Harris ZX2500 Technical Manual Download Page 164

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7-2

888-2595-001

12/20/11



WARNING: Disconnect primary power prior to servicing.

Section 7 Parts List

ZX Series

7.1

ZX5000 Replaceable Parts List

Table 7-1 XMTR, ZX5000 CONFIG - 995 0035 009 (A)

Harris PN

Description

Qty UM

Ref Des

817 2311 030

DWG, FAMILY TREE, ZX5000

0 DWG

952 9232 034

KIT, ZXB STANDALONE

0 EA

952 9232 035

EXC INTERFACE CABLE KIT, ZXB TO FLEXSTAR HD

0 EA

952 9232 036

EXC INTERFACE CABLE KIT, ZXB TO DIGIT/MICROMAX/FM ONLY0 EA

9710027006G

FLEXSTAR BOOST AMP

0 EA

981 0090 006

ASSY, AMPLIFIER, ZX 5000

1 EA

981 0090 059

ASSY, KIT, BLANK AC MAINS CONNECTORS (POWERCON 20A)1 EA

990 1202 002

KIT, MODULE SPARES, ZXB

0 EA

990 1204 001

KIT, BOARD SPARES, ZX5000

0 EA

990 1261 001

KIT, BASIC, SPARE PARTS, 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 7-2 KIT, ZXB STANDALONE - 952 9232 034 (A)

Harris PN

Description

Qty UM

Ref Des

408 0212 000

BACKSHELL, D-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 9232 033

EXC INTERFACE CABLES, ZXB TO FLEXSTAR (HD & RTAC) 1 EA

Table 7-4 EXC INTR CABLE KIT, ZXB TO DIGIT/MICROMAX/FM ONLY - 952 9232 036 (B)

Harris PN

Description

Qty UM

Ref Des

952 9232 032

EXC INTERFACE CABLES, ZXB TO DIGIT/MICROMAX/FM ONLY1 EA

Table 7-5 FLEXSTAR BOOST AMP - 9710027006G (B)

Harris PN

Description

Qty UM

Ref Des

250 0628 000

CABLE/ASSY, USB-A, BULKHEAD

0.5 EA

250 0671 000

CORD, AC, 3C, NEMA/IEC PLUG RT ANGLE

1 EA

346 0711 000

CARD GUIDE, 6LG, GROUNDED

2 EA

358 3197 000

SLIDES 10 PAIR

1 PR

396 0261 000

DISPLAY, LCD BLUE

1 EA

398 0552 000

FUSE, CART 5X20MM 10A SLOW

2 EA

FL1F1 FL1F2

424 0012 000

GROMMET 0.250 GROOVE DIA

1 EA

430 0192 000

FAN GUARD, 120MM WIRE-FORM

1 EA

430 0313 000

FAN, 12V 110CFM 119MM SQ

1 EA

430 0321 000

FILTER ASSY, AIR 120MM FAN

1 EA

544 1704 000

TERM, 50-OHM SMB 1GHZ

1 EA

Summary of Contents for ZX2500

Page 1: ...es 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 r...

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

Page 3: ...re 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...

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

Page 5: ...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 A...

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

Page 7: ...TIONS column 1 gives the reference designators for the item i e C001 R102 etc that corresponds to the number found in the schematics C001 in a bill of material is equiva lent to C1 on the schematic or...

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 Detecto...

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: ...rtation to a hospital as quickly as possible e If arms or legs are affected keep them elevated NOTE If medical help will not be available within an hour and the victim is conscious and not vomiting gi...

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

Page 15: ...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...

Page 16: ...odic 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 9...

Page 17: ...in 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 Microc...

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...

Page 20: ...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...

Page 21: ...ency 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 F...

Page 22: ...ly 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 indicate...

Page 23: ...ing 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 operatin...

Page 24: ...red 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 indi...

Page 25: ...W 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 Z...

Page 26: ...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...

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: ...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...

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 con...

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 split...

Page 34: ...xhaust 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 upp...

Page 35: ...abinet 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...

Page 36: ...ed 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...

Page 37: ...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...

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...

Page 39: ...t 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 s de emphasis 22 Hz to 500 kHz bandwidth Amplitude response 0 1 dB 30...

Page 40: ...itude modulation with 75 s 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 ava...

Page 41: ...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 crosst...

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...

Page 43: ...ata 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 s...

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 s de emphasis Crosstalk stereo to SCA 80 dB...

Page 45: ...epresentative 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 installa...

Page 46: ...g 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 shou...

Page 47: ...nying 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 tr...

Page 48: ...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 s...

Page 49: ...itters 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 transmitt...

Page 50: ...nue 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 ac...

Page 51: ...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 thre...

Page 52: ...safe 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...

Page 53: ...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 shoul...

Page 54: ...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 ai...

Page 55: ...ipment 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...

Page 56: ...smitter 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 connecti...

Page 57: ...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 groun...

Page 58: ...ut 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...

Page 59: ...RSE 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 t...

Page 60: ...s 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...

Page 61: ...out 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...

Page 62: ...nsmitter 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 NO...

Page 63: ...g 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...

Page 64: ...stallation 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 hardwa...

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 re...

Page 66: ...er 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 yello...

Page 67: ...nds 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 em...

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

Page 69: ...ns 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 Con...

Page 70: ...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 wit...

Page 71: ...or 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...

Page 72: ...V 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...

Page 73: ...eration 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 f...

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 R...

Page 75: ...lves 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...

Page 76: ...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...

Page 77: ...ate 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 a...

Page 78: ...itter 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 Amplifie...

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 S...

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

Page 81: ...pe 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 excit...

Page 82: ...ly 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 th...

Page 83: ...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 IP...

Page 84: ...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 cust...

Page 85: ...troller 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 tran...

Page 86: ...he 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...

Page 87: ...ependently 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 correspo...

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...

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 condi...

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 shut...

Page 91: ...emperature 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 g...

Page 92: ...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 vol...

Page 93: ...his 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...

Page 94: ...ed 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 resistan...

Page 95: ...pplications 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...

Page 96: ...ting 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...

Page 97: ...e 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...

Page 98: ...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 me...

Page 99: ...eading 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 modu...

Page 100: ...never 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 ou...

Page 101: ...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 individ...

Page 102: ...ould 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 T...

Page 103: ...re 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...

Page 104: ...neral 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...

Page 105: ...is 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 heats...

Page 106: ...F 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 be...

Page 107: ...st Engineers Uruguay ANDEBU Asociaci n Nacional de Broadcasters Uruguayos 5 2 2 Recommended Tools and Equipment To maximize the effectiveness of maintenance personnel it is important to have the prope...

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 compou...

Page 109: ...r 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...

Page 110: ...est 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 mainte...

Page 111: ...n 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 0...

Page 112: ...pected 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 con...

Page 113: ...TEP 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 ampl...

Page 114: ...ower 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 L...

Page 115: ...S 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 Rep...

Page 116: ...A 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 cleane...

Page 117: ...o 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...

Page 118: ...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...

Page 119: ...e 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...

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 a...

Page 121: ...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 featu...

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 c...

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 FlexSta...

Page 124: ...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 s...

Page 125: ...MES 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 B...

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 c...

Page 127: ...es 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 fi...

Page 128: ...ective 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 transmi...

Page 129: ...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 th...

Page 130: ...e 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 tight...

Page 131: ...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 corr...

Page 132: ...sis 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...

Page 133: ...ults 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 norm...

Page 134: ...r 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...

Page 135: ...l 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...

Page 136: ...dling 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 DAM...

Page 137: ...efore 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 assemb...

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 t...

Page 139: ...jor 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...

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 t...

Page 141: ...e 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...

Page 142: ...ing 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 TRANSM...

Page 143: ...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 HAN...

Page 144: ...ders 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...

Page 145: ...itter 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 Meteri...

Page 146: ...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...

Page 147: ...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 sta...

Page 148: ...2 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...

Page 149: ...d 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 met...

Page 150: ...ine 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 i...

Page 151: ...on 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 s...

Page 152: ...nterference 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 Theo...

Page 153: ...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 re...

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 control...

Page 155: ...spect 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...

Page 156: ...r 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...

Page 157: ...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...

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...

Page 159: ...sible 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 t...

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...

Page 161: ...g 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 int...

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

Page 163: ...OC 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...

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...

Page 165: ...cription 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...

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 94...

Page 167: ...E 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 I...

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 F...

Page 169: ...XB 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 Tabl...

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...

Page 171: ...81 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 5...

Page 172: ...567 582 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...

Page 173: ...Y 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...

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: ...ntrol 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 includ...

Page 176: ...rd 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 cha...

Page 177: ...eb 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...

Page 178: ...rd 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 ea...

Page 179: ...rocedure 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...

Page 180: ...sword 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...

Page 181: ...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...

Page 182: ...face 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 VO...

Page 183: ...P 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...

Page 184: ...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 ou...

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 REST...

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 env...

Page 187: ...ries 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 bu...

Page 188: ...M 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 corres...

Page 189: ...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...

Page 190: ...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 not...

Page 191: ...ressed 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...

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 paramet...

Page 193: ...f 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 tra...

Page 194: ...iod 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...

Page 195: ...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 sett...

Page 196: ...erify 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 SMT...

Page 197: ...e 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 devic...

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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Harris ZX2500, Technical Manual

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