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888-2406-002

5-17

WARNING: Disconnect primary power prior to servicing.

Maintenance and Alignment

5.13.2 Replacing the Power Supply Controller Board

Replacement of a PS Controller Board requires no analog adjustments. Set all dip
switches and jumpers to the same position as the board being replaced. If the new
board does not have the firmware IC’s already installed, then the firmware will have
to be transferred from the old board. Refer to “Removing and Replacing Firmware
ICs” later in this section.

The following is a listing of the normal dipswitch and jumper settings:

a.

For PSC #1 - All switches OFF

b.

For PSC #2 - S1-1 ON, all other switches OFF (PSC #2 is optional and only
used as part of the Z2R Redundancy package).

c.

JP1 pins 1-2

d.

JP2 pins 1-2

5.13.3 Replacing a PA Controller Board

Replacement of a PA Controller Board requires no analog adjustments. Set all dip
switches and jumpers to the same position as the board being replaced. If the new
board does not have the firmware IC’s already installed, then the firmware will have
to be transferred from the old board. Refer to “Removing and Replacing Firmware
ICs” later in this section. The following is a listing of the normal dipswitch settings
for S1 on each PA Controller:

For the Standard Z2:

a.

For PAC #1 - S1-4 = ON, all other switches OFF.

b.

For PAC #2 - S1-1 and S1-5 = ON, all other switches OFF.

For the Z2R:(Redundancy Package)

a.

For PAC #1 - S1-5 = ON, all other switches OFF.

b.

For PAC #2 - S1-1 and S1-5 = 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 turn on.

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Summary of Contents for Platinum Z2 CD

Page 1: ...Platinum Z2 CD FM Transmitter Manual Platinum Z2CD FM Transmitter Manual 888 2406 002 June 9 2003 Rev C T M No 888 2406 002 Copyright Harris Corporation 2000 2001 All rights reserved ...

Page 2: ...tain all PACKING CHECK LISTs Use the PACKING CHECK LIST to help locate and identify any components or assemblies which are removed for shipping and must be reinstalled Also remove any shipping supports straps and packing materials prior to initial turn on Technical Assistance HARRIS Technical and Troubleshooting assistance is available from HARRIS Field Service during normal business hours 8 00 AM...

Page 3: ...isconnect primary power prior to servicing MANUAL REVISION HISTORY Platinum Z2 CD 888 2406 002 Rev Date ECN Pages Affected B 12 17 01 47926 Title page added MRH1 MRH2 sections 2 and 4 C 06 09 03 TBD Title page MRH1 MRH2 and page 2 30 ...

Page 4: ...888 2406 002 WARNING Disconnect primary power prior to servicing ...

Page 5: ...102 etc that corresponds to the number found in the schematics C001 in a bill of material is equivalent to C1 on the schematic or 2 gives added information or further explanation i e Used for 208V operation only or Used for HT 10LS only etc Inside the individual tables some standard conventions are used A symbol in front of a component such as C001 under the REF SYMBOLS EXPLANATIONS column means t...

Page 6: ...888 2406 002 WARNING Disconnect primary power prior to servicing ...

Page 7: ... and fire protec tion standards must be observed The following National Fire Protection Association NFPA standards are recommended as reference Automatic Fire Detectors No 72E Installation Maintenance and Use of Portable Fire Extinguishers No 10 Halogenated Fire Extinguishing Agent Systems No 12A WARNING Always disconnect power before opening covers doors enclosures gates panels or shields Always ...

Page 8: ...888 2406 002 WARNING Disconnect primary power prior to servicing ...

Page 9: ...tation to a hospital as quickly as possible E If arms or legs are affected keep them elevated NOTE If medical help will not be available within an hour and the victim is conscious and not vomiting give him a weak solution of salt and soda 1 level teaspoonful of salt and 1 2 level teaspoonful of baking soda to each quart of water neither hot or cold Allow victim to sip slowly about 4 ounces a half ...

Page 10: ...888 2406 002 WARNING Disconnect primary power prior to servicing ...

Page 11: ...onnection 2 16 Audio Input Connections 2 16 External and Failsafe Interlock Connections 2 17 External Interlock Connection 2 17 Failsafe Interlock Connection 2 17 Initial Turn on 2 18 Remote Control Connections 2 23 Remote Extended Control and Status Connections 2 24 Typical remote extended control and status connec tions 2 25 Extended Metering 2 26 UPS IN Remote Exciter Select Configurable Input ...

Page 12: ...tion 4 26 Power Supply ID Jumpers 4 28 Low Voltage Power Supply Board 4 29 Relays 4 29 Cooling System Description 4 30 Control System Description 4 30 Master Controller 4 31 EEPROM U39 4 31 APC Automatic Power Control 4 32 Calibration Factors and A D Values 4 34 DAC_APC_REF 4 36 Forward Factor and A D_FWD_PWR 4 36 APC Factor 4 37 MAX HIGH MAX LOW and UPS Power Levels4 38 EXC Factor and IPA Factor ...

Page 13: ...eshooting Tips 6 12 Foldback Conditions 6 12 Turning the Transmitter ON with No Power Output 6 12 Asterisk and Pound Signs 6 12 Master Controller Faults 6 13 THERMISTOR Fault 6 13 EEPROM_DEF EEPROM U39 Default Load 6 13 REF_WARNING 5V Reference Warning 6 14 MSTR_REF 5V Reference Fault 6 14 RFL_PWR Reflected Power Fault 6 14 INTLK External Interlock Fault 6 15 FAILSAFE Interlock Fault 6 15 POWER_FA...

Page 14: ... Troubleshooting 6 26 Critical Power Supply Faults 6 26 Soft Start Circuit Fault 6 27 PS1_HS_TEMP Fault 6 27 PS_DSCHG Discharge circuit fault 6 27 PS_PHS_LS Phase Loss 100 120 Hz ripple 6 27 PSC 20V Fault 6 28 PS _CONFIG Configuration Fault 6 28 PS1_JUMP 6 28 Non Critical Power Supply Faults 6 29 PS _TAP Power Supply Tap Fault 6 29 7 Parts List Parts List Index 7 1 ...

Page 15: ...r for use up through the initial turn on of the equip ment 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 under stand the inner workings of the transmitter Section 5 Maintenance Alignments Adjustments lists and explains alignments and ...

Page 16: ...modules Broadband design to eliminate tuning adjustments from 87 through 108MHz N 1 capable Frequency change can be done manually in less than five minutes using simple switch settings and in less than 0 5 seconds using an optional external controller Quick start design provides full output power meeting all specifications within five seconds of an On Command Versatile air cooling design uses eith...

Page 17: ...with an analog interface module for stations with analog program paths easily interchangeable with the digital module 1 3 2 Harris SuperCiter Analog Exciter The optional Harris SuperCiter is a 55 watt high quality analog exciter designed for broadcasters needing state of the art analog performance at a value price The SuperCiter combines time proven PLL technology with modern RF amplifier circuits...

Page 18: ...ating conditions Detailed system information is available using the front panel diagnostic display The controller is designed for direct connection to standard parallel remote control systems The Controller also includes built in logic and controls for automatically switching to the reserve IPA section and a backup exciter if installed The main controller provides automatic power control VSWR over...

Page 19: ... The Z2 can be configured with an optional second supply as part of the Z2 Redundancy package The package includes a second PS Controller a second PA Controller and the second supply For more information refer to Appendix A Z2 Redundancy Package Option 1 3 9 Air System The Platinum Z uses a 2 speed fan to pull air in the back of the transmitter and exhausts it out the top There are air channels up...

Page 20: ...1 6 888 2406 002 WARNING Disconnect primary power prior to servicing Introduction Specifications ...

Page 21: ...are incomplete or if the unit is damaged electrically or mechanically notify the carrier and HARRIS CORPORATION Broadcast Systems 2 3 Returns and Exchanges Damaged or undamaged equipment should not be returned unless written approval and a Return Authorization is received from HARRIS CORPORATION Broadcast Systems Special shipping instructions and coding will be provided to assure proper handling C...

Page 22: ...can be toler ated A closed air system is recommended in these environments that is an air conditioned room that recirculates and properly filters the room air No outside air is brought into the transmitter room 2 5 Z2 Transmitter Installation Prior to installation this Technical Manual and the appropriate FM Exciter Technical Manual should be carefully studied to obtain a thorough understanding of...

Page 23: ...nsmitter was shipped with the power supply installed the power supply tray is covering the bolts so the fan assembly on the rear of the transmitter will also have to be removed to access the rear pallet bolts the power supply itself does not have to be removed Open and remove the rear door by lifting it off its hinges Remove the fan assembly by removing six screws and two nuts located around the o...

Page 24: ... the exciter manual accompanying the transmitter The exciter input cables should be installed in a metal conduit which is separate from the AC supply If the exciter was removed for shipping there are three cables which will need to be hooked up not counting the audio inputs a A ribbon cable which will hook to the remote control connector on the back of the exciter This is A10 J2 on the SuperCiter ...

Page 25: ...the voltage at the site and the transformer tapping should be verified by the installation personnel The input voltage and strapping chart 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 panel on the front of the transmitter and rolling out the power supply this is only if the transmitter ...

Page 26: ...left side of the power sup ply compartment and two smaller gray wires 40 and 41 plug into the gray Wago block connector A17TB1 on the front of the power supply tray A17 designates a component on the power supply tray See Figure 2 1 The wago block has 5 terminals labelled terminal 1 on the left and 5 on the right The connections are as follows 1 Wire 1 connects to terminal 1 2 Wire 2 connects to te...

Page 27: ...nsformer connects to the feed thru terminal C3 at the top of the power supply compartment This is the 52Vdc output from the supply See Figure 2 2 e The large orange ground wire 46 coming from the top of the rectifier assem bly attaches to a ground stud at the top front edge of the power supply com partment It is located under the shelf which separates the power supply from the PA compartment just ...

Page 28: ...e ribbon cable labelled W12 to J4 on the power supply which will be clos est to the rear of the transmitter The supply may now be rolled all of the way into the cabinet i The Wago block on the front of the power supply tray A17TB1 has 8 con nections compared to the 6 connections for the single supply configuration The connections are shown in Figure 2 3 and are as follows 1 Wire 1 connects to term...

Page 29: ... personnel The input voltage and strapping chart 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 panel on the front of the transmitter and rolling out the power supply if the transmitter was shipped with the power supply already installed this depends on where and how it is shipped 2 5 5 2...

Page 30: ...upply tray See Figure 2 4 d The wago block has 4 terminals labelled terminal 1 on the left and 4 on the right The connections are as follows 1 Wire 1 connects to terminal 1 2 Wire 2 connects to terminal 2 3 Wire 40 connects to terminal 3 4 Wire 41 connects to terminal 4 To insert the wires into the wago block insert a screwdriver into the rectangular slot behind the wire hole and then carefully pu...

Page 31: ...r supply attaches to the ground stud at the top front edge of the power supply compartment It is located under the shelf which separates the power supply from the PA com partment g Connect the safety ground wire to the stud on the front of the power supply tray next to A17TB1 see Figure 2 4 h Tighten the two hold down nuts located on the bottom front corners of the power supply compartment Re inst...

Page 32: ...e rolled all of the way into the cabinet b The wago block connection on the front of the power supply tray 1A17TB1 has 6 connections whereas the single supply version has only 4 The connec tions are shown in Figure 2 6 and are as follows 1 Wire 1 connects to terminal 1 2 Wire 2 connects to terminal 3 3 Wire 40 connects to terminal 5 4 Wire 41 connects to terminal 6 NOTE Terminals 1 and 2 are conne...

Page 33: ... model and AC configuration WARNING DISCONNECT AND LOCK OUT STATION PRIMARY POWER TO TRANSMITTER BEFORE ATTEMPTING ANY CONNECTIONS NOTE Proper wire size information is available on the Cabinet Outline Drawing in the drawing package Observe maximum specified ratings for safe operation A customer supplied AC primary power disconnect or means to completely de energize the transmitter primary circuit ...

Page 34: ...AC mains contactor K1 K1 is on the top right side in the rear of the cabinet There is also a large standoff located near the main contactor for the NEUTRAL connection in 380VAC 342 432Vac 4 wire WYE systems Bring the AC wires through the holes in the top of the transmitter and connect to the top terminals on contactor K1 CAUTION THE NEUTRAL CONNECTION IS EXTREMELY IMPORTANT IN 380VAC 4 WIRE WYE AP...

Page 35: ...carry lightning current directly into the ground instead of into your building Additionally coax shield s should be electrically connected to and exit the tower as near to the bottom as practical to minimize the lightning voltage potential carried by the coax into your building For coaxes a single point of entry into the building is best with all connected to a common grounding plate or bulkhead p...

Page 36: ... of the tapping chart without re tapping 2 5 6 6 Exciter AC Voltage Selection Once the site voltage has been checked verify that the exciter s are set for the proper input AC voltage For verification the selected voltage should be visible next to the AC power cord connection on the rear of the exciter The voltage at the exciter AC input can be found by measuring between any two phases of a 3 phase...

Page 37: ...ON command after the external interlock connection is restored CAUTION TO CONNECT TO THE WAGO BLOCK J4 ON THE LIFE SUPPORT BOARD REQUIRES PRESSING A SCREWDRIVER INTO THE RECTANGULAR SLOT ON THE FRONT SIDE OF THE BLOCK SO THE WIRE CAN BE INSERTED FROM THE REAR BE SURE TO PROPERLY SUPPORT THE BOARD SO THAT IT IS NOT BENT OR STRESSED IN ANY WAY WHILE INSERTING THE WIRES 2 5 9 2 Failsafe Interlock Con...

Page 38: ...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 Step 2 Turn on the low voltage power supply breaker CB1 located in the rear of the transmitter cabinet in the upper right hand corner There are 6 green LED...

Page 39: ...elow See Figures 2 8 and 2 9 Step 7 PA Module Installation Four PA modules are inserted in the front of the cabinet and four PA modules in the back of the cabinet The PA modules only have an amplifier on one side and must be inserted with the amplifier side of the module nearest the center of the transmitter For example in the front of the transmitter the modules are inserted with the amplifier on...

Page 40: ...2 20 888 2406 002 WARNING Disconnect primary power prior to servicing Installation Initial Turn On Figure 2 8 PA Compartment Front View Figure 2 9 PA Compartment Rear View IPA_1 IPA_2 1 2 3 4 5 6 7 8 ...

Page 41: ...IPAs Figure 2 10 Default Diagnostics Display Screen STATUS D B If the transmitter is configured with a single IPA then one half of the module will be empty just like the PAs It is recommended that the IPA module be inserted with the amplifier on the right side of the heatsink This places the amplifier in the IPA_1 position the default for the controller If the IPA is on the left side of the heatsi...

Page 42: ...xt step Step 12 Press the HIGH power ON button on the front panel of the controller If there are no faults again verify all of the transmitter display readings against those in the factory test data sheet Step 13 This step is optional as it simply makes the transmitter FWD PWR meter read 100 at the customer specified Transmitter Power Output TPO which should already be factory set This will not ch...

Page 43: ...ations provided in the Platinum Z2 Transmitter allow remote control of the transmitter functions by connection to terminals on TB1 Terminal Board 1 TB1 is a 38 pin Terminal strip with a D connector on the back which connects to J20 on the controller Backplane Display Board Tables 2 1 and 2 2 contain a complete listing and explanation of connections for TB1 Figure 2 11 shows TB1 pinout and connecti...

Page 44: ... 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 indications Maximum exte...

Page 45: ... 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 2 7 1 1 Typical remote extended control and status connections Figure 2 14 shows typical remote extended control and status connections Figure 2 14 Remote Extended Control and Status Connections ...

Page 46: ...Menu press HOME MORE CONFIGURATION A D This should bring up the screen shown in Figure 2 16 The Factory 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 Exciter Select input press B This will switch the display to read EXC This re configures the TB1 9 input so that when it is momentarily pulsed low the transmitter will switch ...

Page 47: ...ware 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 800W and UPS is set for 1kW the transmitter will stay at the LOW power level of 800W If the transmitter is operating at HIGH power when the UPS mode is a...

Page 48: ...de When AUTO mode is selected the transmitter will automati cally optimize the efficiency every 12 hours unless there is an active fault present at the time it is supposed to be activated Inactive faults in the Log will not pre vent optimization However a power failure will reset the 12 hour counter This is the recommended mode of operation and is the default mode from the factory Optimization can...

Page 49: ...en in Figure 2 20 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 20 Remote Low Power Alarm Set HOME MORE CONFIGURATION B D B 2 11 Jumper Settings for Installation of a Harris Exciter The following is for installing an...

Page 50: ...2 30 888 2406 002 WARNING Disconnect primary power prior to servicing Installation Initial Turn On Table 2 1 TB1 Remote Control Interface Connections ...

Page 51: ...888 2406 002 2 31 WARNING Disconnect primary power prior to servicing Installation Initial Turn On Table 2 1 TB1 Remote Control Interface Connections continued ...

Page 52: ...2 32 888 2406 002 WARNING Disconnect primary power prior to servicing Installation Initial Turn On Table 2 2 Jumper Settings for Installing a Harris Exciter ...

Page 53: ...emperature A 5 unbalance will cause destructive temperature rises of 50 greater than normal Similar characteristics can be expected in the windings of a three phase power transformer down inside 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 canno...

Page 54: ...egulation of an unbalanced system is poor 2 12 4 Three Phase Delta Distribution Transformers Figure 2 21 shows open and closed delta systems The closed delta impedance looking into each terminal A B C is exactly the same but this is not the case in the open delta configuration Depending on the impedances of the transformers in the open delta circuit line voltage unbalance sufficient to impair sati...

Page 55: ... are limited in the amount of energy that can be dissipated but will handle if designed properly very large currents You can t take a direct lightning hit and still operate but not many things will It has been reported by engineers that installation of a third transformer and transient protection devices have eliminated the difficulty 2 12 5 Three Phase Wye Distribution Transformers The WYE connec...

Page 56: ...ailable 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 3 Typical Line Voltages Delta or WYE Delta Connected Transformer WYE Connecte...

Page 57: ...ns normal operational procedures and information pertaining to the function of the Platinum Z2 FM Transmitter Most important is the information regarding use of the Diagnostic System All of the information in this section assumes the transmitter and controller are in proper working order Figure 3 1 Controller Front Panel ...

Page 58: ... the foldback is gone ON LOW Turns the transmitter on to the previous LOW setting If the transmitter has folded back power automatically due for instance to high VSWR pressing the LOW button will return the transmitter to the normal low power level provided the cause of the foldback is gone POWER up down arrows used to raise and lower the transmitter power REMOTE DISABLE Located on the left side o...

Page 59: ... of measure for the forward power reading is percentage with 100 representing the nominal power output for the station This percentage can be calibrated to any power level using the Configuration controls in the Diagnostics System If desired the forward power reading can be converted to kilowatt by simply pressing and holding the FWD PWR button for at least 3 seconds After 3 seconds the display sh...

Page 60: ...rawing labelled Diagnostics Display Menu Tree is included in the schematic package This drawing shows all of the menus and screens available in the Diagnostic display system Note that the drawings are divided into layers from left to right with Layer 1 considered the HOME layer at the left and successive layers to the right The diagnostic system consists of the LCD Diagnostic display and 6 functio...

Page 61: ... is the first of two screens in this layer The second screen in the HOME layer is accessed by pressing the D function key to the right of the display which is labelled MORE on the display The screen should now look like Figure 3 4 These two screens give access to all six HOME menus Status Metering Fault Configuration Test Software Revision Figure 3 3 Home Menu Page 1 Figure 3 4 Home Menu Page 2 ...

Page 62: ... it did not take you to the previous screen but back to Layer 1 the HOME layer shown in Figure 3 3 However if instead of pressing BACK you pressed more again this would have taken you to the first screen in layer 2 since there are only two screens Figure 3 5 Status Layer 2 Page 1 3 4 3 MORE MORE is a menu item which is used when there are more menu items on a layer than will fit on one screen It w...

Page 63: ... 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 the brackets Example 1 If you wanted to check the temperature of the individual Power Amplifiers you would press the following keys HOME METERING C A C After entering this key sequence the screen should look like Figure 3 6 This i...

Page 64: ... 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 HOME MORE CONFIGURATION B B 3 4 5 Asterisk and Pound Signs The asterisk and the pound sign characters are used in some of the metering menus of the Diagnostics Display If an asterisk shows up in a metering menu it means that there is no...

Page 65: ...AULT Pressing D then 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 time at which it ...

Page 66: ...should be taken out and swapped for one of the modules on the opposite side of the transmitter placing the PA in a different foursome For example if PA amplifiers B1 and B2 have failed these are in the front of the transmitter pull out the B2 PA module and swap it with any of the PA modules in the rear of the transmitter such as B5 There are still 2 failed PAs B1 and B5 but now each one is in a di...

Page 67: ...er 2 press STATUS D C This will bring up the screen shown in Figure 3 10 Pressing D will toggle between the two Exciters Figure 3 10 Exciter Status Screen HOME STATUS D C 3 7 Manual IPA Switching The active IPA can be switched manually from the Status menus in the Diagnostics Display To manually switch from IPA_1 to IPA_2 press STATUS D B This will bring up the screen shown in Figure 3 11 Pressing...

Page 68: ...de When AUTO mode is selected the transmitter will automati cally optimize the efficiency every 12 hours unless there is an active fault present at the time it is supposed to be activated Inactive faults in the Log will not pre vent optimization However a power failure will reset the 12 hour counter This is the recommended mode of operation and is the default mode from the factory Optimization can...

Page 69: ...n 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 speed using the configuration menus in the Diagnostics Display See Figure 3 14 The normal setting fo...

Page 70: ...3 14 888 2406 002 WARNING Disconnect primary power prior to servicing Operator Guide ...

Page 71: ...o possible designations Z2CD which is a 2kW FM transmitter supplied with the DIGIT digital FM exciter CD stands for Clearly Digital Z2FM which is a 2kW FM transmitter supplied with the SuperCiter analog FM exciter 4 2 RF Flow Block Diagram Description Figure 4 1 is a block diagram of RF flow of the Platinum Z2 transmitter Not shown on this diagram is the control and monitoring associated with the ...

Page 72: ...4 2 888 2406 002 WARNING Disconnect primary power prior to servicing Overall System Theory Figure 4 1 RF Flow Block Diagram ...

Page 73: ... 2 IPAs per IPA Module operate in Main Alternate mode meaning that only one of them is active at a time The block diagram shows that IPA_1 is the normally active amplifier RF switching on the input and output of the IPA is activated by the controller if a fault is sensed in the active IPA The IPA output passes through a hybrid with a shorting cable connected across the output terminals The hybrid ...

Page 74: ...he transmitter The Isolation Board also contains RF switches which can switch out a faulty PA without causing a severe system imbalance allowing greater redundancy This also allows the PA Modules to be HOT PLUGGABLE meaning that a PA module may be removed while the transmitter is operating Interlock pins on the module connectors mute the PAs before it switches out the unplugged module 4 2 4 RF out...

Page 75: ...is installed and the on air exciter fails the controller will automatically switch to the backup exciter and log the fault Note that the controller will wait 10 seconds for the on air exciter to recover before switching to the backup If a backup exciter is added anytime after factory testing the installer must go into the Configuration Menus on the Diagnostic Display and set ALT EXCITER to YES to ...

Page 76: ... output of the transmitter and is varied by changing the gate bias on the IPA amplifiers MOSFETs The gate bias for the IPA is adjusted by the controller specifically the Master Controller Board using the front panel POWER Raise and Lower controls 4 3 2 2 IPA Power Supply The IPA power supply is 52 volts from the PA power supply The 52Vdc is connected to the IPA s via the IPA Backplane Board If the...

Page 77: ... menus refer to Using the Diag nostic Display in Section III Operation and to the Diagnostics Display Menu Tree in the schematic package which gives a complete overview of the Diagnostics menu structure 4 3 3 2 Main Alternate IPA Switching Selection of IPA_1 or IPA_2 both input and output is done via relays K2 K3 and the IPA DRIVER SELECT control signal from the Life Support Board K2 switches the ...

Page 78: ...4 3 3 4 Air flow sensing Airflow is sensed as the difference in temperature between a heated sensor RT1 and an ambient sensor RT2 RT1 is actively biased via R3 which will cause a steady increase in temperature with no air flow Under normal operation the voltage difference between the two sensor outputs will stabilize at some value depending on the amount of air flow If the airflow is reduced or no...

Page 79: ...e of each schematic is identical and is a block diagram of the entire Z Plane The Z Plane assembly contains Edge connectors for 8 PA amplifier boards 4 in front and 4 in the rear These connectors are labeled J1 J8 An 8 way Wilkinson Divider driven by the IPA which feeds RF drive to each of the 8 PA amplifiers An 8 way Wilkinson Combiner which combines the output of the same 8 PA amplifiers The RF ...

Page 80: ...oints labeled E1 E8 on the Combiner schematic If any input is lost due to failure of a PA module the associated ISO load dissipates some power approximately 150 watts until the RF switch on the Isolation board disconnects the ISO load and grounds that point E1 E8 on the combiner This now looks like an open to the 4 way combiner output at E9 or E10 the input to the 2 way combiner 4 3 4 3 PA Modules...

Page 81: ...888 2406 002 4 11 WARNING Disconnect primary power prior to servicing Overall System Theory Figure 4 4 PA Compartment Front View Figure 4 5 PA Compartment Rear View IPA_1 IPA_2 1 2 3 4 5 6 7 8 ...

Page 82: ... the amplifier is fully turned on and drive level from the IPA determines the amplifier power output When the amplifier is used as the IPA VG is used to linearly vary the IPA output which then controls the transmitter power output For an IPA VG comes from the Life Support Board and is controlled by the APC loop on the Master Controller Board Pressing the RAISE and LOWER controls on the front of th...

Page 83: ...n the field Refer to the Maintenance section of this manual for the RF amplifier replacement procedure 4 3 4 4 1Isolation Boards The Z Plane has an associated Isolation Board which contains the isolation resistors and disconnect switches for the two 4 way wilkinson combiners and the isolation resistor for the 2 way Wilkinson combiner The isolation resistors for the four way combiners R1 R8 are eac...

Page 84: ... identical directional couplers with two of the couplers adjusted to produce a sample of the forward output power and one coupler arranged to provide a sample of the reflected output power The isolation or directivity of the couplers is better than 30dB with 40dB typical NOTE The reflected coupler cannot be interchanged with the other 2 couplers due to the different coupling ratio for the forward ...

Page 85: ...e 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 provide excellent efficiency while avoiding the power line harmonic problems associated with switching supplies The regulation range is 48 54Vdc at 2Vdc per tap 4 4 1 1 3 Phase Power Supply The transmitter has one power supp...

Page 86: ...mbination of the extended primary windings and the dual secondaries each at a different phase angle results in an output ripple frequency of 600 720Hz for 50 60Hz input Each of the secondary windings has 4 output taps each of which are connected through an SCR to ground The SCRs act as both tap switches activating the tap which gives the appropriate DC voltage output and as rectifiers This gives a...

Page 87: ...soft start the resistor is bypassed by activating the normal run mode SCRs which are also attached to the lowest voltage output tap but connect directly to ground This allows the supplies to come up to full charge If the voltage is not high enough the Power Supply Controller will activate the next highest tap to increase the voltage It will continue this process until the DC output voltage is appr...

Page 88: ...ap is the 52Vdc output and is filtered by a large choke and 3 large filter capacitors The single phase supply is full wave rectified giving a ripple frequency of 120Hz and therefore requires more filtering than the 3 Phase supply The secondary winding has 8 output taps each of which are connected through an SCR to ground The SCRs act as both tap switches activating the tap which gives the appropri...

Page 89: ...d 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 6 seconds during turn on After the 6 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 connect directly to ground This allows the...

Page 90: ...tage from this secondary is called V SCR on the Rectifier Board It is also fused on the Rectifier Board 4 4 2 Low Voltage Power Supply The Low Voltage Power Supply is a single PC board mounted in the rear of the transmitter near the main contactor It is designated A19 assembly 19 The circuit board is the same for the 3 Phase and single phase configurations only the wiring to and from the board is ...

Page 91: ...ctifier Board contains the SCRs which are used for the tap switching as well as rectification of the 3 phase AC Each secondary winding has four taps see Figure 4 13 Each of these taps have one SCR to ground The Power Supply Controller can turn on any one of the four SCRs at a given time If the voltage is not high enough at the DC output the PS Controller can change the transformer turns ratio by t...

Page 92: ...4 22 888 2406 002 WARNING Disconnect primary power prior to servicing Overall System Theory Figure 4 13 Simplified 3 Phase Transformer Secondary ...

Page 93: ... SCRs for 52V tap J4 7 DRIVER 4 activates SCRs for 54V tap NOTE The circuit for the 48V tap will be explained here as the other three are identi cal but are attached to different transformer taps The DRIVE_1 signal is used to activate the 48Vdc tap on both secondaries When active HIGH it causes the output of U2 17 to go low This turns on Q28 which applies 10VB SS now called DRIVE_1 to R12 on the B...

Page 94: ...e the normal 48V tap SCRs which will tie the taps directly to ground bypassing R48 4 5 1 2 3PA Power Supply Discharge The PA Power Supply Discharge 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 ...

Page 95: ...F signals from the PS Controller board via the Rectifier Board The secondary of T1 uses the unique tap switching design to give a small window of coarse regulation approximately 2Vdc change per tap to compensate for AC line variations 4 5 2 1 Rectifier Board The SCRs for the single phase supply are required to carry a much larger amount of current than the 3 Phase counterparts and are therefore mu...

Page 96: ... 2 2 1Tap Switching Circuit Operation The control signals for the SCRs are active high and come directly from the PS Controller Board They enter the Rectifier Board at J4 1 DRIVER 1 activates SCRs for 48V tap J4 3 DRIVER 2 activates SCRs for 50V tap J4 5 DRIVER 3 activates SCRs for 52V tap J4 7 DRIVER 4 activates SCRs for 54V tap NOTE The circuit for the 48V tap will be explained here as the other...

Page 97: ... CR8 which will tie the taps directly to ground bypassing R48 4 5 2 2 3PA Power Supply Discharge The PA Power Supply Discharge 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...

Page 98: ... heatsink is monitored by Thermistor RT1 A fault is triggered if the temperature of the rectifier heatsink exceeds 100 C and the power supply will be shut off This temperature can be monitored in the Status Menu of the Diagnostics Display If the thermistor is shorted the temperature reading will be about 155 C or higher and the supply shut off If it is open it will cause a Thermistor Fault to show...

Page 99: ...dc to the Rectifier Boards on the PA power supply transformers All three voltages pass through the rectifier boards and are sent to the Backplane Board to power all of the controller PC boards 4 5 4 1 Relays There are three mechanical relays on the Low Voltage Power Supply Board assembly A19 They are A19K1 A19K2 and A19K3 The relays are powered by 12Vdc from the Life Support Board in the controlle...

Page 100: ... be manually set to HIGH speed or AUTO in the Configuration Menus of the Diagnostics Display 4 7 Control System Description The control system is a micro controller based master slave system It monitors over 100 operating functions in the transmitter and can make intelligent operating decisions based on operating conditions It has the standard parallel remote connections The microprocessor control...

Page 101: ... the front panel However the rest of the control system is designed to operate with the Master Controller removed from the system in what is called Life Support Mode The PA and PS Controllers report to the Master Controller but operate independently to allow them to continue operating even if the Master is removed In the event of a Master Controller failure the Life Support Board disconnects all M...

Page 102: ...be replaced since a memory location is probably bad For information on replacing EEPROM U39 see Section V Maintenance and Alignments The following is a listing of all of the Default Values which are stored in the Firmware Forward Factor 0 003079 Reflect Factor 0 000123 Cal APC Factor 3 03 Cal Frequency 98MHz Operating Frequency 98MHz IPA Factor 200 Exciter Factor 200 TPO 100 02 00kW Max High 03 00...

Page 103: ...eet This number can be checked by pressing HOME MORE CONFIGURATION C B The DAC_APC_REF output voltage APC_REF can be metered at TP8 or in the Diagnostics Display by pressing METERING B B The output at U5 7 is the difference between the forward power sample and the APC_REF voltage This difference can be measured at TP3 on the Master Controller and is called the APC voltage R13 and R102 divide this ...

Page 104: ...er Controller Board This switch opens the APC Loop disconnecting the APC voltage from the IPAs When S1 10 is opened MANUAL PWR REF R25 on the Life Support board controls the transmitter power output R25 also serves as the power control for Life Support Mode which means the Master Controller Board has failed If the Master Controller fails U5 pins 1 2 are opened removing the APC voltage from the IPA...

Page 105: ... numbers obtained during the factory calibration are recorded in the Factory Test Data NOTE If the transmitter is calibrated at other than 2kW these numbers will change and their new values should be recorded It is important to note that as long as the hardware calibration of the forward and reflected directional couplers is not disturbed the Cal Factors could be entered manually and the transmitt...

Page 106: ...nal and the APC Loop switch S1 10 is closed 4 7 2 2 Forward Factor and A D_FWD_PWR The Forward Factor is a calibration factor that is calculated during forward power calibration To check the Forward Factor press HOME MORE CONFIGURATION C A A All Z2 transmitters are factory calibrated with a forward sample voltage of 8 9vdc at 2kW as measured at TP9 on the Life Support Board This sample voltage is ...

Page 107: ...REF number or APC_Factor FWD PWR kW DAC_APC_REF APC_Factor 2kW 660 3 03 Once the APC_Factor is known the controller uses this number to calculate the DAC_APC_REF necessary to obtain the MAX HIGH MAX LOW and UPS power levels in the Diagnostics Display 4 7 2 3 1Operating APC versus Calibrated APC There are actually 2 APC_Factors due to the fact that the directional coupler outputs are not flat acros...

Page 108: ...o find the DAC_APC_REF that would represent each of the power levels and sets that number as the power level limit This maximum DAC_APC_REF setting is called DAC_MAX and is calculated for each mode from the formulas below For HIGH ON mode 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...

Page 109: ...ry calibrated by reversing the reflected coupler it now measures forward power and adjusting for a reflected sample voltage of 2 1V at 60W as measured at TP18 on the Life Support Board This sample voltage is low pass filtered on the Master Controller and then A D converted in the micro for metering This A D value shows up as A D_RFL_PWR HOME MORE CONFIGURATION C B which at 2 1V should be very clos...

Page 110: ... 44W Therefore the VSWR_FB_LVL DAC is set to 602 and its dc output voltage will be about 1 8V This voltage is sent to U7 12 as one input to the open loop gain differential amplifer U7 13 is the calibrated voltage from the reflected coupler from Life Support Board As long as there is little or no reflected power the voltage at U7 13 will be zero and the U7 14 output will be at the positive rail Thi...

Page 111: ...e transmitter will again mute for 3 or 6 seconds start the 10 second timer again and slowly ramp the power up again Strike 3 A third fault detected within this 10 seconds will cause the transmitter to be muted until the operator gives the transmitter an ON command High or Low locally or by remote If the cause of the fault is still present the transmitter will simply repeat the 3 strikes and mute a...

Page 112: ... PAs which are controlled by the other PA Controller Board in case of a failure only available in the Z2R 4 7 4 1 PA Turn On Turn Off The PA Controller s primary responsibility is to turn the PAs on and off The PAs are turned on and off by varying the bias voltage on the gates of the MOSFETs on the PAs If the gate voltage is 0 6V the PA is turned on full If the gate voltage is 18V then the PA is t...

Page 113: ...ndicates an imbalance in the phase or amplitude of a PA output NOTE The temperature of the different PA ISO resistors A1 A8 can vary quite a bit but are considered okay if they are under Ambient 75 C AZ which also shows up in this screen is the temperature indication for the 2 5kW 2 way combiner isolation load resistor A rise in this temperature would indicate an imbalance between the outputs of t...

Page 114: ... called PS_DISABLE and comes in on J3 13 The signal originates on the Master Controller but passes through a logic gate on the Life Support Board before reaching the PS Controller PS_DISABLE is an active high signal which means that if the signal is high the power supply will be shut off the secondaries will be deactivated by shutting of the SCRs but primary voltage could still be present If it is...

Page 115: ...tes the PA Power Supply Discharge circuit which allows a quick and safe discharge of the PA supply 4 7 5 3 Power Supply Standby Mode Under certain circumstances such as RF Mute the power supplies will be placed in standby mode via the signal PS_STANDBY This signal comes from the Master and PA Controllers PS_STANDBY shuts off all the DRIVER signals which deactivates all of the SCR taps on the power...

Page 116: ...imer The watchdog timer U4 is basically looking for two things First it must receive a pulse from the micro controller every 1 0mSec If it does not it will activate the RESET line at TP4 and the supply will be shut off It is also monitoring the 20Vdc supply If the voltage falls below the minimum limit of 12V it will activate the RESET line 4 7 5 7 Analog Inputs U7 acts as a linear amplifier and bu...

Page 117: ...ter Controller fail If the Master Controller board fails the Life Support Board disconnects via AND gates all signals from the Master Controller and allows the transmitter to stay on the air at 1 4 power with minimal fault protection and no visible monitoring for the operator Transmitter functions available in Life Support Mode a VSWR Protection b System Mute c Transmitter ON LOW only and OFF both...

Page 118: ...ternal Interlock signal To satisfy the External Interlock there must be a closed connection between J4 10 and J4 7 GND on the Life Support Board or between TB1 7 and TB1 6 on the Remote Control Interface terminal strip This will activate the optical isolator U24 making U27 11 and U33 1 both low U27 10 inverts the signal and makes U6 12 high allowing the high turn on signal at U6 13 to pass to inve...

Page 119: ...he trans mitter to turn on In summary the signal at U33 12 CONTACTOR_ON BAR will not allow a second turn on pulse to be deliv ered while the transmitter is still running and in Life Support Mode b The CONTACTOR_ON BAR signal at U30 12 is used to disable the power supply when the contactor is turned off The signal is high when the transmit ter is off and low when turned on The other input U30 13 co...

Page 120: ...there is a jumper from TB1 8 to TB1 10 ground b It can also be connected directly to the Life Support Board to J4 7 and J4 8 Be very careful when connecting to these terminals The pressure necessary to operate the wago connector on the rear of the board must be properly sup ported to keep from bending and possibly damaging the Life Support Board c Lastly it can be connected at J20 8 a 37 pin D con...

Page 121: ...n active high signal at U30 6 and passes through to U38 3 The signal then splits and goes to relay K1 13 as the exciter mute and to inverter U13 7 as an IPA mute a Exciter Mute K1 directs the mute signals SOFTSTART_MUTE and SYSTEM_MUTE to the on air exciter K1 is shown in the RESET or Exciter 1 on air mode The mute will pass through to either U36 8 or U36 11 depending on the position of K1 If your...

Page 122: ...troller is working MSTR_NORMAL 1 will be high This passes through inverter U13 16 and RESETs K1 This places K1 in the position shown on the schematic K1 4 will be pulled low This is sent two places a The low from K1 4 goes off the board to the IPA Backplane Board where it actuates the exciter select relay K1 to the position shown on the schematic It also goes to the Master Controller as a status s...

Page 123: ...ve 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 For more information on Power Control refer to the APC discussion earlier in this section under the Master Controller 4 7 6 1 8IPA Current and Voltage Samples IPA current is detected as the differential voltage across a current shunt resistor...

Page 124: ...the Master Controller is operational The VSWR fault comparator output at U3 2 will only be able to effect transmitter operation in Life Support Mode 4 7 6 2 Life Support Mode The following contains all pertinent circuit information for operating in the Life Support Mode This is when the Master Controller has failed and the Life Support Board has taken over control of the transmitter 4 7 6 2 1Maste...

Page 125: ...the following actions to occur a MSTR_NORMAL 1 applies a low to AND gate U6 4 fan speed select gate When in Life Support Mode the fan will be forced to high speed operation due to the possible higher than normal dissipations when running at reduced power The output of AND gate U6 6 passes through to U16 16 and on to the Low Voltage Power Supply Board and the fan select relay K3 b MSTR_NORMAL 1 app...

Page 126: ...e Support Mode Note that the HIGH ON push button on the front panel overlay has no function when in Life Support Mode f MSTR_NORMAL 1 applies a low to all four AND gates in both U12 and U14 This prevents the Master Controller from applying exciter mute exciter select or IPA select signals 4 7 6 2 1 3 MASTER_NORMAL BAR This signal goes high when the Master Controller fails It causes the following a...

Page 127: ... normally takes care of this function via the SYSTEM_MUTE line d MASTER_NORMAL BAR applies a high to the CLEAR line of U8 13 This enables U8 10 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 at least 3 seconds to allow the supplies to fully charge U8 is o...

Page 128: ... the MASTER_NORMAL line This line will be high only if the Master Controller has failed which is the case here for Life Support Mode Therefore the LS_SYST_FAULT will cause U6 3 to go high Next OR gates U33 3 and U33 6 will also go high making U16 10 output high This is connected to the RESET side of latching relay K4 When K4 resets K4 14 will go low which will send a low to the Low Voltage Power S...

Page 129: ...llers and gives the designation and connector number for each of the PAs The last 2 columns give the component designator for the Isolation Switch and Isolation Resistor for each of the PAs Ths Isolation switches and resistors are located on the Isolation boards mounted on the side of the Z Plane PA Designations on PA Controller Schematic PAC 1 PAC 2 Z2R Only PA Designations on Combiner and Divide...

Page 130: ...4 60 888 2406 002 WARNING Disconnect primary power prior to servicing Overall System Theory ...

Page 131: ... such that lethal voltages are shielded behind doors or clear lexan shields which require a tool to be opened Shut off all power before servicing the transmitter other than replacement of modules The Front and rear doors are hinged and can be opened while the transmitter is running for access to the modules The modules are HOT PLUGGABLE which means they can be accessed and removed or replaced with...

Page 132: ...PANCY Describe the nature of the malfunction Include all observable symptoms and performance characteristics CORRECTIVE ACTION Describe the repair procedure used to correct the malfunction DEFECTIVE PART S List all parts and components replaced or repaired Include the following details a COMPONENT TIME IN USE b COMPONENT PART NUMBER c COMPONENT SCHEMATIC NUMBER d COMPONENT ASSEMBLY NUMBER e COMPON...

Page 133: ...s Ambient temperature will give a quick indication of a possible problem or that cleaning is necessary To check the ambient temperature reading press METERING C D B 5 2 3 2 Cleaning the Air Filter The indication as to when to clean or replace the air filter is basically the same as mentioned in the previous paragraphs mainly with the airflow indicator but temperatures and or a visual inspection wo...

Page 134: ...MORE TEST C This will bring up the screen in Figure 5 1 Press D to run the test or C to go back to the previous menu For further details see Self Diagnostics in Section 6 in this manual Figure 5 1 System Test Menu 5 5 Isolation Board Maintenance There is only 1 Isolation Board in the Z2 transmitter The board is mounted on the side of the PA near the center of the transmitter Access to the board is...

Page 135: ...OARD TO THE Z PLANE THESE ARE EASILY BENT IF THE ASSEMBLY IS NOT PULLED STRAIGHT OUT IF BENT THEY WILL HAVE TO BE STRAIGHTENED BEFORE IT WILL BE ABLE TO BE RE INSTALLED IF BENT TOO FAR THE PINS MAY BREAK OFF WHEN STRAIGHTENED NOTE If the assembly is replaced the new one should have the ID jumpers set to the same position as the one to be replaced The programming is a simple jumper selection on the...

Page 136: ... the notch on one end of the sheet metal of the Isolation assembly which fits around the rf drive cable from the IPA Re install the 4 hex standoffs and the 2 ribbon cables making sure that the cables are connected to the same port from which they were removed Be careful not to over tighten the hex standoffs 5 6 PA Replacement Since field repair of the Power Amplifiers is not a recommended procedur...

Page 137: ...ble which attaches to it NOTE The Directional Couplers Are Held In Place On The Harmonic Filter With 2 Hose Clamps Be Sure To Place The Clamps As Far Toward The Edge Of The Coupler Body As Possible And Do Not Over tighten d A calibration of the Forward or Reflected power should be done depending on which coupler was replaced NOTE If both couplers are being replaced at the same time Reflected Power...

Page 138: ... HIGH SET screen HOME MORE CONFIGURATION B B change to the new maximum power level and press BACK to save the changes STEP 3 Press Raise to make sure the power level will not go above the new MAX HIGH setting The MAX HIGH setting in Step 2 can be adjusted slightly to get the exact desired power level The MAX LOW Power limit is set as follows STEP 1 Turn the transmitter on at LOW power and set the ...

Page 139: ... 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 5 10 Setting Life Support Power Level This procedure is to be used to set the MANUAL PWR REF pot R25 on the Life Support Board to the proper level R25 sets the power output of the transmitter if the Master Controller ever fails The proce...

Page 140: ...e 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 CONFIGURATION B A Set this screen to read the power at which you are going to calibrate 2kW or your TPO STEP 3 Press HOME MORE CONFIGURATION B B This should take you to the MAX HIGH SET screen Make a note of the setting and then change it to 2kW for this procedure ...

Page 141: ...rify STEP 8 Press HOME MORE CONFIGURATION C B This will take you to the screen shown in Figure 5 4 Using the Raise and Lower buttons set the DAC_APC_REF to 660 Figure 5 4 A D FWD PWR Screen HOME MORE CONFIGURATION C B STEP 9 Re Adjust R127 on the Life Support Board until the external meter reads 2kW or the TPO at which you are calibrating The adjustment will be sensitive so be careful not to go to...

Page 142: ...play will flash Calibration Done very quickly at the bottom of the Diagnostics Display The external meter and the FWD PWR reading on the transmitter should now agree STEP 13 Return to the 100 TPO SET screen HOME MORE CONFIGURATION B A and change the level to match your TPO Press BACK to save the changes The FWD PWR meter should read 100 or your TPO in kW depending on the setting STEP 14 Set the MA...

Page 143: ...e the settings STEP 4 Press HOME MORE CONFIGURATION C A B Set the value of REFLECT FACTOR to 0 000123 To access the edit controls for the screen press and hold the D and then press the C button See Figure 5 6 Figure 5 6 Reflected Calibration Factor Screen HOME MORE CONFIGURATION C A B STEP 5 Open the back of the transmitter and locate the Reflected power directional coupler it should be the one on...

Page 144: ...TEP 9 Set the Transmitter LCD meter the right hand display to read RFL PWR in kW If it reads VSWR press and hold the button for about 5 seconds and it will change to kW STEP 10 Press HOME MORE CONFIGURATION C D The will take you to the Reflected Power Cal screen and should look like Figure 5 8 Set this screen to 00 06kW Press and hold D and then press BACK to calibrate the reflected power meter to...

Page 145: ... all power at the wall breaker STEP 2 Remove the two screws holding the controller assembly in place and slide it out It will come almost all of the way out before catching and will then drop down in the front to about a 30 degree angle Then remove bracket across the boards STEP 3 Set all jumpers on the new Life Support Board to the same locations as the board to be replaced There are only 3 jumpe...

Page 146: ...ower when Life Support Mode is active STEP 10 Set R127 Maximum CW This sets power output at a minimum STEP 11 Set R128 Maximum CCW This reduces the sensitivity of the VSWR circuit STEP 12 Set R25 Maximum CCW WARNING TURNING R128 MAXIMUM CCW DEFEATS THE VSWR PROTECTION THE REFLECTED POWER CALIBRATION SHOULD THEREFORE BE DONE FIRST TO PREVENT DAMAGE TO THE TRANSMITTER TRANSMITTER POWER IS ONLY RAISE...

Page 147: ...Board Replacement of a PA Controller Board requires no analog adjustments Set all dip switches and jumpers to the same position as the board being replaced If the new board does not have the firmware IC s already installed then the firmware will have to be transferred from the old board Refer to Removing and Replacing Firmware ICs later in this section The following is a listing of the normal dips...

Page 148: ...nsmitter off and remove AC power from the transmitter STEP 2 Remove the defective Master Controller Board Carefully remove U39 STEP 3 Remove U39 from the new Master Controller Board and replace with the EEPROM from the defective Master STEP 4 To transfer the Firmware IC s from the old board to the new one or to simply install new firmware refer to Removing and Replacing Firmware ICs later in this ...

Page 149: ... AN ANTI STATIC WRIST STRAP WHEN HANDLING PC BOARDS OR IC S TO PREVENT DAMAGE TO THE COMPONENTS STEP 1 Shut the transmitter off and remove AC power from the transmitter STEP 2 Remove the Master Controller Board If only the EEPROM U39 is being replaced then replace U39 with the new one reinstall the Master Controller Board and skip to Step 6 If the Master Controller and or the firmware is also bein...

Page 150: ...d where necessary change the values to those listed in Table 5 1 To edit any of these screens press and hold D and then press C The edit controls should appear on the screen STEP 8 Press the HIGH ON button and then quickly press and hold the LOWER button for 10 seconds This will turn the transmitter on at zero power output STEP 9 Proceed to System Configuration and Calibration Table 5 1 EEPROM U39...

Page 151: ... 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 in the following steps NOTE For the following procedures do not press HOME or BACK unless specif ically told to do so STEP 1 ...

Page 152: ...n kW which is to be displayed as 100 TPO on the FWD PWR meter Default is 02 00KW MAX HIGH SET This screen will let you set the upper limit the transmitter will be allowed to go to in the High Mode of operation 120 TPO or 03 00KW is the MAX setting MAX LOW SET This screen will let you set the upper limit the transmitter will be allowed to go to in the Low Mode operation Default is 50 TPO or 1 00KW ...

Page 153: ...ch of the controller boards with the exception of the Life Support Board have 2 Firmware IC s which contain the software for the microcontrollers It is possible that these may need to be replaced as part of a firmware upgrade or they may need to be transferred from a defective controller board to a new one Each of these IC s has a printed label on top which gives a The part number of the software ...

Page 154: ...urers do make a special extraction tool for these type of IC s but it has been found that a sharp meter lead or ice pick actually works better for extracting them Place the sharp tool point into one of the slots at the corners of the IC pry it up just a little Then move to the opposite corner and pry it up a little Work back and forth from one corner to the other until the IC comes out If the IC i...

Page 155: ...888 2406 002 5 25 WARNING Disconnect primary power prior to servicing Maintenance and Alignment Table 5 2 Z2 Recommended Minimum Transmitter Log Readings ...

Page 156: ...5 26 888 2406 002 WARNING Disconnect primary power prior to servicing Maintenance and Alignment ...

Page 157: ...at 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 also easy to damage these boards with improper equipment and soldering techniques due to the size of the components traces and...

Page 158: ... THE NECESSARY SAFETY PRECAUTIONS AFTER USE DISPOSE OF AS CHEMICAL OR SPECIAL WASTE ACCORDING TO THE REGULATIONS APPLY ING AT THE LOCATION OF THE USER IT MUST NEVER BE THROWN OUT WITH THE GENERAL OR DOMESTIC WASTE Defective PAs should be exchanged by contacting the Harris Service Parts Department available 24 hours a day 7 days a week 6 2 1 Transmitter Power vs Module Failures The Table below list...

Page 159: ...he transmitter on the same foursome pull out B2 and swap it with any one of the PAs in the rear of the transmitter B8 for example There are still 2 failed PAs B1 and B8 but now each one is in a different foursome This will restore balance to the system and the transmitter will still be able to operate near full power output by automatically increasing the drive to the remaining PAs via the APC vol...

Page 160: ...TX_RESTART Pressing the ON LOW or HIGH button on the transmitter will issue the TX_RESTART command and attempt to return the transmitter to normal operation after any fault has occurred Note that this will not reset or erase any of the faults stored in the Fault Log in the Diagnostics Menu Take the example of a failed and switched out PA The controller writes to memory the fact that the PA has fai...

Page 161: ...in and slowly ramp the power up again Strike 3 A third fault detected within this 10 seconds will cause the transmitter to be muted until the operator gives the transmitter an ON command High or Low locally or by remote If the cause of the fault is still present the transmitter will simply repeat the 3 strikes and mute again NOTE If no faults occur during either of the 10 second time periods then ...

Page 162: ...play and ABCD to the right To avoid confusion every line from one screen to the next is labelled A B C or D where it leaves a screen to correspond with the keypress required on the actual display The function and use of the buttons is very straight forward However an explanation is given in Section III Operation for these and all other front panel transmitter controls 6 6 Fault Log The Fault Log i...

Page 163: ... Reset Note the warning asking if you really want to erase the faults in the log just in case this screen was reached by accident Pressing YES D will erase any of the faults in the Fault Log which are inactive an active fault cannot be erased Pressing NO C will simply take you back to the previous MENU without erasing the fault log Figure 6 3 Fault Reset Screen 6 6 3 Abbreviations Used In Fault Re...

Page 164: ...Display Menu including their effect on transmitter operation and a brief comment explaining the fault Table 6 1 includes faults that are associated with the Master Controller Board which includes the IPA Table 6 2 includes faults that are associated with the PA Controller Board PAs and ISO Loads Table 6 3 includes faults that are associated with the PS Controller Board and the power supply itself ...

Page 165: ... 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 results of the test will be either Aborted Failed or Passed If t...

Page 166: ...w seconds If it does not the test will be aborted and a B _ISO_LOW will be reported to the Fault Log This could indicate one of four main possibilities a The most likely problem is a defective PA RF Switch on an Isolation Board K1 K8 The PA RF switch could simply have bad or open contacts which would disconnect the resistor from the PA The PA would operate normally as long as the system is balance...

Page 167: ...dware Test The other option in Figure 6 4 is to test the hardware Pressing D should bring up the screen in Figure 6 6 This screen gives 3 more choices Figure 6 6 Hardware Test Menu a LCD LED Test This is a test of all of the LCD segments and LEDs on the front panel to make sure the overlay indicators are operational Pressing B will active the test Press B again to shut off the test b EEPROM TEST T...

Page 168: ... a problem will be evident If the front panel FOLDBACK LED is illuminated it is possible to check the SYSTEM FOLDBACK screen in the Diagnostics Display under STATUS A B This screen shows that there are 3 possible foldback conditions VSWR FOLDBACK YES or NO SYSTEM ISO TEMP YES or NO IPA FOLDBACK YES or NO These screens can be extremely helpful in determining where to start looking for the source of...

Page 169: ...reading If the thermistor circuit becomes open the detector input goes high which gives a cold temperature reading This leaves the device to which the thermistor is connected unprotected from an over temperature condition Once this fault is detected it will stay active in the log until the Fault Log is reset NOTE If one of the thermistors or connecting cables is shorted a tempera ture fault for th...

Page 170: ...CR11 will supply 5Vdc to TP19 if the actual 5V REF has failed but with the diode drop it will be less than 4 6Vdc and adjusting R28 on the Life Support Board will have no effect 6 9 5 RFL_PWR Reflected Power Fault This fault is activated when the VSWR overload trip point is exceeded This fault will only show up if there is a large and quick change in the transmitter load impedance or if the VSWR f...

Page 171: ...ck contacts are opened There must be a closed contact between the failsafe interlock contacts in order for the transmitter to operate This fault also flashes the Interlock Fault LED on the controller front panel See the Table at the end of Section II Installation for more information on Failsafe Interlock Connections 6 9 8 POWER_FAIL Fault This fault is activated as a result of an AC power failure...

Page 172: ...d power directional coupler to the Life Support Board is disconnected The fault immediately mutes the transmitter until the cable is re connected due to the effect this would have on the APC loop 6 9 12 IPA_ _MUTE Fault This fault could be for IPA_1 or IPA_2 Whenever the IPA is muted the control system checks the IPA current draw by the IPA amplifier If the current is not less than 1 amp then the ...

Page 173: ...If the amplifier is not inserted far enough into the connector these 2 pins will not make contact and the amplifier will not be activated The control system will switch to the other IPA if it is not faulted also 6 9 18 IPA_LOAD Fault To check for bad RF Cables the Master Controller checks Z Plane currents for proper IPA load balance If an imbalance is found the transmitter is muted 6 9 19 PSC _COM...

Page 174: ...ster Controller has a foldback routine it will use to protect the ISO_Bz load called ISO APC Foldback ISO APC Foldback uses 2 thresholds 115 C and 130 C If the ISO_Bz load 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 go...

Page 175: ...tput PA currents voltages and temperatures and PA_ISO load temperatures should be checked as a likely cause of this problem 6 9 24 EXC _FAULT Fault Indicates there is an exciter malfunction This is a summary fault including VSWR Overtemp etc 6 9 25 EXC _LOW Fault If forward power drops to 70 or less of normal exciter RF output an indication is given 6 9 26 EXC _AFC Fault This is the PLL Unlock fau...

Page 176: ...ntroller 1 would reveal that it is actually connected to the PA8_GATE signal on the PA Controller schematic Table 4 1 on page 4 59 in Section IV is intended to ease this confusion For instance in the process of troubleshooting a PA problem it is found that amplifier B2 has no gate control voltage Tracking this back to its source can be tricky Table 4 1 gives you the necessary information to skip s...

Page 177: ...will be switched out This optimizes the combiner for the other PAs until a TX_RESTART is initiated by pressing one of the ON buttons This will un mute the faulty PA If the current is still too high the PA will be switched back out again However it should be noted that the Z2 control system is adaptive With the failure of one PA the other 3 PAs in that foursome will have a reduced PA current foldba...

Page 178: ...perature of each PA is sensed by thermistor RT1 located on each individual amplifier board If the temperature reaches 100 C the transmitter will disconnect the problem PA via the isolation switch If one of the thermistors or its wiring is shorted the temperature indication will be 155 C or higher 6 11 7 PA _OUT PA Out Fault This is the interlock fault for each PA Two of the edge connector contacts...

Page 179: ...ansmitter off if one of the PA Isolation resistors in the combiner physically reaches 170 C no prediction This protects against a failure in the combiner system where the Isolation resistor does not get switched out of circuit The primary cause would be a failure of the Isolation Switch associated with the resistor However a shorted thermistor each PA isolation resistor has one attached to it for ...

Page 180: ...mperature of the Iso load The foldback description is in the Master Controller Faults under System ISO Foldback 6 11 13 PAC _REF 5V Reference Fault This fault means that the 5V reference voltage which comes from the Life Support Board and is common to all of the controller boards is less than 4 6V This voltage is used as the reference for all system calibration A change in this voltage would cause...

Page 181: ... The ID jumpers prevent cabling errors Cabling of these boards is critical because it determines the control distribution Since there is only one of each of these in the Z2 the ID jumpers are only important because the ID s are checked by the PA Controller software which is basically the same as the higher power configurations If the PA Controller does not see the proper ID the transmitter will be...

Page 182: ... to The only other easy troubleshooting would be to swap out the controller card if a spare is available This also requires setting the ID switches on the new PS Controller board to the same as the one being replaced and possibly moving the firmware from the old board to the new one See Replacing the PS Controller Board in Section V Maintenance and Alignments If the transmitter has the dual PS Con...

Page 183: ...arge and charge at the same time During normal operation the voltage at the soft start resistor which is also used for discharge must be very close to 0 Volts This voltage called DISCHARGE SAMPLE is monitored by comparator U1 on the PS Controller board and will trigger the fault if the voltage is not low enough The most likely cause is a failure of the discharge FETs on the Rectifier Board or an o...

Page 184: ... The controller is continuously checking the configuration meaning the number of supplies connected and their identification numbers ID as part of this process a check of the valid configurations is also carried out not allowing any power supply number above 4 or two equal ID numbers The Supply number is set by Jumpers JP1 JP2 and JP3 on the Rectifier Boards as follows 6 12 2 7 PS1_JUMP If a power...

Page 185: ...d 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 completely floating this induces a considerable amount of 50 60Hz in the voltage sample lines to the controller so as to erroneously trip this type of fault The fault is logged...

Page 186: ...s 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 component numbers...

Page 187: ...888 2406 002 6 31 WARNING Disconnect primary power prior to servicing Troubleshooting Figure 6 7 3 Phase Power Supply Component Locator Top View ...

Page 188: ...6 32 888 2406 002 WARNING Disconnect primary power prior to servicing Troubleshooting Figure 6 8 Single Phase Power Supply Rectifier Assembly Component Locator Top View ...

Page 189: ...m Low fan TO high fan OR high fan TO AC off UPS Logic LOW detected at Remote UPS input Transmitter is switched to the UPS Forward Power setting CPLR_NC Forward power Directional coupler cable is not connected Mute XMTR Restart required to restore power IPA1_MUTE IPA_AB1 current still present with Vg 15V Mute XMTR exciter and PAs IPA1_LOW IPA_AB1 power is 30 of calibrated output with Vg 0V Mute the...

Page 190: ...r faults refer to the exciter manual Exciter AFC fault and or Exciter FAULT are detected by the exciter and are recorded in the transmitter fault log No action will be taken until an exciter low power condition is detected Controller will then delay 10 seconds before switching to another exciter if it is available EXC _AFC Phase Locked Loop not locked 10 Sec to recover then switch to 2nd Exciter i...

Page 191: ...e PA module are engaged where is a number from 1 8 Mute XMTR 120ms switch out the PA and release the mute on the rest of the PAs Re inserting the PA into the connector should clear the fault and re initialize the PA and the system PA _MUTE_F LT Designated PA cannot be muted Any time PAs are muted the system checks to see if any PA is drawing current If so then the controller does not have the abil...

Page 192: ...lt Check cabling and ID jumpers Mute XMTR PAC _J12 Configuration or Cabling fault Check cabling and ID jumpers Mute XMTR PAC _J1 Configuration or Cabling fault Check cabling and ID jumpers Mute XMTR PAC _J2 Configuration or Cabling fault Check cabling and ID jumpers Mute XMTR Table 6 4 Z2 or Z2R PA Controller Related Faults ...

Page 193: ..._TAP1 Tap 1 failed One 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 automa...

Page 194: ...6 38 888 2406 002 WARNING Disconnect primary power prior to servicing Troubleshooting ...

Page 195: ...888 2406 002 7 1 WARNING Disconnect primary power prior to servicing Parts List 7 Refer to separate Acrobat PDF file for Replaceable Parts List information 7 1 Parts List Index ...

Page 196: ...7 2 888 2406 002 WARNING Disconnect primary power prior to servicing Parts List ...

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