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XR6/XR3 Installation Manual

Control and monitoring

Page 9-6

Issue 3.1 2014-06-04

The backup battery should be replaced while ac power is

If the ac power faults, without adequate

backup battery power, then the log files will be lost.

CAUTION:
Do not wait for an extended period to replace the batteries. The control/monitor
PWB’s microcontroller may not retain its settings if ac power is turned off when
the backup battery voltage is too low.

Summary of Contents for XR3

Page 1: ...XR6 XR3 Transmitter Installation Manual Document XR6 XR3 INST Issue 3 1 2014 06 04 Status Standard...

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: ...ds xii Toxic Hazards xii Other Hazards xii Safety Precautions xiii Personal Safety xiii Site Safety xiv Equipment Safety xvi Preparing for installation 1 1 Unpacking and positioning 2 1 Installing the...

Page 6: ...ternal RF drive source 10 1 External 10 MHz frequency reference 10 2 Commissioning tasks 11 1 Pre commissioning tasks 11 1 Commissioning 11 3 Going on air 11 6 Parts and tools 12 1 Contacting Nautel 1...

Page 7: ...XR6 XR3 Installation Manual Issue 3 1 2014 06 04 Page vii On site support 13 3 Training 13 4 Standard warranty 13 5 Extended warranties 13 9 List of terms 14 1 Index IX 1...

Page 8: ...XR6 XR3 Installation Manual Page viii Issue 3 1 2014 06 04...

Page 9: ...ries or spares see Accessories on page 10 1 of the XR6 XR3 Pre Installation Manual For standard warranty information see Pre installation assistance on page 11 1 of the XR6 XR3 Pre Installation Manual...

Page 10: ...order to 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...

Page 11: ...serious danger is present DANGER HIGH VOLTAGE Indicates dangerous voltage in excess of 72 volts capable of causing a fatal electrical shock are present on or near parts bearing this label Mount the tr...

Page 12: ...ous during normal device operation and under normal device failure conditions These devices are specifically identified with BeO in the Description column of the Troubleshooting Manual s parts list s...

Page 13: ...f training 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...

Page 14: ...l does 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 perso...

Page 15: ...near 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 c...

Page 16: ...the 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 st...

Page 17: ...o prevent 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...

Page 18: ...XR6 XR3 Installation Manual Page xviii Version 3 1 2014 06 04...

Page 19: ...d on 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 cra...

Page 20: ...d 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 Commissi...

Page 21: ...module See Figure 2 2 on page 2 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 conn...

Page 22: ...XR6 XR3 Installation Manual Unpacking and positioning Page 2 2 Issue 3 1 2014 06 04 Figure 2 1 RF Power Module Top Mounting Screw Holes Rear Panel Cutout Connector Bottom Mounting Screw...

Page 23: ...ts 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 connector on th...

Page 24: ...XR6 XR3 Installation Manual Unpacking and positioning Page 2 4 Issue 3 1 2014 06 04...

Page 25: ...One label identifies the tap number and the line to line or line to neutral voltage Another label identifies the tap All phases must be set to the same tap see also Figure 3 1 and Table 3 1 on page 3...

Page 26: ...XR6 XR3 Installation Manual Installing the power transformer Page 3 2 Issue 3 1 2014 06 04 Figure 3 2 Single phase XR6 power transformer line voltage tap layout 1 2 3 4 LOAD 2 LINE 2 LOAD 1 LINE 1...

Page 27: ...er back cover from the transmitter WARNING The main power transformer weighs approximately 68 kg 150 lbs Do not attempt to move it unless sufficient manpower or mechanical assistance is available to m...

Page 28: ...ers connect the nine wires terminated on contactors K1 and K2 to the transformer s Load terminals see Figure 3 1 on page 3 1 H1 90 wire T1 LD1 Low H2 90 wire T1 LD2 Low H3 90 wire T1 LD3 Low H1 150 wi...

Page 29: ...ormer Issue 3 1 2014 06 04 Page 3 5 Figure 3 3 XR6 XR3 1 phase choke shim removal Figure 3 4 XR6 XR3 3 phase power transformer installation Shims Qty 4 TB1 T2 Load 1 3 connections Line 1 3 connections...

Page 30: ...ht hand wall of the transmitter as viewed from the back see Figure 3 3 Based on your nominal line to line or line to neutral voltage select the tap position identified in Figure 3 6 that is closest to...

Page 31: ...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 32: ...4 2 Issue 3 1 2014 06 04 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 33: ...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 34: ...nd 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 35: ...hen 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 one disc shaped capacitor e g see Figure 6...

Page 36: ...re 6 1 XR6 XR3 Exciter Panel Assembly NAE93 A2 A2A6 A2A1 A2 Exciter Interface PWB Exciter Panel assembly mounting screws 11 Remote Interface PWB A2A2 RF Synthesizer PWB A A2A4 RF Synthesizer PWB B A2A...

Page 37: ...the 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 t...

Page 38: ...rge 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 b...

Page 39: ...large 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 wi...

Page 40: ...XR6 XR3 Installation Manual Installing the RF connector Page 6 6 Issue 3 1 2014 06 04...

Page 41: ...Figure 7 1 on page 7 2 Measure the air gap between the spark gap balls using a feeler gauge 6 The air gap should be the distance listed in Table 7 1 Spark Gap Setting versus Altitude for the carrier f...

Page 42: ...XR6 XR3 Installation Manual Adjusting the spark gap Page 7 2 Issue 3 1 2014 06 04 Figure 7 1 RF Output Spark Gap Location Spark Gap E1...

Page 43: ...6 XR3 0 074 XR6 570 0 046 XR3 0 073 XR6 575 0 046 XR3 0 072 XR6 580 0 045 XR3 0 072 XR6 585 0 045 XR3 0 071 XR6 590 0 044 XR3 0 071 XR6 595 0 044 XR3 0 070 XR6 600 0 044 XR3 0 069 XR6 605 0 043 XR3 0...

Page 44: ...0 072 XR3 0 115 XR6 720 0 071 XR3 0 114 XR6 725 0 071 XR3 0 113 XR6 730 0 070 XR3 0 112 XR6 735 0 070 XR3 0 111 XR6 740 0 069 XR3 0 110 XR6 745 0 069 XR3 0 109 XR6 750 0 068 XR3 0 108 XR6 755 0 068 X...

Page 45: ...0 058 XR3 0 092 XR6 870 0 057 XR3 0 091 XR6 875 0 057 XR3 0 091 XR6 880 0 057 XR3 0 090 XR6 885 0 056 XR3 0 090 XR6 890 0 056 XR3 0 089 XR6 895 0 056 XR3 0 088 XR6 900 0 055 XR3 0 088 XR6 905 0 055 X...

Page 46: ...3 0 077 XR6 1020 0 048 XR3 0 077 XR6 1025 0 048 XR3 0 076 XR6 1030 0 048 XR3 0 076 XR6 1035 0 048 XR3 0 076 XR6 1040 0 047 XR3 0 075 XR6 1045 0 047 XR3 0 075 XR6 1050 0 047 XR3 0 074 XR6 1055 0 047 XR...

Page 47: ...XR3 0 067 XR6 1170 0 042 XR3 0 067 XR6 1175 0 042 XR3 0 066 XR6 1180 0 042 XR3 0 066 XR6 1185 0 041 XR3 0 066 XR6 1190 0 041 XR3 0 066 XR6 1195 0 041 XR3 0 065 XR6 1200 0 041 XR3 0 065 XR6 1205 0 041...

Page 48: ...XR3 0 127 XR6 1320 0 079 XR3 0 126 XR6 1325 0 079 XR3 0 126 XR6 1330 0 079 XR3 0 125 XR6 1335 0 078 XR3 0 125 XR6 1340 0 078 XR3 0 124 XR6 1345 0 078 XR3 0 124 XR6 1350 0 077 XR3 0 123 XR6 1355 0 077...

Page 49: ...XR3 0 112 XR6 1470 0 070 XR3 0 111 XR6 1475 0 069 XR3 0 111 XR6 1480 0 069 XR3 0 110 XR6 1485 0 069 XR3 0 110 XR6 1490 0 069 XR3 0 109 XR6 1495 0 068 XR3 0 109 XR6 1500 0 068 XR3 0 108 XR6 1505 0 068...

Page 50: ...XR3 0 100 XR6 1610 0 063 XR3 0 100 XR6 1615 0 063 XR3 0 099 XR6 1620 0 062 XR3 0 099 XR6 1625 0 062 XR3 0 099 XR6 1630 0 062 XR3 0 098 XR6 1635 0 062 XR3 0 098 XR6 1640 0 061 XR3 0 098 XR6 1645 0 061...

Page 51: ...e 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 15 XR3 1 16 XR6 4 000 1 21 XR3 1 22 XR6 5 000 1 28 XR3 1 29 XR6 6 000 1 35 XR3 1 36...

Page 52: ...XR6 XR3 Installation Manual Adjusting the spark gap Page 7 12 Issue 3 1 2014 06 04...

Page 53: ...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 processor a...

Page 54: ...re 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 XR...

Page 55: ...ace 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 Con...

Page 56: ...drive 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 inte...

Page 57: ...tallation 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 Rout...

Page 58: ...XR6 XR3 Installation Manual Audio and IBOC inputs Page 8 6 Issue 3 1 2014 06 04 Figure 8 3 Location of cable entry hole top view of XR6 XR3 transmitter Front AC IN Rear AUDIO CABLE ENTRY...

Page 59: ...the XR6 XR3 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 b...

Page 60: ...roximately 250 V 150 V or 91 V for three phase XR6 transmitters to correspond to the B voltage level currently in use For three phase XR3 transmitters the alarm threshold voltage is factory calibrated...

Page 61: ...the microcontroller will attempt a changeover to exciter B If it cannot or if the exciter transfer function is set to manual then this fault will cause a shutback Mod driver fault B This fault is repo...

Page 62: ...predefined time limit that must expire before the cutback level returns to the previous level e g level three back to level two If there are no further cutbacks this process continues until Level 0 no...

Page 63: ...rs this fault if that value is greater than 150 C 302 F While this fault is on RF power will not be available The temperature is assumed to rise 20 C 68 F for each cold start and 10 C 50 F for each wa...

Page 64: ...hile ac power is ON If the ac power faults without adequate backup battery power then the log files will be lost CAUTION Do not wait for an extended period to replace the batteries The control monitor...

Page 65: ...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 s...

Page 66: ...l 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 th...

Page 67: ...input 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 Sch...

Page 68: ...to 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...

Page 69: ...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 pr...

Page 70: ...e is a pure square law function and will be 3 9 0 5 V when the forward power is 6 5 kW XR6 or 2 8 0 5 V when the forward power is 3 3 kW XR3 The monitoring circuit s impedance must be greater than 1 0...

Page 71: ...PWB This port allows you to remotely control and interrogate the XR6 XR3 s operational status If the NxLink Ethernet interface module option is installed and you wish to use it as the remote interfac...

Page 72: ...XR6 XR3 Installation Manual Control and monitoring Page 9 14 Issue 3 1 2014 06 04...

Page 73: ...th 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 betwee...

Page 74: ...or 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...

Page 75: ...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 3 4 Confirm that...

Page 76: ...then 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 77: ...e 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 as seen from the back Verify that both power status LEDs...

Page 78: ...h B 1 B 2 and B 3 as applicable for your power level The B 1 level should correspond to a B voltage between 105 V and 125 V the B 2 level should correspond to a B voltage between 186 V and 206 V the B...

Page 79: ...y that the RF output s modulation envelope is acceptable 29 If the program audio can be set to 10 dBm when 100 modulation is required it is recommended the AUDIO GAIN potentiometer on the interphase P...

Page 80: ...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 81: ...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...

Page 82: ...or 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 rep...

Page 83: ...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...

Page 84: ...XR6 XR3 Installation Manual Parts and tools Page 12 4 Issue 3 1 2014 06 04...

Page 85: ...with you to ensure that your site will be ready for the installation of your XR6 XR3 transmitter For support contact Nautel Cus tomer Service and request assistance On site support on page 13 3 Insta...

Page 86: ...been 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...

Page 87: ...arize yourself with specifica tions operation maintenance and troubleshooting prior to the delivery of your equipment Docu mentation is also provided on CDROM and in paper binders that are delivered w...

Page 88: ...rams are made up of individual modules that can be mixed and matched to meet the customer s specific training needs All Nautel training courses are available at the Nautel Training Center Training can...

Page 89: ...the instruction manual 3 Nautel shall provide replacements for all Parts to the Buyer when they become defective during the warranty period and upon the return of the defective part Replacement parts...

Page 90: ...ftware a is free or errors bugs or defects b will be compatible with third party software c results output or data provided through or generated by the software are accurate complete or reliable and d...

Page 91: ...m Web www nautel com Module exchange service In order to provide Nautel customers with a fast and efficient service in the event of a problem Nautel operates a factory rebuilt module exchange service...

Page 92: ...urned will ensure prompt attention and will expedite the dispatch of replacements Refer to the nameplate on the transmitter and or the appropriate module assembly to obtain name type part and serial n...

Page 93: ...r performed by Nautel authorized personnel to repair the product back to factory specifications Necessary components Modifications to correct performance problems Return shipping Details Extended Warr...

Page 94: ...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...

Page 95: ...The 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...

Page 96: ...resets 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 pro...

Page 97: ...ing assistance 13 1 control and monitor wiring 12 2 D digital PHASE COMPONENT BNC connector 10 1 documentation online 13 3 E electrical power cables 12 2 engineering support 13 1 exciter active 9 1 9...

Page 98: ...arts 12 2 reset system alarm 9 1 9 7 9 13 RF drive source 8 1 RF output coaxial cable 12 2 RF output voltage waveform 9 12 RF power preset 9 1 9 7 S scheduling onsite support 13 3 square law function...

Page 99: ......

Page 100: ...NAUTEL 662 8835 Canada USA only or Phone 1 902 823 3900 or 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...

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