCA TION OF THE USER IT MUST NEVER BE THROWN OUT WITH THE GENERAL OR DOMESTIC WASTE Defective PAs should be exchanged by contacting the Harris Service Parts Department available 24 hours a day 7 days a week 6 3 Software Revision Each of the controller boards...

Page 195: ...on The data concerning the failed PA will be reset and the controller will try to operate normally turning the previously defective PA on with all of the rest of the PAs Naturally if it still has a problem it will be switched out again However if the PA is fixed and re installed the controller will automatically activate the PA 6 5 3 Strike Routine The faults in the transmitter that will initiate ...

Page 196: ...mps are designed to allow the transmitter to operate at the maximum possible power level without over dissipating the isolation resistors or exposing the transmitter to excessive reflected power This would mean that there would be a fault in the log but it would be inactive and the transmitter would be in a foldback condition 6 6 Diagnostics Display Menu Tree The most important documentation conce...

Page 197: ...fault is active or non active Pressing A or PREV Previous will take you to the next fault in the log Figure 6 2 Fault Log 6 7 1 Front Panel Fault LED When a fault is detected the Fault LED on the front panel of the controller will illuminate a steady red as long as there is an active fault If there are faults in the log but none are active the Fault LED will flash to alert the technician to check ...

Page 198: ...FLT Fault REF Reference Voltage CPLR Directional Coupler NC Not Connected IPA_AB IPA for Z Planes A B IPA_CD IPA for Z Planes C D OT Over Temperature OC Over Current UC Under Current PAC Power Amplifier Controller COMM Communications XOVER Crossover Protection One PA Controller crosses over to protect the PAs controlled by another PA Controller should it become inoperative PSC Power Supply Control...

Page 199: ...ics Display Menu including their effect on transmitter operation and a brief comment explaining the fault Table 6 2 includes faults that are associated with the Master Controller Board which includes the IPA Table 6 3 includes faults that are associated with the PA Controller Boards PAs and ISO Loads Table 6 4 includes faults that are associated with the PS Controller Board and the power supply it...

Page 200: ...ke routine is programmed into the sensing circuits If any of the following faults are indicated it is because 3 separate momentary fault conditions over a specified period of time or a continuous fault condition over a specified time has occured VSWR TRIP Reflected power overload based on the TX type and modulation defined in the master configuration file FWD PWR TRIP Forward power overload based ...

Page 201: ...analog I O has failed 6 9 BoostPro Diagnostics Programming For all meter readings and programming including and beyond the front panel abilities the VT100 is the emulation method used to interface a computer with the BoostPro amplifier Any parameter accessable on the front panel GUI can also be viewed and modified via VT100 By using a PC and terminal application of your choice such as HyperTermina...

Page 202: ...rsor within page To edit a numerical entry STEP 1 Type the line number or letter in parenthesis do NOT hit Enter STEP 2 Use up down arrow keys to increase decrease numerical value with the exception of the Meter Calibration section where it is required to type in the numerical value STEP 3 Press the Enter key to store that entry To toggle turn on off a command STEP 1 Type the corresponding number ...

Page 203: ...gnal Fast Mute Status ON OFF Status of the Fast Mute condition for the BoostPro when OFF the BoostPro is not muting the signal Fault Strike Status OK FAIL Status of the fault strike condition when OK the BoostPro has not entered or completed a three strike fault condition 3 separate momentary fault conditions over a specified period of time or a continuous fault condition over a specified time FAI...

Page 204: ...e Flexstar exciter Check cable and connectors Verify all CAN addresses ID s in circuit are correct e Reset Defaults Typing e will change all settings back to factory presets f Fault Reset Typing f will reset the Fault Strike Status The voltages displayed in the upper right side of the VT100 screen are samples of the voltages present on the controller board VSWR foldback 0 4095 Reference value indi...

Page 205: ...3_5_CD Z_7_10_CD Z_CD_DUAL LP_HT MP_HT HT_20_25 HT_30_35_B HT_30_35_A HTD_60_70 PT_2_4_5 PT_8_10 CUSTOMIZED NOTE When Operation Mode is set to STAND ALONE TX the TX Type automati cally changes to STAND ALONE TX This is the only condition where the TX Type STAND ALONE TX is available 4 Mute Polarity ACTIVE LOW ACTIVE HIGH DISABLED 5 Fast Mute Polarity ACTIVE LOW ACTIVE HIGH DISABLED 6 Power Mode EX...

Page 206: ...k is given next to the title CONFIGURE SETTINGS LOCK or UNLOCK CAUTION UNLOCKING AND THEN MODIFYING THESE CONFIGURATION SETTINGS INCORRECTLY COULD CAUSE DAMAGE TO THE BOOSTPRO AND OR ANY DOWNSTREAM EQUIPMENT TRANSMITTERS COMBINERS REJECT LOADS ANTENNAS ETC FAULTS The faults listed on the right side of the screen are self explanatory with the exception of A BIT fail and D BIT fail A BIT fail refers...

Page 207: ... 6 15 WARNING Disconnect primary power prior to servicing Section 6 Troubleshooting Platinum Z16HD 6 9 4 VT100 Page 3 Build in Test page CTRL bit to run test Figure 6 6 Build in Test Passed Figure 6 7 Build in Test Failed ...

Page 208: ...WARNING Disconnect primary power prior to servicing Platinum Z16HD Section 6 Troubleshooting 6 9 5 VT100 Page 4 Z Serial information Commands l Loopback Typing l will initiate a serial communication test Figure 6 8 VT100 Page 4 ...

Page 209: ... primary power prior to servicing Section 6 Troubleshooting Platinum Z16HD 6 9 6 VT100 Page 5 Remote Output Remote Input The information displayed on this page is the digital data the micro module is receiving and send ing Figure 6 9 VT100 Page 5 ...

Page 210: ...al analog to digital converter The internal analog to digital converter is being used to sample the voltages on the controller board Also on the left side bottom of the screen is the data showing that a power cal has been done The cal slope and the cal offset will show 10 for each if a forward power calibration has not been done The information on the right is data that the micro module is sending...

Page 211: ... and integrity The length of time required for the SYSTEM test will be indicated on the display The test will bring the output level to approximately 1750W regardless of current modulation format and will be going through a MUTE cycle for each PA The test can be started at any time The user can abort the test at any time by pressing the OFF button or via the test screen on the Diagnostics Display ...

Page 212: ...is test should be used as part of a routine maintenance program at least once a year It should also be done if major combiner components are removed and or replaced such as a Z Plane or Isolation Board or if cabling is disconnected and re connected to the Z Planes or Isolation Boards The following sequence of tests make up the SYSTEM TEST PA Muting Test PA ISO Resistor and Thermistor Test PA RF Sw...

Page 213: ...B b The PA RF switch could be stuck in the energized position In this position the ISO resistor is open and does not draw any current However if this is the prob lem the PA may be failed since the switch is grounding its output A normal PA current would rule this out c The ISO resistor is open which means it would not draw any current and would not get hot These resistors are 50 ohms 12W and are l...

Page 214: ...B again to shut off the test b EEPROM TEST This will test EEPROM U39 on the Master Controller the only socketed IC on the board This is where all of the user data and the Factory Default Settings are stored This test should only be done if there is a problem recalling the Factory Default Settings in the Diagnostics Display or if the Master Controller needs to be replaced If it fails the test U39 w...

Page 215: ...he SYSTEM FOLDBACK screen in the Diagnostics Display under HOME STATUS B B This screen shows that there are 3 possible foldback conditions VSWR FOLDBACK YES or NO SYSTEM ISO TEMP YES or NO PA FOLDBACK YES or NO These screens can be extremely helpful in determining where to start looking for the source of the fault This screen will only show a YES status if the front panel FOLDBACK LED is illuminat...

Page 216: ...risk shows up in a metering menu it means that there is no data being received for that reading The pound sign will only be used in the Vg Gate Control Voltage for the individual PAs menus and signifies that there has been a crossover this is a condition where one PA Controller crosses over and mutes the PAs associated with another PA Controller 6 12 Master Controller Faults The following is a lis...

Page 217: ...oking at all of the temper ature readings One of them will show a sign instead of a temperature The tem peratures to look for include 1 IPA Temps IPA_AB1 and IPA_AB2 The thermistor is located on the IPA right next to the FETs 2 PA Temps for A1 A8 and B1 B8 The thermistor is located on the PA right next to the FETs 3 ISO Resistor Temps for A1 A8 and Az B1 B8 and Bz These are all located on the Isol...

Page 218: ... the 5Vdc reference voltage used for system software calibration is less than 4 75Vdc No transmitter action is taken other than to report the fault in the fault log and light the Fault LED on the front panel The 5V Ref can be checked at TP4 on the Life Support Board where it originates It is adjusted with R28 also on the Life Support Board for 5 0Vdc 6 12 4 MSTR_REF 5V Reference Fault This fault m...

Page 219: ...any changes press HOME The default for this setting is 1 70 1 The VSWR foldback setting is under CONFIGURATION B A D D and should be 1 30 1 For all system calibrations refer to Section V Maintenance and Alignment It is also possible that a VSWR fault could be caused by a defective forward or reflected directional coupler or simply from calibration error An external reflected power meter should be ...

Page 220: ...t occurs the transmitter will be shut off The air flow percentage can be seen on the Diagnostics Display by pressing METERING A C Depending on the ambient temperature one of several temperature faults could proceed an air flow fault The most likely cause of this fault is failure of the blower motor The motor also has thermal protection which will automatically shut the motor down CAUTION TURN OFF ...

Page 221: ...e from the IPA Backplane Board the controller will switch to the second IPA provided it has not previously faulted off The controller looks to see if the exciter or IPA is muted before reporting this fault 6 12 14 IPA_xx _OC Fault This IPA Over Current fault could be for IPA_AB or IPA_CD The overcurrent threshold is 14 0 amps If this IPA current limit is exceeded the transmitter will automatically...

Page 222: ... are designed to operate without the Master Controller It is simply used to alert the operator to the fault condition All meter readings associated with that PA Controller will be replaced with an asterisk Table 4 3 on page 4 69 shows which PAs are associated with each PA Controller 6 12 20 AMB_WARNING Ambient Temp Warning If the ambient temperature exceeds 40 C the controller will switch the fan ...

Page 223: ...ds reaches 130 C the Master Controller will switch the fan to high speed and start the foldback routine by reducing the APC voltage at a fixed rate If the temperature is reduced the foldback will stop at 115 C If the temperature goes below 110 C the foldback will be reversed and the power will be very slowly increased until the power output is back to normal or until the load temperature again ris...

Page 224: ...uld be checked as a likely cause of this problem An imbal ance between the IPA outputs could also cause heating of this load Verify IPA opera tion by checking IPA currents voltages and power outputs in the Diagnostics Display 6 12 23 RFSOURCE _LOW Fault If the RF source s forward power drops to 40 or less of normal RF output an indication is given 6 12 24 RFSOURCE _AFC Fault This is the PLL unlock...

Page 225: ...le 4 1 amplifier B2 is controlled by PAC 2 Following this across the table the PAC 2 output labeled PA6_GATE on the PA Controller schematic is the control line for B2 Following this on across this signal would also pass through the Divider schematic as PA6 and connect to the combiner connector J6 The last 2 columns give the Isolation Switch and the Isolation Resistor associated with the PA in ques...

Page 226: ...e of these PAs has a current reading that is less than 10 of the average current of the other three the system will be muted for 120mS the isolation switch for that PA activated removing the PA from the combiner and the mute released on the rest of the PAs The Master Controller actually detects this fault since the PA Controller does not have the current readings on all four PAs in a foursome each...

Page 227: ...are located on the Isolation Boards mounted on each side of the power blocks Normally the ISO resistors have minimal current flow through them and run about 40 100 C If the amplifier connected to the ISO resistor has a difference in phasing or amplitude compared to the other three amplifiers in its foursome then the resistor will try to absorb the imbalance increasing its temperature The bigger th...

Page 228: ... _ISO there should also be one of these in the Fault Log fault number and use Table 4 1 to cross reference 6 14 9 PA_ISO_LOW Fault This fault will only show up if there is a problem found with the PA ISO resistor during the System Test During the System Test the PAs are muted one at a time This should cause the temperature of the ISO resistor to heat up If it does not then the System Test is abort...

Page 229: ...puts of the two power blocks This is a temperature fault 145 C which is caused by an imbalance in phase or amplitude between the outputs of the two power blocks AB and CD This could be caused by failed PAs or an imbalance between the outputs of the IPAs The temperature of this resistor is sensed by the Master Controller and all 4 PA Controllers Therefore this fault should be pre ceded by a an ISO ...

Page 230: ...auses a system mute effectively taking the transmitter off the air 6 14 15 PAC _J Cable Fault There are four cables connected to each PA Controller at J1 J2 J11 and J12 J1 and J2 connect to the Isolation Boards while J11 and J12 connect to the Z Planes The PA Controller boards have ID jumpers to select the board as PA Controller 1 2 3 or 4 The Z Planes have ID jumpers to select whether they are Z ...

Page 231: ... at fault the problem will move to a different supply each supply has its own ID and will therefore show up as the same supply no matter what controller port they are connected to The only other options at this point are to actually swap the controller cards themselves or replace the suspected PS Controller board Swapping the PS Controller cards requires re setting the ID dip switches on each boar...

Page 232: ...d will not change To monitor the heatsink temperature on the Diagnostics Display press METERING D A B This screen gives the heatsink temperature of each power supply 6 15 2 3 PS _DSCHG Discharge Circuit Fault This fault will cause the individual supply to be shut off but will not effect the other supplies If during the operation of the supply the discharge circuit becomes active due to a malfuncti...

Page 233: ...operation of the controller without it no analog reading can be carried out it is continuously monitored by the watchdog IC MAX 705 If it is below 12 volts the fault is tripped Troubleshooting will require tracing the 20Vdc back to the Low Voltage Supply to find out where it is being lost It originates on the Low Voltage Power Supply but is regulated to 20V on the Rectifier Boards in the PA Power ...

Page 234: ... voltage data from the PA Power Supply 52Vdc It is interpreted as an indication of a transformer secondary fault which could be a fuse or SCR If one of the taps has been detected as faulty the next available tap lower ones are the first choice and the next upper one is the second choice will be connected depending on availability Note that if the power supply chassis is not properly grounded or is...

Page 235: ...es SCRs Fuses SCRs Fuses TAP 1 48V Q13 F13 Q4 F4 CR4 F4 Q17 F17 Q8 F8 CR8 F8 Q21 F21 Q12 F12 TAP 2 50V Q14 F14 Q3 F3 CR3 F3 Q18 F18 Q7 F7 CR7 F7 Q22 F22 Q11 F11 TAP 3 52V Q15 F15 Q2 F2 CR2 F2 Q19 F19 Q6 F6 CR6 F6 Q23 F23 Q10 F10 TAP 4 54V Q16 F16 Q1 F1 CR1 F1 Q20 F20 Q5 F5 CR5 F5 Q24 F24 Q9 F9 Soft Start Tap There are no Soft Start SCRs on Rectifier Board A Q34 F4 Q10 F1 Q35 F8 Q11 F2 Q36 F12 All ...

Page 236: ...6 44 888 2586 001 9 15 06 WARNING Disconnect primary power prior to servicing Platinum Z16HD Section 6 Troubleshooting Figure 6 14 3 Phase Power Supply Component Locator Top View ...

Page 237: ...9 15 06 888 2586 001 6 45 WARNING Disconnect primary power prior to servicing Section 6 Troubleshooting Platinum Z16HD Figure 6 15 Single Phase Power Supply Rectifier Assembly Component Locator Top View ...

Page 238: ... 12V Mute XMTR save fault time Transmitter will automatically return to operation when power returns LOW_AIR Low air flow fault at 25 88 cf m Low fan TO high fan OR high fan TO AC off UPS Logic LOW detected at Remote UPS input XMTR is switched to the UPS Power setting CPLR_NC Forward power Directional coupler cable is not connected Mute XMTR Restart required to restore power IPA_MUTE An IPA has cu...

Page 239: ...OUT IPA_CD2 is not inserted completely into the connector Switch to IPA_CD1 if it is not faulted ISO_CD Reject Load ISO_CD on the CD 3dB hybrid is 130o C Will follow the 3 Strike Routine described in Section 6 ISO_ABCD Reject load ISO_ABCD on the ABCD 3dB hybrid 130oC Will follow the 3 Strike Routine described in Section 6 PSC _COMM Communication lost between Master and one of the PS controllers I...

Page 240: ...rolled by designated PAC A _OC B _OC C _OC D _OC The designated Power Amplifier has exceeded 14 0A where is a number from 1 8 Mute XMTR 120ms switch out the PA and release the mute on the rest of the amplifiers A _OT B _OT C _OT D _OT The designated Power Amplifier has exceeded 100oC where is a number from 1 8 Mute XMTR 120ms switch out the PA and release the mute on the rest of the amplifiers A _...

Page 241: ...or the 2 way combiners on each Z Plane Heating is caused by PA imbalance PAC _ISOAB PAC _ISOCD Designated ISO load Temp 130o C Means ISO_APC foldback has failed to reduce temperature of the load Foldback level is 115 o C Will follow the 3 Strike Routine described in Section 6 Press ON button to restart transmitter NOTE These are the reject loads on the 3dB hybrids which are combining the designate...

Page 242: ... or more of the secondary SCRs for the 48V tap have failed on the designated Power Supply Tap1 fault indication PSC will automatically switch to Tap2 if it is not faulted If Tap2 is faulted off shut Tx off with PS _JUMP fault PS _TAP2 Tap 2 failed One or more of the secondary SCRs for the 50V tap have failed on the designated Power Supply Tap2 fault indication PSC will automatically switch to Tap1...

Page 243: ... 12 ASSY DIRECTIONAL COUPLER DB 992 9803 001 B 7 8 Table 7 13 P S 10KW 3PH 3W 992 9719 007 F1 7 8 Table 7 14 ASSEMBLY RECTIFIER 3PH 992 9719 006 C 7 9 Table 7 15 PWA MOV AC 198 250 VAC 992 8553 001 E1 7 11 Table 7 16 P S 10KW 3PH 4W 992 9719 008 F1 7 11 Table 7 17 PWA MOV AC 342 432 VAC 992 8553 003 B1 7 11 Table 7 18 AUX P S CAB 1 PHASE 992 9719 019 H 7 12 Table 7 19 P S 5KW 1PH 992 9719 013 H2 7...

Page 244: ...95 0013 001 FLEXSTAR FM EXCITER 0 EA A16 995 0015 001 FLEXSTAR FM HD EXCITER 0 EA A15 A16 Table 7 2 FLEXSTAR BOOST AMP 971 0027 006 F Harris PN Description Qty UM Reference Designators 250 0628 000 CABLE ASSY USB A BULKHEAD 1 EA J4 250 0671 000 CORD AC 3C NEMA IEC PLUG RT ANGLE1 EA 346 0711 000 CARD GUIDE GROUNDED 2 EA 358 3197 000 SLIDES 10 PAIR 1 PR 396 0261 000 DISPLAY LCD BLUE 1 EA 398 0552 00...

Page 245: ... BRZ FINGERS TWIST 97 56 36 IN 007 4060 079 BRZ FGR STK 0097 0606 02 16 EA 026 6010 003 GROMMET STRIP 0 125 8 030 FT 302 0146 000 SCR 10 32 X 7 8 16 EA 356 0208 000 CLAMP FLAT CABLE 2 22 EA 356 0214 000 CLAMP FLAT CABLE 1 IN 2 EA 358 0498 000 CLAMP HOSE DIA 2 563 MIN 3 50 MAX 4 EA 358 1214 000 SCREWLOCK FEMALE 1 EA 358 2598 000 CABLE TIE MOUNT 4 WAY 8 0 EA 358 2772 000 STANDOFF 6 32 X 3 4 8 EA 398...

Page 246: ...PANEL SIDE COMBINER COVER 2 EA 939 8168 060 ANGLE SLIDE L R 2 EA 939 8168 061 SPACER RECT L R 2 EA 939 8168 065 ANGLE GASKET MTG 1 EA 939 8168 067 ANGLE GASKET MTG 2 EA 939 8168 097 FLANGE CLOSEOUT 2 EA 939 8168 155 SIDE COMBINER SHIELD 10KW 2 EA 939 8168 166 TOP COMBINER SHIELD 10KW 2 EA 939 8168 170 PANEL FRONT MTG 2 EA 939 8168 181 CHASSIS REAR 2 EA 939 8168 182 CHASSIS FRONT 2 EA 939 8168 185 ...

Page 247: ...1260 041 SPACER HEX 375 X 6 07 6 EA 922 1295 060 MARKER PLATE 1 EA 939 8168 059 BAR BOARD RESTRAINT 1 EA 939 8168 062 PLATE CHASSIS RUNNER 2 EA 943 5467 075 CHASSIS CONTROLLER 1 EA 992 9517 001 PWA CONTROLLER P S 2 EA A6 A7 992 9992 015 PWA PA CONTROLLER 4 EA A2 A3 A4 A5 992 9992 131 PWA DISPLAY BACKPLANE 1 0 EA A10 992 9992 141 PWA LIFE SUPPORT 1 0 EA A8 992 9992 211 PWA MASTER CONTROLLER 1 EA A1...

Page 248: ...00 CONN EDGECARD 112 POSITIONS 1 EA J8 612 1492 000 CONN EDGECARD 36 POSITIONS 6 EA J2 J3 J4 J5 J6 J7 612 1495 000 CONN EDGECARD 188 POSITIONS 1 EA J1 612 2139 001 RECP D STRT 9C METAL SHELL 2 EA J24 J25 843 5569 131 SCH DISPLAY BACKPLANE 0 DWG 843 5569 133 PWB DISPLAY BACKPLANE 1 EA 917 2435 039 STANDOFF LCD DISPLAY 4 EA 4 XDS1 Table 7 7 PWA LIFE SUPPORT 992 9992 141 C Harris PN Description Qty U...

Page 249: ...PER PWB TEST POINT 2 EA TP002 TP006 610 0981 000 HDR 20C VERT 2ROW TOP LATCH 1 EA J007 612 1488 000 CONN EDGECARD 36 CONT 2 EA J001 J002 620 1677 001 JACK BNC PCB MT VERTICAL 5 EA J003 J004 J005 J006 J008 843 5467 070 PWB IPA BACKPLANE GND 2 EA 843 5471 201 SCH IPA BACKPLANE 0 DWG 843 5471 203 PWB IPA BACKPLANE 1 EA 999 2871 001 HARDWARE LIST IPA BACKPLANE 1 EA Table 7 9 PWA EXC SWITCHER DIVIDER 9...

Page 250: ... 0760 000 TAB ADAPTOR 250 SERIES 3 EA 424 0016 000 GROMMET 1 1 8 MTG D 1 EA 424 0031 000 GROMMET 2 5 MTG DIA 1 EA 574 0388 000 RELAY 240VAC DPDT 1 EA K2 606 0816 000 CB 3 POLE 10 AMP 250VAC 1 EA CB1 917 2435 201 INSULATOR AC MAIN 1 EA 917 2435 949 CABLE CAB AC DISTRIBUTION 1 EA 917 2538 001 PLATE C B CLOSEOUT 1 EA 939 8168 295 COVER AC DISTRIBUTION 1 EA 939 8168 296 CHASSIS AC DISTRIBUTION 1 EA 99...

Page 251: ...00 SCREW PPHMS 6 32 X 1 4 26 EA 302 0105 000 SCR 6 32 X 5 16 2 EA 2 R048 302 0213 100 SCR 1 4 20 X 1 2 1 EA 1 RT001 302 0791 000 SCREW PPHMS SEMS 6 32 X 1 2 6 0 EA 6 PCB BOTTOM 302 0792 000 SCREW PPHMS SEMS 6 32 X 5 8 4 0 EA 4 PCB TOP 310 0003 000 WASHER FLAT NO 4 4 EA 310 0012 000 WASHER FLAT 6 2 EA 314 0003 000 WASHER SPLIT LOCK 4 4 EA 314 0005 000 WASHER SPLIT LOCK 6 28 EA 314 0009 000 WASHER S...

Page 252: ...08 RES 200 OHM 3W 5 9 EA R004 R008 R010 R012 R025 R027 R029 R031 R065 542 0286 000 RES 5 OHM 5 100W 1 EA R048 548 2400 130 RES 20 OHM 1 2W 1 1 EA R060 548 2400 201 RES 100 OHM 1 2W 1 30 EA R005 R007 R009 R011 R013 R015 R016 R017 R018 R020 R021 R022 R023 R026 R028 R030 R032 R034 R035 R036 R037 R039 R040 R041 R046 R049 R051 R052 R064 R066 548 2400 209 RES 121 OHM 1 2W 1 3 EA R042 R056 R058 548 2400 ...

Page 253: ... 3 EA A17C10 A17C11 A17C9 524 0355 000 CAP 120 000 UF 60 VDC 10 75 4 EA A17C1 A17C2 A17C5 A17C6 540 1600 305 RES 1 5K OHM 3W 5 4 EA A17R1 A17R2 A17R5 A17R6 614 0808 000 TERM BLK 2C MODULAR 283 8 EA A17TB1 614 0810 000 JUMPER 2 POLE ADJACENT 283 3 EA 646 1426 000 END PLATE 283 FRONT ENTRY 1 813 5611 137 STUD 8 EA 917 2435 225 LABEL PS OUTLINE 3 PH 10KW 1 00 EA 917 2435 948 CABLE 10KW PWR SUPPLY 1 E...

Page 254: ...9 8168 105 PANEL FRONT BLANK LOWER 1 EA 939 8168 106 PANEL FRONT BLANK FILLER 1 EA 939 8168 107 SUPPORT FAN ENCLOSURE 1 EA 939 8168 108 ANGLE FAN CLOSEOUT 2 EA 939 8168 109 PANEL MOUNTING FILTER FRAME 1 EA 939 8168 110 PANEL CLOSEOUT FAN 1 EA 939 8168 111 DEFLECTOR FAN 1 EA 939 8168 112 RAIL EIA FRONT UPPER LEFT 1 EA 939 8168 113 RAIL EIA FRONT UPPER RIGHT 1 EA 939 8168 114 RAIL EIA FRONT LOWER LE...

Page 255: ...ECTOR 4C 8 EA 614 0808 000 TERM BLK 2C MODULAR 283 6 EA A17TB1 614 0810 000 JUMPER 2 POLE ADJACENT 283 2 EA 614 0885 000 MODULAR TERMINAL BLOCK 1 EA 646 1426 000 END PLATE 283 FRONT ENTRY 1 813 5611 137 STUD 12 00 EA 917 2435 061 SPACER FUSE PLATE 8 EA 917 2435 223 LABEL PS OUTLINE 1PH 1 00 EA 917 2435 954 CABLE 5KW 1PH PS 1 EA 922 1195 010 RAIL TERM BLOCK MTG 1 EA 922 1260 071 ASSY RECTIFIER HEAT...

Page 256: ...C2 A17C5 A17C6 540 1600 305 RES 1 5K OHM 3W 5 4 EA A17R1 A17R2 A17R5 A17R6 614 0808 000 TERM BLK 2C MODULAR 283 8 EA A17TB1 614 0810 000 JUMPER 2 POLE ADJACENT 283 3 EA 646 1426 000 END PLATE 283 FRONT ENTRY 1 813 5611 137 STUD 8 EA 917 2435 225 LABEL PS OUTLINE 3 PH 10KW 1 00 EA 917 2435 948 CABLE 10KW PWR SUPPLY 1 EA 922 1260 114 BRACKET WAGO 1 EA 922 1260 237 PANEL FUSE MTG 1 EA F901 902 922 12...

Page 257: ...00 1354 000 CAP 91PF 5 250V 2 EA C008 C009 500 1359 000 CAP 150PF 5 250V 1 EA C032 500 1379 000 CAP MICA VAR 8 45PF 175WVDC 1 EA C001 500 1380 000 CAP 180PF 500V 10 CLAD 1 EA C010 500 1381 000 CAP VAR 16 100PF 250V SMT 1 EA C019 516 0417 000 CAP 1000PF 10 200V 5 EA C006 C007 C012 C014 C016 516 0484 000 CAP 0 1UF 100V 10 4 EA C013 C017 C018 C024 516 0768 000 CAP 18PF 5 100V C0G 2 EA C026 C027 522 0...

Page 258: ...N Description Qty UM Reference Designators 917 2572 092 KIT FRMWR 1PH Z4HD SPARE 0 EA 917 2572 093 KIT FRMWR 3PH Z4HD SPARE 0 EA 917 2572 094 KIT FRMWR 1PH Z4HD R SPARE 0 EA 917 2572 095 KIT FRMWR 3PH Z4HD R SPARE 0 EA 917 2572 098 KIT FRMWR 1PH Z8HD SPARE 0 EA 917 2572 099 KIT FRMWR 3PH Z8HD SPARE 0 EA 917 2572 102 KIT FRMWR 1PH Z16HD SPARE 0 EA 917 2572 103 KIT FRMWR 3PH Z16HD SPARE 0 EA 992 855...

Page 259: ...ISC 6 EA 560 0121 010 POSISTOR 0 9 AMP 60VDC DISC 2 EA 560 0121 011 POSISTOR 1 1 AMP 60VDC DISC 1 EA 560 0121 015 POSISTOR 1 6 AMP 60VDC DISC 2 EA Table 7 28 KIT ZHD 3PH SEMICOND FUSE 992 9992 209 A Harris PN Description Qty UM Reference Designators 380 0190 000 XSTR PNP 2N3906 ESD 1 EA 380 0587 000 XSTR MJE210 ESD 1 EA 380 0721 000 XSTR MOSFET IRF9640 ESD 3 EA 382 0406 000 IC MC7812CT ESD 1 EA 38...

Page 260: ...imary power prior to servicing Section VII Parts List Platinum Z16HD 560 0049 000 MOV 275WVAC 75J 14MM DISC 6 EA 560 0111 000 MOV 275WVAC 140J 20MM DISC 6 EA 560 0121 010 POSISTOR 0 9 AMP 60VDC DISC 2 EA 560 0121 015 POSISTOR 1 6 AMP 60VDC DISC 2 EA ...

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