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XR12 Transmitter Pre-installation Manual

Physical requirements

Page 3-8

Issue 0.17   2005-08-31

Weight

For the weight of components in their crates, see 

Table 3.1, “Weight of components, XR12 with two 

modules only”

. 

The total weight of the assembled transmitter, once installed, is 329 kg (725 lb.). 

Table 3.1: Weight of components, XR12 with two modules only

Uncrated weight

Crate contents

kg

lb.

Main cabinet

216  

476  

Power transformer

113   

249   

Summary of Contents for XR12

Page 1: ...Document XR12 PREINST Issue 0 17 2005 08 31 Status Preliminary XR12 Transmitter Pre installation Manual ...

Page 2: ... 04401 Phone 207 947 8200 Fax 207 947 3693 Email support nautel com Web www nautel com The comparisons and other information provided in this document have been prepared in good faith based on publicly available information The reader is encouraged to consult the respective manufacturer s most recent published data for verification Copyright 2005 NAUTEL All rights reserved ...

Page 3: ...e installation tasks 2 1 Preparing for installation 2 1 Selecting a location for the transmitter 2 3 Installing an antenna feedline 2 3 Physical requirements 3 1 Dimensions 3 1 Clearances 3 2 Weight 3 8 Cooling requirements 4 1 Air flow in the transmitter 4 1 Cooling 4 3 Heating 4 4 Electrical requirements 5 1 Electrical power 5 1 Station reference ground 5 4 ...

Page 4: ...xternal 10 MHz frequency reference 7 2 RF output requirements 8 1 Antenna feed cable 8 1 Antenna system 8 3 Parts and tools 9 1 Parts supplied by Nautel 9 1 Parts not supplied by Nautel 9 2 Tools for installation 9 3 Accessories 10 1 AC line surge protection 10 1 Automatic antenna transfer control unit 10 2 RF contactor 10 2 Automatic switching system 10 3 Dynamic carrier control unit 10 3 Spares ...

Page 5: ...ii XR series on site or factory training 10 6 Pre installation assistance 11 1 Pre installation consulting 11 1 Installation and commissioning service 11 1 Online documentation 11 4 Onsite support 11 4 Training 11 4 Extended warranties 11 5 List of terms 12 1 Index 13 1 ...

Page 6: ...XR12 Transmitter Pre installation Manual Page iv Issue 0 17 2005 08 31 ...

Page 7: ...or to receiving and installing the XR12 transmitter Later sections of this manual provide reference information regarding physical cooling electrical and antenna requirements Features of this manual This manual contains a number of useful features Online Click on blue text to jump to a related section or get additional information for example to view a definition of a term To find keywords use Fin...

Page 8: ...Maintenance Manual provides instructions for operating maintaining and troubleshooting an XR12 transmitter It also provides reference information needed when performing diagnostic procedures XR12 Technical Reference Manual XR12 REF The Technical Reference Manual provides detailed technical information about the XR12 transmitter Online resources The Nautel website provides useful resources to keep ...

Page 9: ... cabinet to remind anyone who has not turned off the power that the system is live and that there is serious danger Mount the transmitter disconnect close to the transmitter so that it can be reached quickly in an emergency Clearly label the disconnect After turning off the power always perform a measurement to confirm that the power is off before touching anything within the transmitter If the wr...

Page 10: ...zards A serious RF hazard and very high voltages exist in the vicinity of the antenna and its networks during normal operations Other hazards Ensure that appropriate fire alarms and fire extinguishers are available Extinguishers must be suitable for use on electrical fires Many other site safety risks exist It is beyond the scope of this manual to identify all the risks and procedures WARNING It i...

Page 11: ...exciters on a preset for a specific operating mode for example exciter A for conventional AM and exciter B for IBOC The power output can also be scheduled to correspond with authorized daytime power levels Modulation The XR12 lets you use a number of modulation schemes including double sideband amplitude modulation AM IBOC requires additional equipment DRM requires additional equipment Duty cycle ...

Page 12: ... about remote control and monitoring see Section 6 Control and monitoring on page 6 1 Redundancy The XR12 features redundancy in all key systems RF power modules Exciters Modulators Cooling fans AC power The XR12 s variable power transformer can be set to use a range of input voltages and power frequencies Options DCC The XR12 supports Dynamic Carrier Control DCC as an optional external module DCC...

Page 13: ...ternal DRM signal source provides a signal to the XR12 exciter Safety interlocks Optional safety interlocks present unsafe access to the transmitter unless the ac power has been disconnected This section provides a description of how the XR12 transmitter operates For detailed technical descriptions schematics and mechanical drawings refer to the XR12 Reference Manual ...

Page 14: ...XR12 Transmitter Pre installation Manual Description Page 1 4 Issue 0 17 2005 08 31 ...

Page 15: ...abinet or bringing in external cooling air For detailed information about temperature requirements see Section 4 Cooling requirements on page 4 1 4 If this is an upgrade or replacement transmitter that is if the site is already set up for a transmitter go to Step 9 If you are upgrading a site verify the feedline the lightning protection systems and the AC power service Refer to the Nautel Site Pro...

Page 16: ...e transmitter or its power transformer into place for installation For information about component weight see Weight on page 3 8 12 Implement a safety interlock if required 13 If you are going to use an external RF drive ensure that the drive meets required specifications See External RF drive source on page 7 1 14 If you are going to use an external frequency reference ensure that the reference s...

Page 17: ...nsmitter Installing an antenna feedline When installing an antenna feedline for the XR12 transmitter perform the following tasks 1 Ensure that the RF feedline that will connect the transmitter and the antenna system has a suitably rated coaxial cable 2 Connect the shield of the antenna feedline coaxial cable directly to the station reference ground where it enters the building For more information...

Page 18: ...XR12 Transmitter Pre installation Manual Pre installation tasks Page 2 4 Issue 0 17 2005 08 31 ...

Page 19: ...ifications for the XR12 transmitter and its components and lists physical site requirements This section includes the following topics Dimensions Clearances see page 3 2 Weight see page 3 8 Dimensions The XR12 transmitter cabinet has the following dimensions Height 184 cm 72 5 inches Width 72 4 cm 28 5 inches Depth 104 cm 41 0 inches Figure 3 1 XR12 transmitter ...

Page 20: ...heck the clearance to ensure that you will be able to open all doors and access panels The front control panel is hinged on the left when looking at the front of the transmitter Also consider access to the rear of the transmitter during transformer installation and servicing and access to the front of the transmitter during power module replacement You must allow space to open the front panel and ...

Page 21: ...XR12 Transmitter Pre installation Manual Physical requirements Issue 0 17 2005 08 31 Page 3 3 Figure 3 2 XR12 top view CLEARANCE 72 CLEARANCE 48 ...

Page 22: ...XR12 Transmitter Pre installation Manual Physical requirements Page 3 4 Issue 0 17 2005 08 31 Figure 3 3 XR12 transmitter cabinet front view 184 cm 72 5 72 4 cm 28 5 ...

Page 23: ...XR12 Transmitter Pre installation Manual Physical requirements Issue 0 17 2005 08 31 Page 3 5 Figure 3 4 XR12 transmitter cabinet side view 184 cm 72 5 104 41 ...

Page 24: ...XR12 Transmitter Pre installation Manual Physical requirements Page 3 6 Issue 0 17 2005 08 31 Figure 3 5 XR12 transmitter cabinet rear view 184 cm 72 5 72 4 cm 28 5 ...

Page 25: ...XR12 Transmitter Pre installation Manual Physical requirements Issue 0 17 2005 08 31 Page 3 7 Figure 3 6 XR12 transmitter cabinet base seen from above ...

Page 26: ...ht of components in their crates see Table 3 1 Weight of components XR12 with two modules only The total weight of the assembled transmitter once installed is 329 kg 725 lb Table 3 1 Weight of components XR12 with two modules only Uncrated weight Crate contents kg lb Main cabinet 216 476 Power transformer 113 249 ...

Page 27: ...ng see page 4 4 Air flow in the transmitter The XR12 uses redundant cooling fans and hot air convection to ensure effective cooling Cool air is drawn in through filters in the upper portion of the back of the transmitter or from an intake duct through an opening in the top of the transmitter Air circulates down into the base of the transmitter and is then pushed up through the front rack of the tr...

Page 28: ...Figure 4 1 Air flow in the XR12 transmitter cabinet with back panel filter installed Figure 4 2 Air flow in the XR12 transmitter cabinet with airflow ducts installed Exhaust air Front of XR12 Back of XR12 Fans Incoming air Front of XR12 cabinet Back of XR12 cabinet Fans Exhaust duct Intake duct ...

Page 29: ...r and then multiply the product by 3 413 Closed loop or forced air cooling systems Closed loop or forced air cooling systems can be used so long as the air is well filtered to prevent dust and insects from entering the transmitter and so long as a minimum of 1 400 cubic feet per minute CFM at 0 5 pounds per square inch PSI is supplied to the intake duct Table 4 1 Cooling plant requirements for the...

Page 30: ...smitter Pre installation Manual Cooling requirements Page 4 4 Issue 0 17 2005 08 31 Heating The transmitter room must contain a heating system that will ensure the ambient air temperature does not drop below 0 C ...

Page 31: ...imum and maximum The primary winding of the main AC power transformer contains taps to accommodate voltages that differ from the ideal voltage of the power source These taps provide increments and are selected during installation to provide the nominal voltage for the transmitter The comes standard with taps for 350 380 410 450 480 and 510 Vac Voltage stability The AC power source nominal voltage ...

Page 32: ...uctor and the station reference ground In addition pass all the conductors as a group through a ferrite toroid Install the ferrite toroid on the AC feed between the transmitter and the bi directional surge protector The ferrite toroid is provided by Nautel with the transmitter A surge protector panel containing suitably rated varistors is available from Nautel Install the surge protector panel clo...

Page 33: ...ditions related to transmitter power and wiring allow it A certified electrician should be consulted to ensure that all wiring meets local electrical code requirements CAUTION Do NOT use open delta three phase AC power sources that use two identical transformers These systems are susceptible to third harmonic distortion and line transients and may cause peak voltages to exceed the line voltage Thi...

Page 34: ...he site s AC service entrance ground is directly connected to the station reference ground outside the transmitter building If a surge protector is being used connect the transmitter cabinet s designated reference ground point the shield of the coaxial feedline and the ground connection of the power source directly to the surge protector Connect the surge protector to the station reference ground ...

Page 35: ...motely Alarms The XR12 provides the following alarms through its GUI Fan P S Fault The power supply used for the fans is no longer in the voltage range 48 V 10 High B Voltage The B voltage has risen above 380 V This is caused by high ac mains voltage Low B Voltage The B voltage has fallen below the alarm threshold triggering an alarm and shutback The softstart relays open and the fan and RF drive ...

Page 36: ...tter will change over to exciter A If auto changeover is not possible or if the exciter transfer function is set to manual then this fault will cause a shutback PDM Drive Fail The PDM drive has failed If the exciter transfer function is set to auto then the transmitter will change over to the other exciter If auto changeover is not possible or if the exciter transfer function is set to manual then...

Page 37: ...vel Replace the battery while the AC is on If AC power fails and the backup battery is low or removed then the log files will be lost PM Fault A There is a fault in power module A PM Fault B There is a fault in power module B PM Fault C There is a fault in power module C Remote control circuits and alarms You can control the on off status the active A B exciter the on off status of the RF power st...

Page 38: ...to provide RF power if possible Provide an active pulse to acti vate The associated 3 pin header 2 socket shunt post on the remote interface board is E11 TB1 7 and 8 Reset Causes a system reset Provide an active pulse to activate The associated 3 pin header 2 socket shunt post on the remote interface board is E10 J3 22 and 23 IBOC Input Select A Sets IBOC Analog for Exciter A Continuous active sig...

Page 39: ...power presets Provide an active pulse to activate The associated 3 pin header 2 socket shunt post on the remote interface board is E3 J2 17 and J2 18 PRESET 4 inputs Selects one of six RF power presets Provide an active pulse to activate The associated 3 pin header 2 socket shunt post on the remote interface board is E1 J2 19 and J2 20 PRESET 5 inputs Selects one of six RF power presets Provide an...

Page 40: ... board is E8 TB1 7 and TB1 8 SYSTEM RESET inputs Generate a reset pulse that is applied to the control and RF power stages These pulses reset alarms on the RF power modules and clears the cutback state The associated 3 pin header 2 socket shunt post on the remote interface board is E10 J3 22 and J3 23 Auto Power Scheduler Select The auto power scheduler select circuit causes the power levels to au...

Page 41: ... 6 1 J3 11 High VSWR See High VSWR shutback on page 6 2 J3 17 Cutback See Cutback Level 1 8 on page 6 2 J3 16 Shutback indicates 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 preset is currently active J3 4 Remote Status indicates whether or not the system is...

Page 42: ... B Voltage and J2 7 DC Current J8 RF Monitor Forward power level A buffered DC voltage that reports the forward power level on J2 1 This voltage is a square law function and will be 3 9 0 5 Vdc when forward power is 10 kW The monitoring circuit s impedance must be greater than 1 000 ohms Reflected power level A buffered DC voltage that reports the reflected power level on J2 3 This voltage is a sq...

Page 43: ...ion monitor with a 50 ohm input impedance It may also be monitored by an oscilloscope during maintenance procedures The RF monitor output can be set to provide 1 0 V RMS for each preset power level provided they are preset to a level that is between 1 kW and 12 kW The RMS output level is adjusted from the GUI Setting the level higher than 1 Vrms carrier will cause distortion in the wafevorm and ma...

Page 44: ...XR12 Transmitter Pre installation Manual Control and monitoring Page 6 10 Issue 0 17 2005 08 31 ...

Page 45: ...ncy oscillator for one or both exciters A B The external RF drive must be the carrier frequency ƒc 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 0 V and 12 V sine wave or square wave be phase modulated with no other modulation be spectrally pure when it is not being modulated Note There is only one external RF ...

Page 46: ... length terminate it with a coaxial BNC connector and connect it to the remote interface board s EXT RF connector J6 External 10 MHz frequency reference You can apply an externally generated 10 MHz signal such as a GPS clock signal for use as the reference frequency for the RF drive carrier frequency to the synthesizer board 1 The external 10 MHz frequency reference must remain stable at 10 MHz wi...

Page 47: ...n flashovers can occur in poor installations Ensure that this part of your installation is installed by professionals experienced with high power radio frequency circuits Insulator flashover Surface flashovers along an insulator occur when there is an electrical breakdown in the gas normally air at its surface The mechanism that triggers a flashover depends on the insulation surface conditions Gas...

Page 48: ...vides a conductive path and reduces the effectiveness of the insulator Pitting and erosion of the insulator may also occur To reduce the possibility of tracking damage clean all insulator surfaces periodically and use stress control techniques at the conductor insulator junction Other causes Other causes of breakdowns may include improperly adjusted spark balls or the disruption of air gaps by rai...

Page 49: ...OC and DRM systems require better performance from antenna systems To ensure the proper operation during digital broadcasting ensure that the VSWR does not exceed 1 4 1 at the carrier frequency 15 kHz In order to achieve the proper sideband symmetry Hermitian symmetry needed for IBOC operation you may need to adjust the tuning of the antenna system to balance the impedances at the sidebands You mu...

Page 50: ...XR12 Transmitter Pre installation Manual RF output requirements Page 8 4 Issue 0 17 2005 08 31 ...

Page 51: ...heels to attach to the frame of the power transformer to allow manual installation Documentation Nautel includes the following documents with the XR12 transmitter XR12 Pre installation Manual XR12 PREINST The Pre installation Manual provides instructions and reference information needed when planning and preparing for the installation of an XR12 transmitter Nautel Site Protection Manual The Site P...

Page 52: ... supplied by Nautel Some parts and materials required to complete installation are not supplied by Nautel The parts you need vary with the installation requirements The list of parts you normally provide yourself during installation include A suitable 50 ohm RF output coaxial cable terminated by a 1 5 8 inch EIA connector com plete with center male connector at the transmitter end All external con...

Page 53: ...up to 24 mm 15 16 inch Metric and Imperial wrench set up to 25 mm 1 inch For manual installation of the power transformer 5 16 Allen Key provided 1 m 3 foot 2x4 board to pinch and lift the power transformer in place Multiple wood blocks to provide 150 mm 6 inches of height Wheeled cart for transporting the power transformer to the installation site Wheels are provided in the ancillary kit shipped ...

Page 54: ...XR12 Transmitter Pre installation Manual Parts and tools Page 9 4 Issue 0 17 2005 08 31 ...

Page 55: ...el offers an AC line surge protection panel which is suitable for use with the XR12 transmitter Various versions are available depending on your AC configuration and supply voltage However you can use any surge protector with at least a 1 500 Joule per phase rating Connect the surge protector s ground terminal directly to the station reference ground using a 10 cm wide copper strap Also connect th...

Page 56: ...ters In automatic mode the forward power levels of both transmitters are monitored If the main on air transmitter s RF output falls below a preset threshold typically 3 dB an automatic changeover to the standby transmitter takes place An interlock override feature allows the operator to enable the RF output of the standby off air transmitter into a dummy load for maintenance or troubleshooting Fig...

Page 57: ... throw latching switch Dynamic carrier control unit The Dynamic Carrier Control DCC option is an add on DSP based module for the XR12 exciter This system reduces AC power consumption by reducing the carrier power when the instantaneous modulation level of the transmitter drops below a threshold The DCC unit supports Amplitude Modulation Companding AMC Dynamic Amplitude Modulation DAM and Dynamic C...

Page 58: ...with all XR series transmitters Figure 10 3 XR power module Module testing cable The module testing cable allows bench testing and troubleshooting of RF power modules using a direct connection to the transmitter The test cable provides a temporary connection from the transmitter to a power module that has been removed from the transmitter and placed on a workbench The test cable provides low level...

Page 59: ...r modulator unit Extended warranty plans Extended warranty plans add 12 or 24 months to Nautel s standard 13 month warranty and includes a module exchange program for many common modules and circuit boards a toll free hotline necessary labor conducted at Nautel facilities or by Nautel authorized personnel to repair to specifications necessary components modifications to improve performance and ret...

Page 60: ...can be ordered from Nautel All technical manuals are also available online For detailed information see Online documentation on page 11 4 XR series on site or factory training This includes product overview site and pre installation theory of operation testing and adjustments operating instructions system level troubleshooting component level troubleshooting component parts lists and wiring route ...

Page 61: ...e page 11 4 Extended warranties see page 11 5 Pre installation consulting Nautel field support specialists are available to answer questions and work 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 Installation and commissioning service Nautel offers an installation and commissioning se...

Page 62: ...uired connector Where required all remote control and monitoring cables are installed and connected to the station equipment for example modulation monitor frequency monitor and power meter The site is ready for the equipment and adequate protection against lightning and lightning induced transients has been provided The transmitter is unpacked and has been closely checked for any damage caused by...

Page 63: ...e that the transmitter is operating normally in compliance with its specifications The service representative also provides a demonstration and a short explanation of the operation of the transmitter Finally the customer signs an Acceptance of Installation Certificate that provides feedback to Nautel regarding the commissioning service ...

Page 64: ...Atlantic time or Eastern time in North America requests sent by fax or email will be acknowledged within one working day Training Nautel s SBE certified broadcast training programs satisfy your day to day knowledge requirements Students participating in Nautel s broadcast transmitter or RF basics training programs earn one SBE credit for each completed day of training Nautel s comprehensive select...

Page 65: ...wo year Extended Warranty Plans to cover electrical and mechanical repairs or replacements for all Nautel equipment Coverage The Extended Warranty Plan includes A module exchange program for many common modules and circuit boards North America only Toll free hotline North America only Necessary labor performed by Nautel authorized personnel to repair the product back to factory specifications Nece...

Page 66: ...rial number and date of purchase Once you purchase of an Nautel Extended Warranty Plan you receive an extended warranty plan certificate plan number and a toll free number North America only to call for any service related issues Using the Extended Warranty Plan Contact Nautel s Canadian or U S service facility by phone fax or email as soon as a problem occurs The following will be required when c...

Page 67: ...o High Definition HD Radio is another term for In Band On Channel IBOC technology HD Radio is a trademark of iBiquity Digital Corporation IBOC Nautel In Band On Channel technology provides high quality digital audio over existing AM radio channels NE IBOC Nautel s In Band On Channel signal generator See IBOC Required for XR series IBOC installations Preset A setting that controls power level activ...

Page 68: ...XR12 Transmitter Pre installation Manual List of terms Page 12 2 Issue 0 17 2005 08 31 ...

Page 69: ...nit NX1 10 2 automatically switched hybrid combiner 10 3 B bench testing 10 4 bi directional surge protection 5 2 binders documentation 11 4 bowl type bushing insulators 8 2 breakdown flashover 8 1 breakdown level 8 1 British thermal units Btu 4 3 building entrance 2 3 bushing insulators 8 2 C cabinet size 3 1 cable coaxial 2 3 capacitive RF divider on insulators 8 2 carbon tracks causing insulato...

Page 70: ...ebsite 1 vi feed throughs 8 1 feedline termination 2 2 ferrite toroid 5 2 field upgrades 1 vi filters 3 2 flange connector 2 2 flange RF feedline 8 2 flashover 8 1 forward power level 6 8 frequency impedance 8 3 frequency oscillator 7 1 frequency reference 2 2 frequently asked questions on Nautel web site 1 vi G gas breakdown flashover 8 1 gas insulator 8 2 GPS clock signal 7 2 ground point 5 4 gr...

Page 71: ...4 opto couplers 6 3 oscilloscope 6 9 output voltage waveform 6 8 over capacity AC power 5 2 P panel rear 3 2 parts 9 1 PDF documentation 1 vi peak voltages RF feedline 8 2 phases balanced to ground AC power 5 3 planning assistance 11 1 plug in power amplifier unit XR PA 10 4 plug in power modulator unit XR MOD 10 5 pollution as a trigger of insulator break down 8 2 power amplifier unit XR PA 10 4 ...

Page 72: ...rotection 5 2 10 1 surge protector panel 5 2 switching system automatic 10 3 symmetry sideband 8 3 synthesizer board 7 2 system alarm reset 6 1 6 3 system performance 8 3 T taps transformer 5 1 technical support 11 1 temperature transmitter room 4 3 terminating devices 9 2 test cable 10 4 three material junction 8 1 tone modulation 4 3 tools 9 1 toroid 2 3 5 2 total weight 2 3 3 8 tower 2 1 traini...

Page 73: ...2 2 workbench 2 2 workbench testing 10 4 Wye star configuration AC power 5 3 X XR MOD plug in power modulator unit 10 5 XR PA plug in power amplifier unit 10 4 XR PM XR series power module 10 4 XR PMTK module testing cable 10 4 XR series power module 10 4 XR12 KIT spares kit 10 4 XR12 spares kit XR12 KIT 10 4 ...

Page 74: ...XR12 Transmitter Index Page 13 6 Issue 0 17 2005 08 31 ...

Page 75: ......

Page 76: ...7 2005 08 31 Nautel Limited 10089 Peggy s Cove Road Hackett s Cove NS Canada B3Z 3J4 Phone 1 902 823 2233 Fax 1 902 823 3183 Nautel Maine Inc 201 Target Industrial Circle Bangor Maine USA 04401 Phone 207 947 8200 Fax 207 947 3693 Email support nautel com Web www nautel com ...

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