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12/20/11

888-2595-001

5-3

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WARNING: Disconnect primary power prior to servicing.

Section 5 Maintenance and Alignments

ZX Series

WABE - Western Association of Broadcast Engineers

Hong Kong:

SBE - Society of Broadcast Engineers - Hong Kong Chapter

India:

BES - Broadcast Engineering Society

Korea:

KOBETA - Korean Broadcast Engineers & Technicians Association

Mexico:

AMITRA - Asociación Mexicana de Ingenieros y Técnicos en Radiodifusión

Phillipines:

SBETP - Society of Broadcast Engineers and Technicians of the Philippines

United States:

SBE - Society of Broadcast Engineers

Uruguay:

ANDEBU – Asociación Nacional de Broadcasters Uruguayos

5.2.2

Recommended Tools and Equipment

To maximize the effectiveness of maintenance personnel, it is important to have the
proper set of tools and test equipment for the job. Below is a list of tools and equipment
that should be available on site. Note that not all items are specifically required for the
ZX series transmitter, but may be useful in general.

Tools:

1.

Tool chest with following items

a.

Hex driver set with assorted sizes

b.

Allen key set with assorted sizes

c.

Flat and Phillips (star) screwdriver set with assorted sizes

d.

Drill and drill bit assortment

e.

Tap and die set with assorted sizes

f.

Adjustable wrench(es)

g.

Pipe cutter for rigid transmission line

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Summary of Contents for ZX10

Page 1: ...ies FM Transmitters ZX2500 ZX3750 ZX5000 ZX7 5 ZX10 TECHNICAL MANUAL 888 2595 001 ZX Series FM Transmitter Dec 20 2011 Rev J T M No 888 2595 001 Copyright Harris Corporation 2009 2010 2011 All rights reserved ...

Page 2: ...ii 888 2595 001 12 20 11 WARNING Disconnect primary power prior to servicing ...

Page 3: ...are was shipped Replaceable Parts Service Replacement parts are available from HARRIS Service Parts Department from 7 00 AM to 11 00 PM US Central Time UTC 6 seven days a week Telephone 1 217 222 8200 or email servicepartsreq harris com to contact the Service Parts Department Emergency replacement parts are available by telephone only 24 hours a day seven days a week by calling 1 217 222 8200 Unpa...

Page 4: ...iv 888 2595 001 12 20 11 WARNING Disconnect primary power prior to servicing ...

Page 5: ...e revisions C 2009 Dec 58482 Revised Title Page MRH1 TOC added Appendix A D 2010 Jan 58572 Revised Title Page MRH1 Sheets 2 15 and 2 16 E 2010 May 58978 Revised to include 7 5 and 10 kW models F 2010 Aug 59394 Revised Title Page MRH1 Sheet 4 2 G 2010 Sep 59487 Revised Title Page MRH Table 2 2 on Page 2 14 H 2011 Jan 59870 Updated Appendix A Web Remote Option J 2011 Dec 61074 Revised Titl Page MRH ...

Page 6: ...MRH 2 888 2595 001 12 20 11 WARNING Disconnect primary power prior to servicing ...

Page 7: ...ATIONS column 1 gives the reference designators for the item i e C001 R102 etc that corresponds to the number found in the schematics C001 in a bill of material is equiva lent to C1 on the schematic or 2 gives added information or further explanation i e Used for 208V operation only or Used for HT 10LS only etc NOTE Inside the individual tables some standard conventions are used A symbol in front ...

Page 8: ...viii 888 2595 001 12 20 11 WARNING Disconnect primary power prior to servicing ...

Page 9: ...12 20 11 888 2595 001 ix WARNING Disconnect primary power prior to servicing ...

Page 10: ...x 888 2595 001 12 20 11 WARNING Disconnect primary power prior to servicing ...

Page 11: ... this equipment local building codes and 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 S...

Page 12: ...xii 888 2595 001 12 20 11 WARNING Disconnect primary power prior to servicing WHILE IT IS HOT DUE TO THE POSSIBILITY OF A CASE RUPTURE AND SUBSE QUENT INJURY ...

Page 13: ...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 14: ...xiv 888 2595 001 12 20 11 WARNING Disconnect primary power prior to servicing ...

Page 15: ...1 Safety circuits 2 11 Remote Control Installation 2 12 Exciter Connections 2 17 System Bus Connections 2 20 Initial Start up Procedure 2 20 Section 3 Operation Introduction 3 1 Controls and Indicators 3 1 Front Panel 3 1 Controller board 3 3 Internal LEDs 3 6 System Metering Assembly 3 7 Basic Operational Procedures 3 8 ON OFF Procedure 3 8 Power Raise Lower Procedure 3 9 Switch Operating Mode Pr...

Page 16: ...iodic Cleaning and Inspection 5 26 Service one PA chassis while transmitter is on air ZX7 5 ZX10 5 28 Check balance by disconnecting load ZX7 5 ZX10 5 28 Special Part Replacement Notes 5 30 PA Module 992 9992 041G or otherwise 5 30 PA Amplifier Assembly PWA PA 992 9992 021G or otherwise 5 30 PS Module 736 0445 000 5 32 Transmitter Controller PCB 901 0203 541 5 33 PA Backplane PCB 901 0203 381 5 33...

Page 17: ...ain page A 5 Theory of Operation A 11 Maintenance A 12 Access Configuration Page A 12 Perform Simple Reset A 17 Perform Expert Reset A 18 Change Clock Battery A 19 Calibrate Clock Speed A 20 Use Microchip Discoverer Utility A 20 Troubleshooting A 22 USB Flash Drive A 23 ...

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

Page 19: ... kW FM transmitter NOTE This manual does not address the ZX transmitter models listed below ZX500 500W FM transmitter ZX1000 1000W FM transmitter ZX2000 2000W FM transmitter ZX3500 3500W FM transmitter These transmitters are addressed in Instruction Book 888 2594 001 This manual contains the following sections Section 1 Introduction identifies the versions of the product available and the possi bl...

Page 20: ...D or HD mode when used with FlexStar exciter Broadband design to eliminate tuning adjustments from 87 5 MHz through 108 MHz N 1 capable Frequency change can be done electronically in seconds with Micro Max or FlexStar exciter or Digit exciter with external controller Redundant hot plug RF amplifier modules allow module replacement while transmit ter is in operation Redundant hot plug power supplie...

Page 21: ...uency signals in the FM broadcast band 87 5MHz 108MHz The complete ZX transmitter consists of one or more of each of two major assemblies an FM exciter and the ZX amplifier chassis These are shown in Figure 1 1 Figure 1 1 Major subassemblies of ZX series transmitter 1 3 1 Exciter The exciter accepts an audio signal in either analog or digital format and modulates it onto an RF carrier Depending on...

Page 22: ...ely 1 4 Transmitter Nomenclature The complete ZX transmitter is named according to the particular combination of exciter and amplifier chassis being employed The number following the ZX prefix indicates the full nominal FM power level either in watts for power levels below 5000W or in kilowatts for power levels above 5000W A suffix of FM CD FLX or HD is assigned according to the exciter type For e...

Page 23: ...ting mode is made by the exciter To transmit a digital HD Radio signal an HD Radio exciter such as the FlexStar HDX exciter is required The ZX amplifier can switch on the fly between all three operating modes as commanded by the exciter through an exciter interface cable 1 6 ZX Transmitter General Construction The ZX transmitter features all solid state construction and utilizes a series of FET ba...

Page 24: ...ired power level Information on the number of PA and PS modules as a function of transmitter model for power levels of 5000W and below is given below in Table 1 1 and Figure 1 3 NOTE 1 designation indicates an IPA module a PA module installed in the IPA posi tion Table 1 1 Complement of Modules vs Transmitter Model Model PA Modules PS Modules Cooling Fans ZX5000 8 1 8 5 ZX3750 6 1 6 5 ZX2500 4 1 4...

Page 25: ...kW and above are made by combining the outputs of multiple ZX3750 or ZX5000 amplifier chassis in an integrated system The number of amplifier chassis per model is as follows ZX7 5 2 x ZX3750 ZX10 2 x ZX5000 Additional information on important transmitter parameters such as size weight and power consumption may be found in drawing 839 8464 033 Outline Drawing ZX Transmitters in the drawing package ...

Page 26: ...X Series 1 7 Simplified Block Diagrams Figures 1 4 through 1 6 provide simplified block diagrams of the amplifier models discussed in this manual Figures 1 7 and 1 8 provide a simplified block diagram of the ZX7 5 and ZX10 model transmitters Consult the exciter manual for a block diagram of the exciter ...

Page 27: ...12 20 11 888 2595 001 1 9 WARNING Disconnect primary power prior to servicing Section 1 Introduction ZX Series Figure 1 4 ZX2500 amplifier simplified block diagram ...

Page 28: ...1 10 888 2595 001 12 20 11 WARNING Disconnect primary power prior to servicing Section 1 Introduction ZX Series Figure 1 5 ZX3750 amplifier simplified block diagram ...

Page 29: ...12 20 11 888 2595 001 1 11 WARNING Disconnect primary power prior to servicing Section 1 Introduction ZX Series Figure 1 6 ZX5000 amplifier simplified block diagram ...

Page 30: ...1 12 888 2595 001 12 20 11 WARNING Disconnect primary power prior to servicing Section 1 Introduction ZX Series Figure 1 7 ZX7 5 similified block diagram Figure 1 8 ZX10 simplified block diagram ...

Page 31: ...h 1 14 indentify the major subassemblies found in full cabinet transmitters with output powers of 7 5kW and above The role of these subassemblies is discussed in detail in Section 4 Theory of Operation Figure 1 9 ZX5000 amplifier front view with front face removed 002 003 004 005 006 001 001 PS module 002 Controller board 003 Filter door and air filter 004 Hex key to open rear door 005 Air intake ...

Page 32: ... forward monitor port SMA M RF reverse monitor port SMA M RF input port BNC F 202 User interface subpanel Ethernet port RJ 45 Exciter interface port D sub 15 System interface port D sub 15HD Remote control port D sub 25 203 AC mains inputs PowerCon NAC3MPA ZX5000 IEC C20 ZX2500 ZX3750 204 Individual fan alarm LEDs 205 Chassis cooling fan 206 Hex key latch to open rear door 207 EIA 1 5 8 flangeless...

Page 33: ... ZX Series Figure 1 11 ZX5000 exploded interior view 301 302 303 304 305 306 307 301 AC mains filters ZX5000 302 8X PS interface board 303 2X IPA splitter board 304 3dB attenuator assembly 305 8X splitter board 306 PA backplane board 307 Output assembly combiner harmonic filter and directional couplers ...

Page 34: ...exhaust ports 102 RF output flange 103 ZX5000 amplifier chassis 104 ZX5000 amplifier chassis 105 AC distribution chassis 106 System metering assembly 107 Exciter Exciter switcher 1RU drawer between upper and lower exciter 108 Exciter 201 RF output flange 202 Exciters 203 ZX5000 amplifier chassis 204 ZX5000 amplifier chassis 205 2X hybrid combiner 206 RF directional couplers 207 Access door exciter...

Page 35: ...cabinet Certain components shown in Figure 1 15 above will not be present in certain transmitter models 301 2 5kW RF load 302 Component panel side wall 303 Cabinet rear door 401 Coaxial transfer relay 402 Reserve exciter RF test load 403 2X splitter RF load 404 2X splitter 700W hybrid 405 Remote terminal board 406 5X HD15 divider board system interface bus 407 5X DB15 divider board exciter interfa...

Page 36: ...sed as stand alone units and mounted in an equipment rack provided by the customer Alternatively Harris sometimes provides a complete rack integration package especially for customers requiring ducted output and or input air Transmitters at the 7 5kW level and above are furnished with racks as part of an integrated system 1 9 2 AC Distribution Signal Monitor Chassis A customized AC distribution ch...

Page 37: ...y power prior to servicing Section 1 Introduction ZX Series 1 9 4 Dual Drive Main alternate Switcher A second exciter and exciter switchover controller are sometimes provided The operation of the main alternate switcher is addressed in a separate manual ...

Page 38: ...stability 3 ppm 0o C to 50o C 4 minute stabilization period Power stability 0 25 dB Reverse power Protected against open or short circuit all phase angles Capable of operation into infinite VSWR with user adjustable foldback threshold Threshold set to 2 5 of FM nameplate power level at factory Harmonic spurious output Meets or exceeds FCC Canadian CE and Chinese requirements Modulation type Direct...

Page 39: ...level 3 5 V p p 1 24 V rms nominal for 75 kHz deviation FM signal to noise ratio 80 dB below 75 kHz deviation at 400 Hz with 75 µs de emphasis 22 Hz to 500 kHz bandwidth Amplitude response 0 1 dB 30 Hz to 53 kHz Total harmonic distortion THD N 0 02 30 Hz to 100 kHz with 75 µs de emphasis Intermodulation distortion SMPTE 0 03 60 7000 Hz 1 1 CCIF All distortion products down 74 dB reference 14 kHz 1...

Page 40: ...litude modulation with 75 ȝs de emphasis and 400 Hz highpass filter FM deviation 75 kHz by a 1 kHz sine wave 1 VSWR 1 2 1 or less De rate to nameplate rating for VSWR up to 1 5 1 2 EIA 3 1 8 flanged available as option ZX7 5 and ZX10 AC mains requirement 90 264 V3 47 63 Hz IEC C14 inlet for exciter and following connections to power amplifier ZX2500 3750 190 264 V4 47 63 Hz triple IEC C20 inlets C...

Page 41: ...z square wave 14 kHz sine wave modulation Linear crosstalk L R to L R and L R to L R due to amplitude and phase matching of L R channels DC 15 kHz 85 dB below 100 modulation reference Non linear crosstalk L R to L R and L R to L R due to distortion products 75 dB below 100 modulation reference DC 15 kHz RBDS RDS synchronizing signal 19 kHz quasi sine wave nominal 5 6 V p p AC coupled 100 ohm outpu...

Page 42: ...ed direct to channel HD digital direct to channel FM HD digital direct to channel Operating modes On the Fly switching between FM only HD only FM HD modes FM modulation capability Greater than 300 kHz Asynchronous AM S N ratio 50 dB minimum below equivalent 100 amplitude modulation by 400 Hz using 75 ȝs de emphasis no FM modulation present Synchronous AM S N ratio 50 dB minimum below equivalent 10...

Page 43: ...data input D sub 9 pin female RS 232 External 10MHz clock input BNC female unbalanced 50 ohm 10 dBm to 10 dBm External 1 PPS clock input BNC female unbalanced 50 ohm TTL level User remote interface D sub 25 pin female N 1 interface D sub 25 pin female RF sample out BNC jack 66 dBc post harmonic filter 19 kHz pilot sync output BNC female unbalanced 50 ohms resistive sine wave AC coupled 4 5 V p p n...

Page 44: ... 7000 Hz 1 1 0 2 or less no pre de emphasis SCA generator low pass filter bypassed Crosstalk SCA to stereo 80 dB below 100 modulation L or R channel with 75 ȝs de emphasis Crosstalk stereo to SCA 80 dB below 100 modulation referenced to 6 kHz deviation and 150 ȝs de emphasis Crosstalk SCA to SCA 80 dB below 100 modulation referenced to 6 kHz deviation and 150 ȝs de emphasis per channel DUAL INTERN...

Page 45: ...representative for more information on obtaining Harris field service assistance Harris offers the following field service options 2 1 1 Installation Service engineers perform complete on site installation of your transmitter When ordering installation you will need to provide Harris with detailed information about your facility such as Information about any remote control system to be installed I...

Page 46: ...ng package and factory test data The factory test data contains information that is vital to installation and opera tion of the transmitter 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 Division Special shipping instructions and coding will be provided to assure proper...

Page 47: ...anying this manual Depending on the particularities of the transmitter installation these drawings may be generic addressing one or more standard transmitter models or site specific for a customized transmitter configuration In the case that both generic and custom drawings are provided the generic drawings are superseded by site model specific drawings and should be discarded to prevent future co...

Page 48: ...r cabinet one for the upper amplifier exciter one for the lower amplifier exciter when pres ent This arrangement was chosen in the interest of providing AC mains redun dancy Three phase models have a single connection point but have AC mains redundancy by virture of their three independent phases Connection to the AC distribution chassis is made at an insulated terminal block which may be accessed...

Page 49: ...mitters without AC Distribution Chassis In the case of lower power transmitters furnished without an AC distribution chassis the customer is responsible for connecting directly to the various transmitter sub assemblies i e exciter and amp The necessary AC mains distribution may be performed in the customer mains panelboard or possibly an in rack outlet strip The various sub assemblies in the ZX se...

Page 50: ...inue to operate provided that the incoming mains power at that input falls within the 190V 264V range indicated above NOTE The transmitter and internal power supply modules have been certified by an accredited testing laboratory for a nominal mains voltage range of 208V 240V This certification requires testing to an over and undervoltage allowance of 10 Accordingly there may discrepancies in certa...

Page 51: ...n made sources e g lightning and inductive load switching Clear preference is to be given to series type surge protection devices featuring protection by both a series inductance choke and a shunt threshold clamping device over simple shunt only devices The surge protector must be connected to the building ground system by short direct connections In the case where the shunt protection elements ar...

Page 52: ...nsafe voltages e g doors on hinges will connect to the PE terminal via a wire jumper connection to the buss bar The RF earth ground prevents damage to the equipment during lightning induced transients and reduces RF interference to low level circuits in general An RF ground strap wire attachment point is located at the rear of the ZX amplifier and exciter chassis This connection is suitable for us...

Page 53: ...y a common grounding plate bulkhead panel with a low impedance connection to building earth ground should be the entry point to the transmitter building for all signal lines including AC mains It should serve as a single point ground for all coaxial and mains surge protection devices Wide copper straps should be used for making the connection from the common grounding plate to earth ground A good ...

Page 54: ...r from the transmitter hall with the transmitter hall being supplied make up air from outside via a filtered inlet vent With an open system it is imperative to correctly balance the input and output air flow volumes paying particular attention to the pressure drops in external ducts and providing external blowers to overcome these losses and ensure correct air flow The ZX transmitter internal air ...

Page 55: ...uipment racks to prevent tip over hazards especially at sites prone to seismic activity When mounting ZX transmitting equipment in a pre existing rack be sure to mount equipment low enough in relation to rack center of gravity to prevent a tip over haz ard Install mains safety disconnects pull box or emergency off button in sight of trans mitter so as to permit visual verification of mains status ...

Page 56: ...nsmitter system may be equipped with an optional emergency shut off button This button is typically a large red plunger pushbutton surrounded by a contrasting yellow border The switch terminal connections of this button may be connected to the external interlock connection described above or brought outside the transmitter cabinet to an AC shutdown mechanism e g contactor or shunt trip circuit bre...

Page 57: ...1 C2 RD Receive Data negative 2 B3 TD Transmit Data positive 3 B2 TD Transmit Data negative 6 NU Ground 4 5 7 8 Table 2 2 REMOTE CONTROL D sub 25 amplifier rear Designation Remarks Pin GND Signal ground 1 INTERLOCK A Connect to pin 3 to allow transmitter to turn on 2 Input INTERLOCK B Connect to pin 2 to allow transmitter to turn on 3 Input TX ON COMMAND Ground pin to turn transmitter on momentary...

Page 58: ...put PA VOLTS METER 2V 50V linear scale 1k source impedance 11 Output PA AMPS METER 2V 200A linear scale 1k source impedance 12 Output FM ON STATUS Open collector 24V 100mA max Ground FM carriers on 13 Output HD ON STATUS Open collector 24V 100mA max Ground HD carriers on 14 Output Mode Summary FM mode pin 13 ground pin 14 open HD mode pin 13 open pin 14 ground FM HD mode pins 13 14 ground SL mode ...

Page 59: ...ERSE FOLDBACK FAULT Open collector 24V 100mA max Ground reverse power too high power being reduced 18 Output RESTARTS EXCEEDED FAULT Open collector 24V 100mA max Ground tx locked out because it tried to restart too many times 19 Output FAN FAULT Open collector 24V 100mA max Ground a fan has low rpms 20 Output LOAD TEMP FAULT LOAD OVERHEATED Open collector 24V 100mA max Ground a combiner load has e...

Page 60: ...is open 25 Output Table 2 3 Remote Terminal Board D sub 9 and screw terminals cabinet rear area component panel ZX7 5 ZX10 only Designation Remarks Pin GND COMMON Signal ground 1 TX ON RESET CMD Ground pin to turn transmitter on 2 Input TX OFF CMD Ground pin to turn transmitter off 3 Input POWER RAISE CMD Ground pin to raise transmitter output power 4 Input POWER LOWER CMD Ground pin to lower tran...

Page 61: ...nout is used to ensure the FM mode is selected at all times CAUTION THE D SUB 15 CABLE USED FOR THE MICROMAX AND DIGIT EXCITERS HAS A DEFINITE AMPLIFIER END VS EXCITER END THAT IS IT CANNOT BE REVERSED END TO END PAY CAREFUL ATTENTION TO THE CABLE LABELING WHEN INSTALLING THIS CABLE When a main alt exciter switcher is present a special interface breakout cable is supplied to allow the optional web...

Page 62: ...ansmitter end to signal a permanent FM mode and that pins 1 and 9 send the Mute command to the exciter The exciter must also be internally configured to mute its RF output when a ground potential is NOT present at pin 9 relative to ground pin 1 Consult the exciter manual for more information Table 2 4 EXCITER INTERFACE D sub 15 amplfier rear Designation Remarks Pin GND Signal ground 1 EXCITER FORW...

Page 63: ...og voltage from transmitter to control exciter output power FlexStar HDx exciter Typically not used for FM only service which utilizes internal AGC bias voltage power control 8 Output MUTE Transmitter grounds pin to mute exciter output 9 Output EXC_B_ON_AIR Used by main alt exciter switcher to inform web remote that reserve exciter is selected logic high exciter B selected logic low exciter A sele...

Page 64: ...nstallation personnel read the general description in Section 1 the controls and operation material in Section 3 and this procedure before starting STEP 1 Carefully inspect transmitter for loose hardware unconnected wires missing parts debris or other signs of damage from shipment STEP 2 If transmitter was supplied with optional rack integration install rack in a suitable location Temporarily remo...

Page 65: ... number tag should be on the left hand side of the module when inserted into the transmitter STEP 6 Ensure these basic requirements have been met before proceeding a Transmitting antenna or terminal resistance dummy load of 50 ohms is connected to system RF output b All rack mounted units have continual AC mains safety ground con nection via green yellow conductor third prong back to main safety g...

Page 66: ...ier chassis Verify following actions take place a Amplifier starts as evidenced by sound of rushing air from main DC fans at PA chassis rear b Amplifier front panel STATUS LED changes from red to yellow and ultimately to green after several seconds c Exciter output un mutes and supplies amplifier with drive power d Amplifier ramps up from zero to full power as indicted by front panel power meter S...

Page 67: ...ands per recommended spectrum mask b Activate RTAC correction system via exciter screen as per instruc tions in exciter manual c Verify RTAC correction system has properly suppressed out of band IMD emissions with spectrum analyzer or other monitoring device STEP 19 Place transmitter in remote mode via REMOTE ENABLED switch on controller board reverse side of front door STEP 20 Verify correct func...

Page 68: ...2 24 888 2595 001 12 20 11 WARNING Disconnect primary power prior to servicing Section 2 Installation ZX Series ...

Page 69: ...ins information concerning operation of the transmitter and its controls indicators and adjustments Basic procedures for the transmitter operator are included in the second half of this section 3 2 Controls and Indicators 3 2 1 Front Panel The front panel of the amplifier chassis contains the basic controls for daily operation of the transmitter ...

Page 70: ...D transmitter is switched off YELLOW transmitter is switched on but alarms exist GREEN transmitter is switched on and no alarms exist FM traditional FM carrier being transmitted FM HD hybrid signal with FM HD radio simulcast being transmitted HD radio carrier only being transmitted SL split level combining FM HD signal with non traditional injection ratio being transmitted 003 Meter position LEDs ...

Page 71: ...oor contains additional controls to be used by maintenance personnel Figure 3 2 Controller board inside amplifier chassis 004 Meter select button Changes the parameter currently being displayed by the meter 005 OFF button Switches the transmitter off 006 ON button Switches the transmitter on Table 3 1 Front panel of ZX amplfier chassis Item Description 113 112 102 103 104 105 106 107 108 109 110 1...

Page 72: ...2V natural log scale to indicate 0 125C maximum load temperature Consult the Advanced Functional Check procedure in Section 5 Maintenance for a scale conversion table PA TEMP 0 2V natural log scale to indicate 0 99C maximum PA module temperature Consult the Advanced Functional Check procedure in Section 5 Maintenance for a scale conversion table PA BIAS Direct sample of the bias voltage being sent...

Page 73: ...peration for more information on these settings 111 METER CAL potentiometers A series of potentiometers to calibrate the forward power readings for FM FM HD and HD modes and the reverse power reading for all modes Consult Section 5 Maintenance for a procedure to adjust these settings 112 POWER LIMIT potentiometers A series of potentiometers to set the maximum power level for FM FM HD and HD modes ...

Page 74: ... 90V PS module AC OK LED Indicates that the PS module is receiving AC mains power with a voltage above 90V This is enough to power the internal 5V transmitter logic but may not be enough to power the RF amplifier portion 190V PS PA ON PS module DC OK LED Indicates that the particular PS module is switched on and supplying 50V to the corresponding PA module Consult the numbering of the PA and PS mo...

Page 75: ...alves of the IPA module are switched on Both LEDs are behind the IPA module heatsink and may be seen through the heatsink fins Because the IPA module accepts the shared voltage of all the PS modules it is not possible to determine its on off status via the PS module DC OK LEDs PA CURRENT PA module current overload LED Indicates that the PA module has shut down due to a current draw of more than 22...

Page 76: ...R LOWER pushbuttons 3 4 1 ON OFF Procedure STEP 1 Power supply internal fans operate whenever AC is applied STEP 2 Press front panel ON button STEP 3 PA power supplies output 50V DC and fans at rear of chassis start STEP 4 Status LED on front panel changes from red to yellow to green STEP 5 RF power is ramped up from zero to full power STEP 6 Consult front panel meter to verify correct power outpu...

Page 77: ...cate POWER RAISE and LOWER pushbuttons on controller board reverse side of front door STEP 3 Adjust output power using POWER RAISE or LOWER pushbuttons With transmitter gain control circuits properly adjusted it should be possible to vary power from 10 to 100 Front panel status LED should remain green at all times STEP 4 Procedure complete NOTE Consult Section 5 Maintenance for procedures for perm...

Page 78: ...mitter is currently switched on STEP 1 Check front panel STATUS LED to verify that correct mode is selected FM FM HD or HD and light is green GREEN Amplifier on and no alarms registered YELLOW Amplifier on but alarms reported RED Amplifier is off STEP 2 Check forward power reading on front panel multimeter s and verify transmitter is currently at desired power level STEP 3 Actuate front panel mete...

Page 79: ... heatsink d Check status of red LEDs behind each PA module NOTE Consult Section 3 2 Controls and Indicators for the location of these indicators STEP 6 If alarms are being reported inside transmitter STEP 5 notify station engineering staff and or proceed to perform Advanced Functional Check Procedure is Section 5 Maintenance STEP 7 Procedure complete ...

Page 80: ...3 12 888 2595 001 12 20 11 WARNING Disconnect primary power prior to servicing Section 3 Operation ZX Series ...

Page 81: ...ype of amplifier used in your transmitter model ZX10 ZX5000 amplifier 839 8464 082 ZX7 5 ZX3750 amplfier 839 8464 084 ZX5000 839 8464 082 ZX3750 839 8464 084 ZX2500 839 8464 086 RF power from the exciter passes through a 3dB attenuator and a two way Wilkinson splitter The resulting two outputs drive the inputs of a PA module serving as an intermediate power amplifier IPA The IPA backplane has the ...

Page 82: ...bly schematic based on amplifier chassis type ZX5000 839 8464 080 ZX3750 839 8464 087 ZX2500 839 8464 088 The output from the PA modules is passed through RG 142 BNC cables from the PA backplanes to the output assembly The output assembly is a combination Wilkinson power combiner and harmonic filter The harmonic filter provides greater than 50 dB attenuation at the second harmonic and greater than...

Page 83: ...e IPA is operated at reduced power and is not exposed to the vagaries of the output transmission line and antenna Therefore it can be expected to have a very low risk of failure The loss of a single IPA results in the following power outputs for the various transmitter models ZX2500 ZX3750 ZX5000 6dB 25 ZX7 5 ZX10 2 5 dB 56 3 The loss figures given here should be considered a worst case scenario T...

Page 84: ...e passed to rms detectors on the I O filter board to drive the internal forward and reverse power meter An additional RF sample is passed to the user interface subpanel at the transmitter rear for customer use This monitor sample may be used to drive monitoring equipment and or the Harris RTAC adaptive correction system for HD Radio The coupling value of the monitor port is listed on the transmitt...

Page 85: ...ntroller communicates to the outside world via the I O filter PCB The I O filter PCB contains RF filtering devices to prevent externally generated interference and voltage spikes from damaging the transmitter 4 5 PA Backplane Consult drawing 801 0203 381 The PA backplane provides all of the necessary support functions to properly operate the RF amplifiers contained on the PA module These functions...

Page 86: ...the PA temperature alarm is similar to the PA reverse power circuit described in the previous paragraph except that the sensor signal comes from a thermistor on the PA module rather than a directional coupler and RF detector A 50k thermistor on board the PA module controls the gain of amplifier U1C U1D via pin J5 N J6 N The temperature variable gain is applied to a 0 1V reference developed by volt...

Page 87: ...dependently for greater redundancy Accordingly there is an independent set of three fault comparators for each half of the IPA module U2 B C D and U3 B C D The IPA module does not have its own corresponding PS module but rather shares the output of all the PS modules from the other PA modules Accordingly it is not possible to shut down the PS module via a 3 5V current sample as in the case of the ...

Page 88: ... rms detectors U2 and U3 CR1 CR2 CR9 provide input voltage clamping for signal lines coming from other amp chassis on SYSTEM INTERFACE bus J9 The SYSTEM INTERFACE bus allows multiple amplifier chassis to be ganged together and all share the same on off raise lower FM mode HD mode and power control commands This allows multiple power blocks to be stacked in parallel to reach power levels beyond 5kW...

Page 89: ... incoming AC mains voltage falls below approximately 190V It is necessary to artificially restrict the AC input range of the PS modules to 190V to prevent excessive current surges during brownout conditions down to 90V the nominal low voltage cutout point of the PS modules as supplied from their manufacturer The other two AC inputs have similar circuits as driven by transformers T2 and T3 on subse...

Page 90: ... output This output is passed via RFI network R8 C8 R9 and J9 10 to the FAN_FAULT line to signal that at least one fan has insufficient speed rpms Comparator U4D generates a module fault PA module shutdown alarm on the controller board whenever it senses that the MODULE_OFF signal line at J9 9 is being held low by any of the backplane boards 4 9 5X Fan Monitor PCB Consult drawing 801 0203 441 The ...

Page 91: ...temperature reading is passed via RFI network R20 C17 R21 and J1 11 to the MAX_LOAD_TEMP line 4 11 PA IBOC PCB Consult drawing 843 5569 071 The RF signal is amplified in the PA modules with a nominal gain of 14 20 dB depending on frequency and operating mode RF drive power enters via J1 C and passes through input matching network C3 C1 T1 to FETs Q1 Q2 Q1 and Q2 operate in push pull to produce app...

Page 92: ...s the existence of fault conditions Provides a means to adjust the drain voltage Senses the ambient temp at the air inlet 4 12 1 On Off Control The transmitter on off state is held in memory by non volatile flip flop U13 page 4 U13 is a type D flip flop It will change state whenever its clock pin pin 5 experiences a low to high transition The new output state at pin 3 depends on the state of input...

Page 93: ...This forces an emergency transmitter shut down if the external interlock is not satisfied A similar shutdown will occur via transistor Q8 if the load temperature sensor circuit detects a combiner load temperature in excess of 125 degrees centigrade Comparator U26D samples the logic output of U13 and provides a logic high output to signal when the transmitter state is off This status is available v...

Page 94: ...sed to electronically controlled variable gain amplifier U27C The gain of U27C is varied by the amount of resistance provided by variable attenuation U11 in the feedback network R8 U11 R34 The resistance setting of U11 is incremented decremented according to the grounding of pin 2 UC up command and pin 7 DC down command which is in turn command by the local RAISE LOWER pushbuttons or the remote co...

Page 95: ...applications In such cases the exciter power setting or IPA bias would following only the highest PWR_CTL level from the multiple chassis An APC idle circuit formed by Q15 R133 R137 Q14 and R135 clamps the power control voltage to a user adjustable maximum level whenever a PA module is shut down anywhere in the transmitter In practice the APC IDLE circuit is typically adjusted so that the average ...

Page 96: ...ating state via the FM_ON_STATUS and HD_ON_STATUS lines available at the transmitter interface connector of the Harris FlexStar HDX exciter These lines are pulled low by the exciter when the FM carrier or HD carriers are present at the exciter output These lines are passed via the I O flter board to the controller via the FM_ON_BUS and HD_ON_BUS signal lines The grounding of the FM_ON_BUS status l...

Page 97: ...se FM HD mode HD mode SL mode the output of U28D is the 0V required for class AB operation This feature can be defeated by placing switch S16 in the off position thereby causing a 0V bias while in the FM mode when using the optional ZFM style PA modules 992 9992 002 or 992 9992 902 NOTE All new ZX amplifiers are supplied with HD compatible IBOC modules unless otherwise specified at time of purchas...

Page 98: ...g multiplier U15 U15 converts the forward power sample from being proportional to voltage square root of power to being directly proportional to power level This output is available for metering via meter selector IC U7 REVERSE POWER position The reverse power sample is processed in a manner similar to the forward power sample described above except there is a single calibration potentiometer R18 ...

Page 99: ...reading in this case PA1 AMPS for the total PA_AMPS reading to be passed on to the meter via U7A Pushbuttons S2 through S8 and the remaining positions of U3 U4 provide similar functionality for PA modules 2 through 8 4 12 5 Fault and Status Signaling page 6 Front panel tri color LEDs DS1 DS2 and DS3 assume one of three states depending on the current operational status Green transmitter is on and ...

Page 100: ...enever the MAX_LOAD_TEMP sample arriving at pin 3 exceeds the 2V reference from voltage divider R98 R105 at pin 2 Positive feedback resistor R99 ensures that circuit remains latched with a 3 5V high output even after the high load temperature condition is resolved A 5V pulse from the ON OFF RESET line via CR26 causes the output to toggle back to a low non fault state A MAX_LOAD_TEMP sample of 2V c...

Page 101: ...l to power Operational amplifiers U6A and U6B provide buffered metering samples for remote control telemetry via the J1 REMOTE connector and for the APC power control web remote circuits in the individual PA chassis via the J3 SYSTEM connector Networks R91 R90 R19 and R94 R95 scale the forward and reverse DC sample to a level appropriate for the front panel LED meters Additional connection lines f...

Page 102: ...could come from any of these sources The ON button on any chassis An ON command issued by the optional web remote card on any chassis A grounding of the TX ON CMD command on the remote terminal board The same functionality exists for the off power raise and power raise commands Figure 4 1 Simplified schematic of command sharing general case of up to four PA chassis When the optional exciter main a...

Page 103: ...ure 4 2 employs the abstraction of showing an adjustable reference voltage for the purpose of simplifying the dis cussion When multiple PA chassis are connected together via the system bus the outputs from all APC comparators are diode ORed together CR11 on page 3 of 801 0203 541 such that the power control for the transmitter either the internal IPA bias voltage or the exciter APC voltage will re...

Page 104: ...eneral case of up to four PA chassis As mentioned previously the POWER RAISE and POWER LOWER pushbuttons are ganged together when all PA chassis are in remote enabled mode This allows all APC circuits to rise and fall together when the power level is temporarily adjusted via these buttons thereby preserving at all times the dominant vs reserve relationship described previously ...

Page 105: ...his section provides basic maintenance procedures for the operator or first level technician Basic Procedures Power amplifier module swap Power supply module swap Air filter replacement PA module heatsink cleaning The third part of this section provides advanced maintenance procedures for the chief engineer lead technician Advanced Procedures Advanced functional check APC power level set Forward p...

Page 106: ...RF technology Contact your Harris representative or visit the Harris Broadcast website at www broadcast harris com for more information on training offerings In addition the reading materials listed below are valuable sources of information on the fundamental operating principles at work in the ZX series transmitter Recommended Reading 1 This manual in its entirety 2 NAB Engineering Handbook Graha...

Page 107: ...ast Engineers Uruguay ANDEBU Asociación Nacional de Broadcasters Uruguayos 5 2 2 Recommended Tools and Equipment To maximize the effectiveness of maintenance personnel it is important to have the proper set of tools and test equipment for the job Below is a list of tools and equipment that should be available on site Note that not all items are specifically required for the ZX series transmitter b...

Page 108: ... on SMT components anticipated otherwise omit 8 Clean shop towels and general cleaning products 9 Thermal compound Wakefield 120 8 10 Razor blade rubber roller or straight edge to spread thermal compound 11 Workshop light with clamp hook 12 Vacuum cleaner with assorted attachments 13 Air compressor 14 Safety goggles Test Equipment 1 Stereo modulation monitor HD Radio monitor where applicable 2 Rad...

Page 109: ...or a complete description of the contents of these kits In addition to these kits complete output assemblies and populated fan doors may be purchased a la carte These minimize downtime during servicing by allowing an entire subsystem to be substituted in just minutes Contact Harris for further details 5 2 4 Safety Precautions The amplifier chassis is composed of two general zones the front half as...

Page 110: ...test data report should be kept available to provide additional information for comparison purposes 5 2 6 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 failure reporting system is as follows DISCREPA...

Page 111: ...an Time Before Failure MTBF estimates for key subassemblies in the ZX series transmitter MTBF of major components PA Modules 600 000 hours approx Source calculated from installed fleet PS Modules 200 000 hours approx including PS module fans Source Lineage Power CAR1248 long form specification Chassis fans 90 000 hours approx Source EBM PAPST Table 5 1 Suggested Maintenance Routine Periodicity Tas...

Page 112: ...spected verify failure by looking for these tell tale signs a Output power has dropped significantly b Front panel STATUS LED has shifted from green to yellow c PA MODULE SHUTDOWN alarm reported on controller board reverse side of amplifier front door d PA PS ON LED of corresponding PS module extinguished while others modules are still lit NOTE The green ON status LEDs for the IPA module halves ar...

Page 113: ...STEP 7 If desired use PA MODULE CURRENTS pushbuttons on controller board and front panel meter PA AMPS position to verify new PA module has a current draw similar to all other modules STEP 8 Close amplifier front door STEP 9 Procedure complete NOTE The PA MODULE CURRENTS pushbuttons are designed to be accessible with the front door mostly closed and the front panel meter visible When accessed in t...

Page 114: ...power has dropped significantly b Front panel STATUS LED has shifted from green to yellow c AC 90V light on PS module extinguished and no corresponding AC MAINS LOW fault is being reported d PA PS ON LED on PS module extinguished and problem does not change module position when corresponding PA module is replaced swapped with another STEP 2 Open amplifier front door STEP 3 Loosen extractor handle ...

Page 115: ...PS module in place STEP 8 Close amplifier front door STEP 9 Verify that transmitter has returned to desired power level and all alarms have been resolved STEP 10 Procedure complete 5 3 3 Air Filter Replacement Procedure The front door air filter requires periodic replacement when filled with dust All ZX transmitters are supplied with a spare piece of filter media so that a new piece may be rotated...

Page 116: ...PA module heatsinks are designed for high efficiency and therefore do not have large openings for airflow As a result it is common for the modules to collect dirt over time The modules should be cleaned with compressed air on a schedule to be determined on site depending on the air system filtering humidity etc at least once a year WARNING THE PA MODULES ARE DESIGNED TO HANDLE VERY HIGH TEMPERATUR...

Page 117: ...to perform any of the procedures in this section before having thoroughly read and understood the entirety of this technical manual WARNING NEVER PERFORM THE PROCEDURES DESCRIBED IN THIS SECTION WHILE ALONE AND OR NOT FULLY ALERT SERIOUS BODILY INJURY OR DEATH COULD RESULT FROM FAILURE TO OBSERVE PROPER SAFETY PRECAUTIONS 5 4 1 Advanced Functional Check This procedure provides additional steps bey...

Page 118: ...e conversion to degrees centi grade d PA BIAS should be either 0V or near 5V depending on module type 1 IBOC modules 5V in FM mode 0V otherwise 2 FM modules 0V e IPA bias should be near 0V 1V depending on internal vs exter nal power control 1 With exciter power control 0V 2 With internal power control 0V to 15V 1V if at full power on POWER RAISE LOWER control STEP 5 If front panel STAUS LED is not...

Page 119: ...ce and Alignments ZX Series Table 5 2 PA TEMP test point scale Max PA temperature degrees C PA TEMP test point volts 0 0 14 10 0 17 20 0 20 25 0 23 30 0 26 35 0 30 40 0 35 45 0 40 50 0 47 55 0 54 60 0 63 65 0 74 70 0 86 75 1 00 80 1 16 85 1 34 90 1 55 95 1 79 100 2 06 formula T o C 35 294Ln V 75 388 ...

Page 120: ... precision measuring instrument such as a calorimetric load through line type wattmeter or precision coupler with average power meter Tools required Calorimetric load or Precision directional coupler and average power meter or Calibrated through line type wattmeter Small adjustment screwdriver Max load temperature degrees C LOAD TEMP test point volts 0 0 12 10 0 13 20 0 15 25 0 16 30 0 18 35 0 20 ...

Page 121: ...t mode via front panel trimmer potentiometer on system metering assembly face to immediate left of meters STEP 5 Procedure complete 5 4 2 1 Precision Directional Coupler The ZX series transmitter features a precision directional coupler at the output of each amplifier chassis and the final combiner output where applicable When used with a quality average power meter this coupler may be used to cal...

Page 122: ... power reading Tools required Precision directional coupler reverse port and average power meter or Calibrated through line type wattmeter reverse direction Small adjustment screwdriver STEP 1 Obtain calibrated reading of transmitter reverse power from external precision measurement source If reading is less than 1 of transmitter rated power perform these steps to generate a sufficient reading a Z...

Page 123: ... exciter control In the case of external control consult the alternate procedure immediately following this one The use of external power control is almost exclusively reserved for use with the FlexStar HDX exciter operating in HD FM HD or tri mode operation NOTE For ZX7 5 and ZX10 model transmitters please also consult section 5 4 6 for additional information on how to adjust the APC control circ...

Page 124: ...r counter clockwise to lower power to 100 of desired power level STEP 8 Verify FORWARD POWER LOW alarm LED has extinguished on controller board STEP 9 Increase exciter output power 10 beyond previous setting to ensure transmitter APC has 10 gain reserve margin Transmitter output power should not change as exciter power is increased STEP 10 Actuate controller board POWER RAISE and LOWER pushbuttons...

Page 125: ...OMES NECESSARY TO CHANGE PERMANENTLY THE TRANSMITTER OUTPUT POWER LEVEL FROM THAT ESTABLISHED AT THE TIME OF IN FACTORY TEST IF THE TRANSMITTER IS UNABLE TO REACH FULL POWER RULE OUT ALL OTHER CAUSES BEFORE PROCEEDING TO PERFORM THIS ADJUSTMENT NOTE It is typical for the gain of the PA modules to drop during the first half hour of operation This procedure should be performed after the transmitter ...

Page 126: ... UNITS AT A TIME FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN DAMAGE TO THE PA MODULE FROM A SUDDEN DRIVE SPIKE AS THE NEW LIMIT SETTING TAKES EFFECT STEP 8 Adjust POWER LIMIT potentiometer for current operating mode counter clockwise until power level drops to 100 of desired power level STEP 9 Verify FORWARD POWER LOW alarm LED has extinguished STEP 10 Increase FlexStar limit setting an add...

Page 127: ...res that the transmitter power will always follow the APC circuit at 100 and behave as if only a single APC loop were present The 90 APC circuit remains in reserve and will only become active if the first APC circuit fails or its chassis only is switched off STEP 1 Verify all PA modules are operational and transmitter has been operating at significant power for at least one half hour to reach a th...

Page 128: ...pective controllers STEP 10 Press POWER LOWER and or POWER RAISE pushbuttons on either controller to verify power is adjustable over a 10 100 range STEP 11 Repeat procedure as desired for other transmitting modes e g FM FM HD HD STEP 12 If frequent mode switching is envisioned fine tune APC LIMIT potentiometer settings for various modes in upper PA chassis only to ensure power always returns to 10...

Page 129: ...t the reverse power foldback threshold is slightly different for larger transmitter models in that a false reading of high reverse power can be generated at the system level by swapping the ports on the REVERSE METER directional coupler at the transmitter RF output This facilitates setting or checking the reverse foldback threshold without actually disconnecting the transmitter output to create hi...

Page 130: ...he section 5 4 10 for a procedure to follow to safely service one PA chassis at a time Tools required Workshop light Vacuum cleaner with hose nozzle attachments Hex key set or screwdriver set for tightening mains connections STEP 1 While transmitter is still operating at full power inspect all external transmission line sections for localized discolorations or hot spots that are warm hot to the to...

Page 131: ...y corrosion that is crusty or pasty It is normal for the coils to change color over time This does not negatively impact their performance provided it is simple oxidation and not a more aggressive corrosion due to harsh air pollution components STEP 16 Verify all push on faston connections are fully seated on PA backplanes PS interface board AC mains inputs etc STEP 17 Shine light through combiner...

Page 132: ...ssis All operations executed from the front face of the PA chassis such as PA and PS module swaps do not require any special precaution and may be performed without following this procedure first Tools required Adjustable wrench STEP 1 Remove AC mains power from PA chassis to be serviced via corresponding circuit breakers on AC distribution chassis STEP 2 Remove RF drive coax cable from RF INPUT c...

Page 133: ...sults in minimal change to the PA chassis reverse power readings WARNING DO NOT DISCONNECT THE LOAD INPUT CABLE WHILE THE TRANSMITTER IS PRODUCING RF POWER ELECTRIC SHOCK COULD RESULT This test is normally performed only in the factory but may have some troubleshooting value in the field Tools required None STEP 1 Record reverse power level on front panel meters of PA chassis to be checked for bal...

Page 134: ...or subassemblies 5 5 1 PA Module 992 9992 041G or otherwise See PA module swap procedure earlier in this section Verify that P N of new module matches old module Do not mix different P N modules within same transmitter No user adjustments Modules are hot pluggable they can be removed and replaced while transmitter is in operation Modules are symmetrical they can be inserted into transmitter with e...

Page 135: ...al presence of a burned smell Tools Required 1 star Phillips screwdriver 7 64 hex key Thermal compound Wakefield 120 8 or equivalent 404 0899 077 thermal pad Rubber roller razor blade or straight edge STEP 1 Obtain replacement power amplifier assembly Replacement PA board will include thick copper plate under PC board Do not remove PC board from copper plate STEP 2 Remove cover of damaged power am...

Page 136: ...ndling damaged PA modules please observe the following warning regarding beryllium oxide WARNING THIS PRODUCT CONTAINS BERYLLIUM OXIDE THE PRODUCT IS ENTIRELY SAFE PROVIDED THAT THE BEO DISC IS NOT DAMAGED ALL PERSONS WHO HANDLE USE OR DISPOSE OF THIS PRODUCT SHOULD BE AWARE OF ITS NATURE AND OF THE NECESSARY SAFETY PRECAUTIONS AFTER USE DIS POSE OF AS CHEMICAL OR SPECIAL WASTE ACCORDING TO THE RE...

Page 137: ...before applying power i e not one pin off Ribbon cable connectors prior to June 2010 were not keyed and easy to misalign 5 5 5 PA Backplane PCB 901 0203 381 It may be convenient to remove output assembly and or splitter covers to improve access to these cards for removal Set dipswitch address to match setting on backplane being replaced No user calibrations required Certain mounting screws have a ...

Page 138: ... a complete module at the user s discretion A procedure is provided below To facilitate assembly removal and insertion it is possible to first remove the user interface sub panel and support brace on the transmitter rear panel to increase the size of the access hole However this is not strictly required as the output assembly can still be installed without removing these items Certain aspects of t...

Page 139: ...ajor parts of the output assembly Figure 5 4 Output assembly 002 003 004 005 006 001 001 Directional couplers for forward reverse metering customer RF monitor sample 002 20 pin ribbon cable connection to 16X load board 003 Thumbscrew to secure assembly to trans mitter chassis 4 places 004 Heatsink base with ballast loads 005 Combiner with harmonic filter 006 EIA 1 5 8 flangeless RF output ...

Page 140: ... door STEP 4 Disconnect BNC coax cables from PA backplane boards to output assembly STEP 5 Loosed hose clamp at transmitter RF output and break transmission line STEP 6 Disconnect 20 pin ribbon cable to 16X load board Connector may be found on bottom deck of assembly just behind main RF output and coupler section STEP 7 Disconnect mini coax cables to forward monitor reverse monitor forward meter a...

Page 141: ...se only minimum force required to make a snug connection STEP 13 Verify new output assembly has SMA loads installed where indicated on forward and reverse meter couplers If not transfer SMA loads from original output assembly STEP 14 Introduce new output assembly into transmitter at 45 degree angle with bottom of base rotated to right STEP 15 Insert RF output connection through rear transmitter wa...

Page 142: ...ring iron and the load resistance checked with an ohmmeter The loads should read between 48 and 52 ohms Replace any load with a resistance value outside this range WARNING BEWARE OF HOT LOADS IF TRANSMITTER HAS BEEN OPERATING WITH ONE OR MORE PA MODULES REMOVED Tools required 2 star Phillips screwdriver soldering iron and solder ohmmeter thermal compound Wakefield 120 8 or equivalent razor blade o...

Page 143: ...s please observe the following warning regarding beryllium oxide WARNING THIS PRODUCT CONTAINS BERYLLIUM OXIDE THE PRODUCT IS ENTIRELY SAFE PROVIDED THAT THE BEO CHIP IS NOT DAMAGED ALL PERSONS WHO HANDLE USE OR DISPOSE OF THIS PRODUCT SHOULD BE AWARE OF ITS NATURE AND OF THE NECESSARY SAFETY PRECAUTIONS AFTER USE DISPOSE OF AS CHEMICAL OR SPECIAL WASTE ACCORDING TO THE REGULATIONS APPLYING AT THE...

Page 144: ...aders when plugging card in to I O PCB 5 5 13 Fan Monitor PCB 901 0203 441 No user adjustments Ensure jumpers in same position as previous board 5 5 14 Cooling Fans 430 0458 000 Ensure finger guard is re installed with new fan Do not attempt to separate fan from door while it is rotating If a quick swap is desired entire fan door may be lifted off its hinges removed from transmitter and replaced w...

Page 145: ...litter 901 0203 591 No user adjustments 5 5 19 Input 3dB Attenuator 971 0023 050 No user adjustment Apply thin layer of heatsink compound before mounting attenuator to chassis wall 5 5 20 System Metering Assembly Where possible record all valid power readings from old metering assembly and calibrate readings to same values upon installing new assembly Forward and reverse meter calibration generall...

Page 146: ...5 Maintenance and Alignments ZX Series 5 5 22 2 5 kW RF Load No user adjustments Visually inspect new unit for physical integrity Check input resistance with multimeter Resistance should be between 45 ohms and 55 ohms Thoroughly allow old load to cool down before attempting to replace it ...

Page 147: ...e s user friendly interface and self service menu registered users can Enter service requests and track the progress of those requests online Request a Return Merchandise Authorization RMA and view status online Access technical information from the Knowledge Base Locate technical solutions and information quickly via the Advanced Search Engine Download the latest software updates Stay current on ...

Page 148: ...92 5660 facsimile 86 0 21 5292 5955 e mail Jmei harris com To ensure you get the best assistance as quickly as possible you should have the following items on hand before contacting Harris Transmitter factory test data report Technical manual and drawing package A list of all current meter readings and alarm information 6 2 Troubleshooting Table This section provides a troubleshooting table for th...

Page 149: ...nd installed between exciter and amplifier See Section 2 Installation for more information on exciter interconnect cable Transmitter has shut down spontaneously No front panel lights whatsoever and meter appears dead Possible AC mains failure Verify AC presence by status of AC 90V light on PS modules Reset external breaker or wait for mains power to return as applicable Possible all PS modules rem...

Page 150: ...line for localized heating or other abnormalities Analyze transmission line and antenna with analyzer at earliest possible opportunity If problem occurs during winter storm conditions suspect antenna icing Problem will resolve itself as ice melts and power will automatically return to normal If transmitter is ZX7 5 or larger model and maintenance has just been performed verify that output shorting...

Page 151: ...ion proceed to replace fan alarm board It is normal for this alarm to be present when transmitter is switched off It is normal for this alarm to be reported for up to thirty seconds after transmitter start up if all fans do not start instantly AC MAINS LOW alarm One or more AC inputs has voltage below 190V threshold Inspect AC 90V lights on PS modules and or AC FAULT LEDs on wall behind PS modules...

Page 152: ...interference or other low level circuit failure Repeat test with RF muted If fault occurs proceed to remove output assembly and troubleshoot 16X load board Consult theory of operation in Section 4 Theory of Operation and apply heat to thermistors with finger tips body heat to observe change in reported temperature readings If problem only occurs with RF drive applied switch transmitter off and ins...

Page 153: ...h transmitter off open rear door and inspect red black DC cables for affected PA module It is normal for this alarm to be present when transmitter is switched off RF MUTE ACTIVE alarm Transmitter is receiving an RF mute command from either pin 8 of rear panel REMOTE CONTROL connector ground mute or from FlexStar exciter while switching modes where applicable INTERLOCK LOOP OPEN alarm Transmitter e...

Page 154: ... same alarm suspect arcing or other failure in output assembly combiner board or in output transmission line external to transmitter Reduce power to very low level via POWER LOWER pushbutton on controller board reverse side of front door switch transmitter on and slowly raise power via POWER RAISE pushbutton Observe REV PWR W reverse power reading on front panel If reading is abnormally high probl...

Page 155: ...uspect faulty PA backplane or thermistor sensor on PA module Swap affected PA module with PA module from adjacent slot If problem follows module to new slot replace PA module If problem remains in same slot replace PA backplane board PA CURRENT alarm right LED behind PA module PA module has experienced a drain current of 22A If all PA modules report this alarm simultaneously problem is most likely...

Page 156: ...er Verify exciter is still producing power level listed in factory test data report Adjust exciter power as necessary Excessive spikes in forward power level more than 10 over full power whenever PA or PS modules are inserted Possible misadjustment of exciter power level and or APC circuit Exciter should only have sufficient power to drive transmitter to 110 of desired level Section 5 Maintenance ...

Page 157: ...r vary significantly 1A If a single PA has a current level approximately as great as other PA modules suspect one half of module is either dead or receiving no drive power Swap PA module with PA module from adjacent slot If problem follows PA module to new slot replace PA module If problem remains in same slot switch off transmitter open rear door and swap SMA drive coax cable s from affected PA b...

Page 158: ... readings to track correctly In larger model transmitters forward and reverse power samples provided on remote terminal board ARE already squared proportional to power not voltage No squaring function is required Transmitter does not respond to raise lower commands locally or remote Possible transmitter has fallen out of APC control Inspect reverse side of controller board s for FORWARD POWER LOW ...

Page 159: ...ssible REMOTE DISABLED status Open amplifier front door and inspect status of REMOTE ENABLED DISABLED toggle switch on controller board reverse side of front door Switch should be in ENABLED position to enable remote control of the amplifier chassis Difficulty interfacing to remote control system Verify correct signaling levels are being presented to transmitter on REMOTE CONTROL connections at am...

Page 160: ... signal Possible input overload of spectrum analyzer Increase input attenuation to analyzer to 10dB If sideband levels drop dramatically 10dB problem is distortion being generated by analyzer overload Increase input attenuation until optimal tradeoff between sideband level and noise floor is achieved Possible failure of RTAC system Verify integrity of RF sample from transmitter output to RTAC inpu...

Page 161: ...ng PA chassis forward power levels imbalanced different than original test data Possible failure of modules internal to PA amplifier chassis Verify that all front panel status LEDs are green and no internal faults are being reported Possible failure of 3dB input attenuator inside PA chassis Attenuators have been seen to fail in way that allows signal through without full attenuation Remove SMA con...

Page 162: ...6 16 888 2595 001 12 20 11 WARNING Disconnect primary power prior to servicing Section 6 Troubleshooting ZX Series ...

Page 163: ...BOC 9929992041G A 7 6 Table 7 11 KIT MODULE SPARES ZXB 990 1202 002 A 7 6 Table 7 12 KIT BOARD SPARES ZX5000 990 1204 001 B 7 6 Table 7 13 KIT BASIC SPARE PARTS ZXB 990 1261 001 A 7 6 Replaceable Parts ZX10 List Index Table 7 14 XMTR ZX10 CONFIG 995 0035 013 A P 7 7 Table 7 15 FLEXSTAR BOOST AMP 9710027006G B 5 7 7 Table 7 16 ASSY AMPLIFIER ZX 5000 981 0090 006 J P 7 8 Table 7 17 ASSY BASIC ZX 16R...

Page 164: ... SUB 15C NO SHIELD 1 EA 408 0216 000 BACKSHELL D SUB 25C NO SHIELD 1 EA 610 1212 000 PLUG D 15C STRAIGHT SLDRCUP 1 EA 610 1346 000 PLUG D 25 PIN SOLDER CUP 1 EA Table 7 3 EXC INTERFACE CABLE KIT ZXB TO FLEXSTAR HD 952 9232 035 A Harris PN Description Qty UM Ref Des 256 0246 005 CABLE DB15M DB15M 5FT 1 EA 556 0136 000 ATTEN SMA 20DB 0 5W 50 OHM 1 EA 943 5567 239 ASSY RF SAMPLE SPLITTER 1 EA 952 923...

Page 165: ...scription Qty UM Ref Des 256 0031 000 CABLE ASSY FFC 15C 3 LG 1 EA 430 0292 000 FAN GUARD 6 14 DIA 5 EA 430 0458 000 FAN 48VDC 311CFM 6 DIA 5 EA 476 0528 000 LINE FILTER 20AMP 250VAC 1 PH 3 EA 609 0144 000 RECP AC IN 20AMP POWERCON 3 EA 620 3014 000 ADAPTER BULKHEAD SMA 2 EA 632 1201 000 PNL MTG DIGITAL VOLTMETER 1 EA 646 0665 000 LABEL INSPECTION 1 EA 646 1353 000 NAMEPLATE XMTR EQUIPMENT 1 EA 73...

Page 166: ... BASE PS FRAME 1 EA 943 5567 377 TOP PS FRAME 1 EA 943 5567 378 DIVIDER PS FRAME 7 EA 943 5567 379 LEFT SIDE PS FRAME 1 EA 943 5567 380 RIGHT SIDE PS FRAME 1 EA 943 5567 381 BASE PLATE PS FRAME 1 EA 943 5567 400 FRAME FRONT PANEL 1 EA 943 5567 401 FRONT PANEL 1 EA 943 5567 402 PANEL FRONT DOOR 1 EA 943 5567 403 SHIELD FRONT DOOR 1 EA 943 5567 404 FILTER DOOR 1 EA 943 5567 405 ANGLE DOOR MTG 2 EA 9...

Page 167: ...SE COMBINER 1 EA 943 5567 628 SPACER PLATE 1 EA 943 5567 629 CLOSEOUT PLATE 1 EA 943 5567 630 SHIELD COMBINER 1 EA 943 5567 632 COVER PLATE 1 EA 943 5567 636 HOUSING COMBINER OUTPUT 1 EA 943 5567 637 INNER CONDUCTOR 1 EA 943 5567 638 SPACER OUTPUT 1 EA 943 5567 771 COIL 1 FM 16X COMBINER 1 EA 943 5567 772 COIL 2 FM 16X COMBINER 1 EA 943 5567 773 COIL 3 FM 16X COMBINER 1 EA 943 5567 774 COIL 4 FM 1...

Page 168: ... PWA FM PA BACKPLANE B 1 EA 901 0203 441 PWA 5X FAN MONITOR 1 EA 901 0203 511 PWA FM 8XB SPLITTER 1 EA 901 0203 531 PWA FM 8X PS INTERFACE 1 EA 901 0203 541 PWA FM 8X CONTROLLER 1 EA 901 0203 551 PWA FM I O FILTER 1 EA 901 0203 581 PWA FM IPA BACKPLANE B 1 EA 901 0203 591 PWA FM 2X IPA SPLITTER 1 EA Table 7 13 KIT BASIC SPARE PARTS ZXB 990 1261 001 A Harris PN Description Qty UM Ref Des 385 0059 0...

Page 169: ...ZXB 0 EA 994 9410 005 EXCITER DIGIT CD 0 EA 995 0013 056 FLEXSTAR FM EXCITER 5 6 ROHS 0 EA HARMICROMAXANALOGMICROMAX EXCITER ANALOG AUDIO 0 EA HARMICROMAXDIGITALMICROMAX EXCITER DIGITAL AUDIO 0 EA Table 7 15 FLEXSTAR BOOST AMP 9710027006G B 5 Harris PN Description Qty UM Ref Des 250 0628 000 CABLE ASSY USB A BULKHEAD 0 5 EA J4 250 0671 000 CORD AC 3C NEMA IEC PLUG RT ANGLE 1 EA 346 0711 000 CARD G...

Page 170: ... DIAGRAM AC DC INTERCONNECT ZX5000 AMPLIFIER0 DWG 839 8464 082 WIRING DIAGRAM RF INTERCONNECT ZX5000 AMPLIFIER 0 DWG 901 0203 381 PWA FM PA BACKPLANE B 8 EA A11 A12 A13 A14 A15 A16 A17 A18 901 0203 511 PWA FM 8XB SPLITTER 2 EA A4A1 A4A2 917 2558 080 PATENT LABEL FM XMTRS 1 EA 943 5567 173 SHIELD PA INTERFACE 9 EA 943 5567 602 PLATE FILTER MTG 1 EA 943 5567 603 PLATE CONNECTOR MTG 1 EA 943 5567 642...

Page 171: ...381 BASE PLATE PS FRAME 1 EA 943 5567 400 FRAME FRONT PANEL 1 EA 943 5567 401 FRONT PANEL 1 EA 943 5567 402 PANEL FRONT DOOR 1 EA 943 5567 403 SHIELD FRONT DOOR 1 EA 943 5567 404 FILTER DOOR 1 EA 943 5567 405 ANGLE DOOR MTG 2 EA 943 5567 406 CONTROL PANEL 1 EA 943 5567 408 FILTER 2 EA 943 5567 409 STRIKE PLATE DOOR LATCH 1 EA 943 5567 421 BULKHEAD 1 EA 943 5567 422 BASE PA FRAME 1 EA 943 5567 423 ...

Page 172: ...5567 582 PLATE BACKING 1 EA 943 5567 627 BASE COMBINER 1 EA 943 5567 628 SPACER PLATE 1 EA 943 5567 629 CLOSEOUT PLATE 1 EA 943 5567 630 SHIELD COMBINER 1 EA 943 5567 632 COVER PLATE 1 EA 943 5567 636 HOUSING COMBINER OUTPUT 1 EA 943 5567 637 INNER CONDUCTOR 1 EA 943 5567 638 SPACER OUTPUT 1 EA 943 5567 771 COIL 1 FM 16X COMBINER 1 EA 943 5567 772 COIL 2 FM 16X COMBINER 1 EA 943 5567 773 COIL 3 FM...

Page 173: ...SY REAR DOOR 1 EA 943 5567 562 RAIL RACK CABINET 4 EA 943 5567 564 PLATE CLOSEOUT 1 EA 943 5567 577 ANGLE SUPPORT 4 EA 943 5567 984 PANEL COMPONENT MTG 1 EA 943 5567 985 TOP PLATE RACK CABINET 1 EA 943 5567 986 PANEL EXHAUST AIR 2 EA 943 5568 008 LABEL ZX CABINET WARNINGS 1 EA 943 5568 011 LABEL ZX10 SYSTEM LABELS KIT 1 EA 943 5607 001 BRACKET 30W LOAD 1 EA 971 0023 179 EXHAUST AIR CLOSEOUT COMPAR...

Page 174: ...7 12 888 2595 001 12 20 11 WARNING Disconnect primary power prior to servicing Section 7 Parts List ZX Series ...

Page 175: ...ontrol of the ZX series of FM transmitters via a standard web browser and Ethernet IP connection This allows the transmitter to be monitored and controlled anywhere in the world via the Internet including in a mobile environment via handheld Internet appliances and smart phones The serial IP data stream used to update the main web page may also be used by custom web pages created by the user or a ...

Page 176: ...ard and consumes approximately 150mA at 4V to 5V DC See Figure A 1 for a photo of the web remote installed on the I O board The web remote provides monitoring and control not only for the amplifier chassis but also the Harris Flexstar Main Alt Controller 981 0193 001 and ZX System Metering Panel 981 0090 070 via the normal D sub connections to these units when present Figure A 1 Physical appearanc...

Page 177: ...web remotes are to be used behind a single firewall it will be necessary to use a router with port address translation and assign each web remote its own HTTP port e g 8080 8081 8082 etc With this type of installation the router owns the external IP address and a domain name if desired The web remote port is simply appended to the router IP address with a colon e g http myharristransmitter com 808...

Page 178: ...ard STEP 3 Locate pair of 34 pin headers on reverse side of I O board STEP 4 Note position of 50C ribbon cable headers on both I O and web remote boards Both connectors should be immediately next to each other when web remote card is properly oriented i e not on opposite corners STEP 5 Carefully press web remote card onto 34 pin headers observing correct orientation as described above Be careful t...

Page 179: ...procedure in section A 5 3 STEP 13 On configuration page set IP address to final desired address Where indicated access router configuration page and set port 80 forwarding to web remote IP address Set other user parameters per information given in Table A 5 1 STEP 14 Access main page via procedure in section A 3 1 STEP 15 Verify web remote properly commands and monitors transmitter STEP 16 Change...

Page 180: ...ssword key STEP 4 Enter guest or operator password key in box at upper right Status bar should change color and readings should instantly display upon successful input of full password If guest key was used all command buttons will be blanked out If operator key was used all command buttons will be operational Figure A 3 Main page after successful entry of key ...

Page 181: ...S BAR top compartment Provides a space to enter password key right displays transmitter ID name center and changes color to provide at a glance assessment of transmitter status Green Yellow Grey White Green transmitter is switched on with no active faults Yellow transmitter is switched on but has active faults Grey transmitter is switched off White web remote is awaiting password or has lost seria...

Page 182: ...rface cable PA FWD WATTS Forward output power of amplifier chassis in watts Detector is on I O PC board PA REV WATTS Reverse output power of amplifier chassis in watts Detector is on I O PC board PA VOLTS Drain voltage of PA modules in volts as reported from PA backplane boards PA AMPS Total current of PA modules in amperes final stage no IPA as measured on controller board IPA AMPS IPA module cur...

Page 183: ...MP trap and or e mail notification from being sent if the transmitter drops below the RF ALARM THRESHOLD EXCITER FAULT Exciter is reporting an internal fault via exciter interface cable or an emergency exciter switchover has occurred COMMAND BUTTONS ON Switches transmitter on OFF Switches transmitter off RAISE Raises transmitter output power LOWER Lowers transmitter output power EXC A Commands exc...

Page 184: ...R COMMAND Transmitter lower line was actuated from any source LOG CLEARED Transmitter log was cleared via a command from CLEAR button POWER LOW AGC NOK Transmitter Automatic Gain Control AGC dropped out of a locked condition The term AGC as used here is synonymous with APC NOTE This log entry will not be recorded if due to transmitter simply switching off LOW FAN SPEED One or more cooling fans rep...

Page 185: ... mute line opened again REVERSE FOLDBACK Transmitter output power was automatically reduced due to high reverse power VSWR measured at output REVERSE FOLDBACK OK Reverse foldback condition cleared RESTARTS EXCEEDED Auto restart circuit locked out due to multiple unsuccessful restart attempts EXCITER FAULT Exciter reported an internal fault or an exciter switchover occurred because of a fault condi...

Page 186: ... of security and is designed to be used in a secure LAN setting or paired with a router to provide a firewall encryption security if use over the Internet is envisioned Because use with a router is envisioned a reset button in the amp chassis can forcibly reset the web remote to an IP address of 192 168 1 99 an address compatible with many popular routers A 5 Maintenance The FM Web Remote has no u...

Page 187: ...eries STEP 3 Configuration page with password pop up prompt should display Figure A 4 Configuration page with password prompt STEP 4 Enter expert level password key in box at center and press SUBMIT button Default expert level password is expert STEP 5 Pop up box should disappear revealing all configuration settings ...

Page 188: ...FM Web Remote Option Figure A 5 Configuration page STEP 6 Change settings as desired and press labeled button to right of modified field to submit change for permanent storage in memory NOTE The corresponding button should be pressed after each field is changed Other wise the changes will not be saved ...

Page 189: ...d connec tivity SET MINUTE HOUR DAY MONTH YEAR A means to set the current log for the on board clock used to time stamp log entries NOTE the MINUTE button will also reset the seconds to 00 when pressed SEC DAY The number of seconds added to subtracted from the clock each day A means to fine trim the clock speed See section A 5 5 for an adjustment procedure EMAIL ENABLED Activates the e mail notifi...

Page 190: ...g This distinction becomes important in larger model transmitters LOW POWER ALARM The threshold in watts for the RF ALARM THRESHOLD fault This fault con dition will cause an SNMP trap and or e mail notification to be sent when enabled NOTE This threshold is measured against the system forward power reading not the PA forward power reading This distinction becomes important in larger model transmit...

Page 191: ...pressed continually for full ten seconds STEP 3 Web remote processor resets and will resume operation within seconds of button release STEP 4 Procedure complete WRITE COMMUNITY The SNMP WRITE community for SET commands VALID SET VALUE As an added security measure the value written by the SNMP SET must match this value Otherwise no command will be issued SNMP TRAP ENABLED Enables alarm notification...

Page 192: ... Expert password expert Additionally the expert reset primes the on board EEPROM to be overwritten If DC power to the card is cycled before any values are modified on the configuration page all parameters are overwritten with their factory values To prevent this from happening access the configuration page immediately after performing an expert reset and toggle any setting on the page to force a c...

Page 193: ...ff air and all mains power removed Wait until a scheduled maintenance period to perform this pro cedure Consult Figure A 1 for a photo of battery location appearance STEP 1 Remove AC mains power to transmitter STEP 2 Remove amplifier chassis I O panel STEP 3 Locate 3V battery on web remote PC board STEP 4 Pry battery loose with small screwdriver STEP 5 Insert new battery STEP 6 Reinstall I O panel...

Page 194: ...riod e g 1 sec lost in 12 hour period 2 second adjustment required per 24 hour period STEP 7 Increment decrement SEC DAY time adjustment field on configuration page STEP 8 Recalibrate on board time to correct value as desired STEP 9 Procedure complete A 5 6 Use Microchip Discoverer Utility Purpose The USB flash drive supplied with the web remote contains a small application called Microchip Ethern...

Page 195: ...k is dis played where transmit ter name should be and all readings display 999 Incorrect execution of Javascripts on web page or Javascipts have been disabled in web browser settings Check browser settings and enable scripts NOTE if the web page is a locally stored page hard drive as described in the accompanying USB flash drive this problem can also be caused by no connectiv ity due to an incorre...

Page 196: ...Verify port 25 is not being blocked by an interven ing firewall Possible DNS spam blacklist Verify IP address of web remote is not being blocked by recipient Possible authentication required Verify SMTP server and or recipient does not require authentication username password If so install local SMTP server on LAN to serve as intermediary to pass message on to more demanding server with required c...

Page 197: ...me file provides instructions on how to get started 6 Protocol txt a text file with details on the communication protocol of the web remote for those users who wish to interface it to an external device It is anticipated that the contents of the USB flash drive will evolve over time and may include additional files not listed here The user is encouraged to fully explore the contents of the flash d...

Page 198: ...A 24 888 2595 001 12 20 11 WARNING Disconnect primary power prior to servicing ZX Series Appendix A FM Web Remote Option ...

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