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Nautel XR12, Installation Manual

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XR12 Installation Manual

Parts and tools

Issue 3.0  2009-07-15

Page 12-1

Section 12:  

Parts and tools

This section describes parts associated with the XR12 transmitter, and tools needed during 
installation and routine operation. Topics include:

•

Parts supplied by Nautel

•

Parts not supplied by Nautel - see page 12-2

•

Parts ordering - see page 12-2

•

Module replacement program - see page 12-2

•

Tools for installation - see page 12-3

Contacting Nautel

You can reach Nautel to order parts or for technical assistance at:

Nautel Limited

10089 Peggy’s Cove Road
Hackett’s Cove, NS Canada B3Z 3J4
Phone: +1.902.823.3900
            877 6NAUTEL
Fax: +1.902.823.3183

Email: 

[email protected]

Web: 

www.nautel.com

Parts supplied by Nautel

Ancillary parts kit

An ancillary parts kit is shipped with the XR12. This kit contains hardware needed during the 
installation process. The kit includes toroids, spare fuses, screws and other miscellaneous hardware.

Summary of Contents for XR12

Page 1: ...XR12 Transmitter Installation Manual Document XR12 INST Issue 3 0 2009 07 15 Status Preliminary...

Page 2: ......

Page 3: ...Fax 1 207 947 3693 Customer Service 24 hour support 1 877 628 8353 Canada USA only 1 902 823 5100 International Email support nautel com Web www nautel com The comparisons and other information provi...

Page 4: ......

Page 5: ...ositioning 2 1 Installing the power transformer 3 1 Connecting the station reference ground 4 1 Connecting ac power 5 1 Installing the RF connector 6 1 Adjusting the spark gap 7 1 Audio and IBOC input...

Page 6: ...air 11 6 Parts and tools 12 1 Contacting Nautel 12 1 Parts supplied by Nautel 12 1 Parts not supplied by Nautel 12 2 Parts ordering 12 2 Module replacement program 12 2 Tools for installation 12 3 Pre...

Page 7: ...l For accessories or spares see Accessories on page 10 1 of the XR12 Pre Installation Manual For standard warranty information see Pre installation assistance on page 11 1 of the XR12 Pre Installation...

Page 8: ...access the Nautel customer newsletter product manuals frequently asked questions FAQ information sheets and information about field upgrades Registration is available online and is required Documenta...

Page 9: ...system is live and serious danger is present Mount the transmitter ac power disconnect switch breaker close to the transmitter so that it can be reached quickly in an emergency Clearly label the disc...

Page 10: ...es are specifically identified with BeO in the Description column of the Troubleshooting Manual s parts list s Do not cut crush or grind devices because the resulting dust may be hazardous if inhaled...

Page 11: ...ining courses covering the basic fundamentals of RF systems and transmitters and the operation and maintenance of the transmitter For more information about available courses and schedules go to the N...

Page 12: ...oes not offer first aid training since the hazards associated with high voltage and RF energy are not specific to the transmitter However the customer should provide first aid training to all per sonn...

Page 13: ...the feedline antenna and tower At some sites these fields may cause biological effects including the heating of body tissues Intense fields can also create dangerous high voltages on ungrounded condu...

Page 14: ...e transmitter s ac power feed to prevent over voltage from entering the transmitter Lightning protection The transmitter is designed to resist lightning strike damage However intense or repeated strik...

Page 15: ...event the transmitter from shifting or rocking during an earthquake Even during minor earthquakes rocking or movement of the transmitter is likely to damage the feedline connection and could even caus...

Page 16: ...XR12 Installation Manual Page xvi Issue 3 0 2009 07 15...

Page 17: ...n the outside of the crates For each crate remove the panel labelled open this side The panel is attached using Philips head screws Remove any visible packing material including braces from the crate...

Page 18: ...see page 4 1 Installing the power transformer see page 3 1 Control and monitoring see page 9 1 Other considerations see page 10 1 Commissioning tasks see page 11 1 Perform operational tasks Commissio...

Page 19: ...3 Remove the connector under the front of each RF power module See Figure 2 1 on page 2 2 Remove both top mounting screws and the bottom mounting screw behind the connector on the front of each RF pow...

Page 20: ...XR12 Installation Manual Unpacking and positioning Page 2 2 Issue 3 0 2009 07 15 Figure 2 1 RF Power Module Top Mounting Screw Holes Rear Panel Cutout Connector Bottom Mounting Screw...

Page 21: ...et to its assigned position 4 Verify that the ac power cable conduit from the ac disconnect switch reaches the entry point in the cabinet 5 Verify that the RF feed cable reaches the RF output connecto...

Page 22: ...XR12 Installation Manual Unpacking and positioning Page 2 4 Issue 3 0 2009 07 15...

Page 23: ...he terminal board end of the transformer One label identifies the tap number and the line to line voltage Another label identifies the tap All phases must be set to the same tap see also Figure 3 1 an...

Page 24: ...ransformer closest to the cabinet slightly slide the transformer part way into the cabinet then lower it onto the transmitter s bottom plate Be sure to leave enough room to easily connect the Line Loa...

Page 25: ...cted later Figure 3 2 XR12 power transformer Installation 8 Slide the transformer into its final position in the cabinet Ensure that the anchor holes in the base of transformer line up with the anchor...

Page 26: ...XR12 Installation Manual Installing the power transformer Page 3 4 Issue 3 0 2009 07 15...

Page 27: ...low impedance conductor minimum four inch copper strap or equivalent between the station reference ground and this stud assembly as shown Firmly tighten all hardware Ensure the reference ground wire...

Page 28: ...4 2 Issue 3 0 2009 07 15 Figure 4 1 Safety Ground Stud Assembly Detail INTERIOR 1 M10 BRASS STUD 2 M10 NUT 3 M10 FLAT WASHER 4 M10 SPLIT WASHER 5 EXTERIOR REFERENCE GROUND CONDUCTOR 6 CABINET FRAME 7...

Page 29: ...a group through a ferrite toroid provided in the ancillary kit The preferred entry point is the top of the transmitter Internal conduit is provided to guide the cable to the power supply space at the...

Page 30: ...d terminal are connected to the safety ground stud assembly on the rear of the transmitter see Figure 2 2 on page 2 3 and Step 3 Step 4 page 4 1 4 Verify that the ac power conductors are connected to...

Page 31: ...swing the Exciter Panel to the left to open it and expose the inside of the filter 4 On the back wall of the filter there is an Output Strap attached to two disc shaped capacitors e g see Figure 6 2 o...

Page 32: ...09 07 15 Figure 6 1 XR12 Exciter Panel Assembly NAE90A A2 A2 Exciter Panel assembly mounting screws 14 Remote Interface PWB A2A2 RF Synthesizer PWB A A2A4 RF Synthesizer PWB B A2A3 Interphase PDM Driv...

Page 33: ...e large hole above the output strap and attach with the four supplied M5 x 16 mm long pan head screws split and flat washers 4 Insert a 7 8 EIA Bullet not supplied through the connector plate into the...

Page 34: ...e hole above the output strap and attach with the four supplied M5 x 16 mm long pan head screws split and flat washers 4 Insert a 1 5 8 EIA Bullet not supplied through the connector plate into the bra...

Page 35: ...rge hole above the output strap 3 Slide the brass stud through the hole in the output strap and re attach the M6 nut split washer and flat washer 4 Attach the stud plate on top of the transmitter with...

Page 36: ...XR12 Installation Manual Installing the RF connector Page 6 6 Issue 3 0 2009 07 15...

Page 37: ...vicinity as the RF output connector see Preparation on page 6 1 5 Locate spark gap E1 see Figure 7 1 on page 7 2 Measure the air gap between the spark gap balls using a feeler gauge 6 The air gap shou...

Page 38: ...XR12 Installation Manual Adjusting the spark gap Page 7 2 Issue 3 0 2009 07 15 Figure 7 1 RF Output Spark Gap Location Spark Gap E1...

Page 39: ...kHz Spark Gap in 0 ft Altitude 530 0 163 535 0 161 540 0 159 545 0 157 550 0 156 555 0 154 560 0 152 565 0 151 570 0 149 575 0 148 580 0 146 585 0 145 590 0 143 595 0 142 600 0 141 605 0 139 610 0 13...

Page 40: ...uency kHz Spark Gap in 0 ft Altitude 680 0 197 685 0 195 690 0 193 695 0 192 700 0 190 705 0 188 710 0 187 715 0 185 720 0 183 725 0 182 730 0 180 735 0 179 740 0 177 745 0 176 750 0 174 755 0 173 760...

Page 41: ...uency kHz Spark Gap in 0 ft Altitude 830 0 154 835 0 153 840 0 152 845 0 151 850 0 150 855 0 149 860 0 148 865 0 147 870 0 146 875 0 145 880 0 144 885 0 143 890 0 142 895 0 141 900 0 141 905 0 140 910...

Page 42: ...rk Gap in 0 ft Altitude 980 0 128 985 0 127 990 0 126 995 0 126 1000 0 125 1005 0 124 1010 0 124 1015 0 123 1020 0 122 1025 0 122 1030 0 121 1035 0 120 1040 0 120 1045 0 119 1050 0 119 1055 0 118 1060...

Page 43: ...Gap in 0 ft Altitude 1130 0 110 1135 0 109 1140 0 109 1145 0 108 1150 0 108 1155 0 107 1160 0 107 1165 0 107 1170 0 106 1175 0 106 1180 0 105 1185 0 105 1190 0 104 1195 0 104 1200 0 103 1205 0 103 12...

Page 44: ...Gap in 0 ft Altitude 1280 0 097 1285 0 097 1290 0 096 1295 0 096 1300 0 096 1305 0 095 1310 0 095 1315 0 095 1320 0 094 1325 0 094 1330 0 094 1335 0 093 1340 0 093 1345 0 093 1350 0 092 1355 0 092 13...

Page 45: ...Gap in 0 ft Altitude 1430 0 088 1435 0 088 1440 0 087 1445 0 087 1450 0 087 1455 0 086 1460 0 086 1465 0 086 1470 0 086 1475 0 085 1480 0 085 1485 0 085 1490 0 085 1495 0 084 1500 0 084 1505 0 084 15...

Page 46: ...ued Frequency kHz Spark Gap in 0 ft Altitude 1580 0 081 1585 0 080 1590 0 080 1595 0 080 1600 0 080 1605 0 080 1610 0 079 1615 0 079 1620 0 079 1625 0 079 1630 0 079 1635 0 078 1640 0 078 1645 0 078 1...

Page 47: ...p Issue 3 0 2009 07 15 Page 7 11 Table 7 2 Altitude Scale Factor Altitude ft Spark Gap in Spark Gap Scale Factor multiply gap by 0 1 00 1 000 1 05 2 000 1 10 3 000 1 16 4 000 1 23 5 000 1 30 6 000 1 3...

Page 48: ...XR12 Installation Manual Adjusting the spark gap Page 7 12 Issue 3 0 2009 07 15...

Page 49: ...igured for analog operation The transmitter does not have any audio processing capability Use an external audio processor to ensure that the audio source material is processed properly The audio proce...

Page 50: ...ure 8 1 RF Drive Panel Analog Configuration By default both exciters are configured for analog operation as follows See Figure 8 1 and Figure 8 2 a detail of the RF drive buffer PWB schematic in the X...

Page 51: ...e PWB behind the GUI panel 2 Ensure correct signal polarity for the TB2 connections in order to attain proper asymmetrical modulation TB2 1 is positive TB2 3 is negative and TB2 2 is ground IBOC Confi...

Page 52: ...ve buffer PWB set E1 to Ext by shorting pins 2 and 3 and E2 to Int by shorting pins 1 and 2 Configuring Exciter B for IBOC See Figure 8 1 on page 8 2 and Figure 8 2 on page 8 3 1 On the remote interfa...

Page 53: ...allation Cables 1 Route IBOC cables through the cable entry hole in the transmitter s top panel See Figure 8 3 on page 8 6 2 Route the cables through the ferrite toroid provided in ancillary kit Route...

Page 54: ...XR12 Installation Manual Audio and IBOC inputs Page 8 6 Issue 3 0 2009 07 15 Figure 8 3 Location of cable entry hole top view of XR12 transmitter AC IN AUDIO CABLE ENTRY Front Rear...

Page 55: ...XR12 Operating and Maintenance Manual In addition you can control the on off status the active A B exciter the preset RF power level the power level adjustment and system alarm reset remotely by mean...

Page 56: ...eshold The alarm threshold is factory calibrated to be approximately 250 V Besides being noted on the transmitter s GUI Status screen and by the alarms this alarm also causes the following a shutback...

Page 57: ...is caused by a fault in the active exciter when the exciter transfer function is enabled set to auto These faults cause exciter changeovers Mod Driver Fail A B RF Driver Fail or PDM Drive Fail This f...

Page 58: ...e conditions that they set e g opening the door to the transmitter room A triggered interlock may indicate a safety issue Ext PDM inhibit An EXTERNAL PDM INHIBIT alarm indicates that an external PDM i...

Page 59: ...er module faults PM Fault A B or C A fault is being reported by power module A B or C Other faults Low backup battery This fault indicates that the backup battery voltage has fallen below an acceptabl...

Page 60: ...normally open momentary switch The switches must be configured to operate as a single ended input using the transmitter s 24 V dc as the source or as a differential input using an external dc power su...

Page 61: ...status is set to remote unless otherwise noted That setting can only be made by a local user Inputs are toggled between states by an active pulse unless otherwise noted To ensure proper operation the...

Page 62: ...put otherwise analog input is selected J3 25 IBOC Input Select B input Sets IBOC Analog for Exciter B Continuous active sig nal selects IBOC input otherwise analog input is selected J2 10 Preset Sched...

Page 63: ...o continue decreasing the power Remote status and alarm indications Outputs that indicate the status of operator controlled circuits are available on connectors J2 and J3 on the remote interface PWB A...

Page 64: ...ndicates that a shutback is currently active J3 3 RF On Status Indicates that the RF On LED is active showing the operator s request for RF power J3 5 6 7 8 9 10 Preset 1 6 Status Indicates which pres...

Page 65: ...reports the forward power level on J2 1 This voltage is a pure square law function and will be 3 9 0 5 V when the forward power is 12 5 kW The monitoring circuit s impedance must be greater than 1 000...

Page 66: ...ws you to remotely control and interrogate the XR12 s operational status If the NxLink Ethernet interface module option is installed and you wish to use it as the remote interface connector J12 is lin...

Page 67: ...exciters A B The external RF drive must be the carrier frequency c within 5 Hz or 5 parts per million ppm whichever is greater when it is not being modulated have a peak to peak amplitude of between 5...

Page 68: ...r J6 2 Configure either or both exciter RF synthesizer s to operate on Ext RF drive by setting the E4 jumper s to 1 2 External 10 MHz frequency reference You can apply an externally generated 10 MHz s...

Page 69: ...is switched off at the service entrance 3 Identify which primary winding taps should be used and connected to the transformer s ac power input Line terminals See Table 3 1 on page 3 2 4 Confirm that t...

Page 70: ...hen set the AUDIO FILTER switch accordingly The factory default selection provides a 1 0 dB roll off at 16 kHz This selection is suitable for most installations 8 Refer to Table 11 1 to determine the...

Page 71: ...TB2 1 and TB2 3 on the remote interface PWB 5 Switch on the ac power at the service entrance to turn on the transmitter 6 Look through the window on the left side of the transmitter s lower rear panel...

Page 72: ...g and Maintenance Guide 20 Set up the RF monitor output Depending on the setting of the remote interface PWB s BYPASS GAIN switch the RF monitor should be set no higher than 1 V rms 2 8 V pp switch se...

Page 73: ...be set to 10 dBm when 100 modulation is required the AUDIO GAIN potentiometer on the remote interface PWB must be reset as follows Determine the program audio level in dBm that will be applied when 10...

Page 74: ...witch if one is being used or else at the ac source 2 Connect the transmitter s RF output to an antenna system or verify that the current connection is intact 3 Turn the transmitter s ac power back on...

Page 75: ...ent program see page 12 2 Tools for installation see page 12 3 Contacting Nautel You can reach Nautel to order parts or for technical assistance at Nautel Limited 10089 Peggy s Cove Road Hackett s Cov...

Page 76: ...wiring including the associated terminating devices con duit and conduit clamps All electrical power cables including conduit terminating devices and conduit clamps Parts ordering You can order replac...

Page 77: ...you need during transmitter installation include the following Digital voltmeter Philips screwdrivers sizes 1 and 2 Pliers Wire cutters Slot screwdriver 5 mm 3 16 inch Metric and Imperial socket set u...

Page 78: ...XR12 Installation Manual Parts and tools Page 12 4 Issue 3 0 2009 07 15...

Page 79: ...with you to ensure that your site will be ready for the installation of your XR12 transmitter For support contact Nautel Customer Service and request assistance On site support on page 13 3 Installat...

Page 80: ...en installed and connected to the station equipment e g modulation monitor frequency monitor and power meter The site has been made ready for the equipment and adequate protection against lightning an...

Page 81: ...n can proceed as quickly as possible For more information about on site support including scheduling and pricing contact Nautel Customer Service Telephone 1 902 823 3900 Fax 1 902 823 3183 Email suppo...

Page 82: ...he specified equipment performance a When the equipment is operated within the design parameters and b When the equipment is installed and adjusted according to Nautel s prescribed procedures as state...

Page 83: ...efer to the parts list of the Repair manual for ordering information Provide as much of the information requested for Equipment Being Returned to Nautel on page two of this warranty as is practical Th...

Page 84: ...thin 30 days a credit is issued reducing this charge by one half to 40 of the list price USA customers are required to contact our Bangor Maine facility Canadian and overseas customers should contact...

Page 85: ...r if you want extended coverage Nautel offers one and two year Extended Warranty Plans to cover electrical and mechanical repairs or replacements for all Nautel equipment Coverage The Extended Warrant...

Page 86: ...h warranty period you can contact Nautel by telephone fax mail or email with the model number serial number and date of purchase Once you purchase a Nautel Extended Warranty Plan you receive an extend...

Page 87: ...he high voltage dc generated by the transmitter s ac power supply for use within the transmitter The B voltage is used to supply the transmitter s modulators and other transmitter circuitry Cutback A...

Page 88: ...ets Shutback A complete loss of RF output power caused by any one of a variety of faults including high VSWR low B voltage high RF current RF drive failure external interlock or spark gap Surge protec...

Page 89: ...ng assistance 13 1 control and monitor wiring 12 2 D digital PHASE COMPONENT BNC connec tor 10 1 documentation online 13 3 E electrical power cables 12 2 engineering support 13 1 exciter active 9 1 9...

Page 90: ...ts 12 2 reset system alarm 9 1 9 6 9 12 RF drive source 8 1 RF output coaxial cable 12 2 RF output voltage waveform 9 11 RF power preset 9 1 9 6 S scheduling onsite support 13 3 square law function 9...

Page 91: ......

Page 92: ...00 or Toll Free 1 877 6NAUTEL 6628835 Canada USA only Fax 1 902 823 3183 Nautel Inc 201 Target Industrial Circle Bangor Maine USA 04401 Phone 1 207 947 8200 Fax 1 207 947 3693 Customer Service 24 hour...

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