Platinum Z5 CD Manual Download

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408

ti.f

888-2408-002

WARNING: Disconnect primary power prior to servicing.

MANUAL REVISION HISTORY

Platinum Z5 CD™

888-2408-002

Rev.

Date

ECN

Pages Affected

12-17-01

47926

Title page, added MRH1/MRH2, sections 2 and 4.

06-09-03

TBD

Title page, MRH1/MRH2, and page 2-28.

Summary of Contents for Z5 CD

Page 2: ...ain all PACKING CHECK LISTs Use the PACKING CHECK LIST to help locate and identify any components or assemblies which are removed for shipping and must be reinstalled Also remove any shipping supports...

Page 3: ...sconnect primary power prior to servicing MANUAL REVISION HISTORY Platinum Z5 CD 888 2408 002 Rev Date ECN Pages Affected B 12 17 01 47926 Title page added MRH1 MRH2 sections 2 and 4 C 06 09 03 TBD Ti...

Page 4: ...888 2408 002 WARNING Disconnect primary power prior to servicing...

Page 5: ...02 etc that corresponds to the number found in the schematics C001 in a bill of material is equivalent to C1 on the schematic or 2 gives added information or further explanation i e Used for 208V oper...

Page 6: ...888 2408 002 WARNING Disconnect primary power prior to servicing...

Page 7: ...and fire protec tion standards must be observed The following National Fire Protection Association NFPA standards are recommended as reference Automatic Fire Detectors No 72E Installation Maintenance...

Page 8: ...888 2408 002 WARNING Disconnect primary power prior to servicing...

Page 9: ...ation to a hospital as quickly as possible E If arms or legs are affected keep them elevated NOTE If medical help will not be available within an hour and the victim is conscious and not vomiting give...

Page 10: ...888 2408 002 WARNING Disconnect primary power prior to servicing...

Page 11: ...14 External and Failsafe Interlock Connections 2 15 External Interlock Connection 2 15 Failsafe Interlock Connection 2 15 Initial Turn on 2 16 Remote Control Connections 2 21 Control Inputs 2 22 Stat...

Page 12: ...System Description 4 30 Master Controller 4 31 EEPROM U39 4 31 APC Automatic Power Control 4 32 Calibration Factors and A D Values 4 34 DAC_APC_REF 4 35 Forward Factor and A D_FWD_PWR 4 36 APC Factor...

Page 13: ...ower Output 6 13 Asterisk and Pound Signs 6 13 Master Controller Related Faults 6 14 THERMISTOR Fault 6 14 EEPROM_DEF EEPROM U39 Default Load 6 15 REF_WARNING 5V Reference Warning 6 15 MSTR_REF 5V Ref...

Page 14: ...s 6 28 PS _START Soft Start Circuit Fault 6 29 PS _HS_TEMP Rectifier Heatsink Temperature 6 29 PS _DSCHG Discharge circuit fault 6 29 PS _PHS_LS Phase Loss 100 120 Hz ripple 6 30 PSC 20V Fault 6 30 PS...

Page 15: ...for use up through the initial turn on of the equip ment Section 3 Operators Guide describes operation of the equipment and is intended to be the primary section referenced by operating personnel Sec...

Page 16: ...nd commands for switching between main alternate DIGIT exciters and IPAs Redundant RF amplifier modules that allow maintenance while the transmitter remains on the air at reduced power Hot Pluggable m...

Page 17: ...with all Platinum Z transmitters The DIGIT with its digital input module generates the complete stereo FM waveform in the digital domain using a digital signal processor DSP as a stereo generator and...

Page 18: ...ue isolation means that each module will continue to work into a nominal 50 ohm load regardless of the number of active amplifiers for almost zero stress to the amplifiers during fault conditions The...

Page 19: ...supply powering half of the PA amplifiers Most other sections such as the IPA and the control system are powered from both supplies The supplies are regulated by reliable tap switching techniques non...

Page 20: ...1 6 888 2408 002 WARNING Disconnect primary power prior to servicing Introduction Specifications...

Page 21: ...plete or if the unit is damaged electrically or mechanically notify the carrier and HARRIS CORPORATION Broadcast Systems 2 3 Returns and Exchanges Damaged or undamaged equipment should not be returned...

Page 22: ...an be tol erated A closed air system is recommended in these environments that is an air conditioned room that recirculates and properly filters the room air No outside air is brought into the transmi...

Page 23: ...hipped with the power supply installed the power supply tray is covering the bolts so the fan assembly on the rear of the transmitter will also have to be removed to access the rear pallet bolts the p...

Page 24: ...bles in a metal conduit which is separate from the AC supply Remote control cabling may be included in the same conduit with the exciter cabling AC power wiring and small signal lines should never be...

Page 25: ...Connections on page 2 11 If there are any discrepancies then the transformer tapping will have to be checked and possibly changed as outlined below WARNING DISCONNECT AND LOCKOUT STATION PRIMARY POWER...

Page 26: ...W11 and W12 blue and one control voltage cable W21 gray with orange connector hanging on the right side of the power supply compartment 1 First connect W12 to J4 on the PS2 Rectifier Board See Figure...

Page 27: ...y compartment and two smaller gray wires 40 and 41 plug into the gray Wego block connector A17TB1 on the front of the power supply tray A17 designates a component on the power supply tray See Figure 2...

Page 28: ...ottom front corners of the power supply compartment Re install the front cover panel for the power supply compartment 2 5 5 Single Phase Power Supply Installation Before installing the power supply ch...

Page 29: ...fier Board on PS2 nearest the back of the transmitter and should be connected first Be sure to route this cable so it does not touch the resistor standing up on top of the Rectifier heatsink See Figur...

Page 30: ...block and the wire can be inserted Be very careful not to let the wire ends fray as the connectors are very close together and could cause a short The wire insulation should actually extend just insid...

Page 31: ...ses If you prefer to use a circuit breaker in your installation select one with a motor starting trip curve similar to the RK5 curve for fuses This type of delayed response is needed in order to accom...

Page 32: ...op terminals on contactor K1 Access is also available through the bottom of the transmitter For 380VAC 342 432VAC 3 Phase 4 wire systems there is also a large insulated standoff located near the main...

Page 33: ...s practical to minimize the lightning voltage potential carried by the coax into your building For coaxes a single point of entry into the building is best with all connected to a common grounding pla...

Page 34: ...he blower motor operate from any voltage within the specified range of the tapping chart without re tapping 2 5 6 5 Exciter AC Voltage Selection Once the site voltage has been checked verify that the...

Page 35: ...N command after the external interlock connection is restored CAUTION TO CONNECT TO THE WAGO BLOCK J4 ON THE LIFE SUPPORT BOARD REQUIRES PRESSING A SCREWDRIVER INTO THE RECTANGULAR SLOT ON THE FRONT S...

Page 36: ...ted on the front panel of the Controller STEP 1 Activate the STATION AC POWER source to the transmitter STEP 2 Turn on the low voltage power supply breaker CB1 located in the rear of the transmitter c...

Page 37: ...The modules should only require a minimal amount of force for insertion into the card edge connectors If they do not slide in easily check the connectors on the combiner boards and visually inspect t...

Page 38: ...WARNING Disconnect primary power prior to servicing Installation Initial Turn On Figure 2 6 PA Compartment Front View Figure 2 7 PA Compartment Rear View A1 A2 A3 A4 IPA_AB1 IPA_AB2 B1 B2 B3 B4 B5 B6...

Page 39: ...dules installed the Fault LED on the controller front panel should be flashing at this point This indicates that there are inactive faults in the fault log which need to be cleared at this time To res...

Page 40: ...is optional as it simply makes the transmitter FWD PWR meter read 100 at the customer specified Transmitter Power Output TPO which should already be factory set This will not change the kW reading on...

Page 41: ...Terminations provided in the Platinum Z5 Transmitter allow remote control of the transmitter functions by connection to terminals on terminal board A1TB1 TB1 is a 38 pin Terminal strip with a D conne...

Page 42: ...rated by relay contact or transistor switching See Figure 2 10 Figure 2 10 Ground Switching for Remote Control Lines 2 5 11 2 Status Ouputs The status output lines on TB1 are transistor type open coll...

Page 43: ...ould not exceed 28Vdc NOTE Maximum status line current is 25 mA If the output is used to drive a small printed circuit board type relay check current requirements for relay coil and be sure to install...

Page 44: ...t using the Diagnostics Display Menu press HOME MORE CONFIGURATION A D This should bring up the screen shown in Figure 2 14 The default setting is shown as UPS This means the input is ready to be used...

Page 45: ...set for 2 5kW via software in the Diagnostics Display System However if the transmitter is operating in LOW power when the UPS mode is activated then the transmitter will stay at the LOW power level...

Page 46: ...See Figure 2 16 Automatic Mode When AUTO mode is selected the transmitter will automati cally optimize the efficiency every 12 hours if there are no active faults present This is the recommended mode...

Page 47: ...or a complete listing of all configurable parameters see System Configuration and Calibration in Section VI Troubleshooting Figure 2 18 Low Power Alarm Set Screen 2 9 Jumper Settings for Installation...

Page 48: ...2 28 888 2408 002 WARNING Disconnect primary power prior to servicing Installation Initial Turn On Table 2 1 TB1 Remote Control Interface Connections...

Page 49: ...888 2408 002 2 29 WARNING Disconnect primary power prior to servicing Installation Initial Turn On Table 2 1 TB1 Remote Control Interface Connections continued...

Page 50: ...2 30 888 2408 002 WARNING Disconnect primary power prior to servicing Installation Initial Turn On Table 2 2 Jumper Setting for installation of a Harris Exciter...

Page 51: ...r transmitter Transformers and motors can be designed with extra safety features where thermal rise is limited to acceptable levels however in this case other transmitter parameters cannot be made acc...

Page 52: ...ory operation of the overall transmitter may result For this reason along with their inherent susceptibility to transients Harris does not recommend the use of open delta systems Figure 2 19 Closed De...

Page 53: ...gs will It has been reported by engineers that installation of a third transformer and transient protection devices have eliminated the difficulty 2 10 5 Three Phase Wye Distribution Transformers The...

Page 54: ...ilable with this configuration In summary both symmetrical power distribution systems are satisfactory because of their balanced impedances Use either a closed delta or a four wire WYE system for maxi...

Page 55: ...rmal operational procedures and information pertaining to the function of the Platinum Z5 Transmitter Most important is the information regarding use of the Diagnostic System All of the information in...

Page 56: ...the foldback is gone ON LOW Turns the transmitter on to the previous LOW setting If the transmitter has folded back power automatically due for instance to high VSWR pressing the LOW button will retur...

Page 57: ...of measure for the forward power reading is percentage with 100 representing the nominal power output for the station This percentage can be calibrated to any power level using the Configuration contr...

Page 58: ...ing labeled Diagnostics Display Menu Tree is included in the schematic package This drawing shows all of the menus and screens available in the Diagnostic display system Note that the drawings are div...

Page 59: ...is the first of two screens in this layer The second screen in the HOME layer is accessed by pressing the D function key to the right of the display which is labelled MORE on the display The screen sh...

Page 60: ...nly two screens Figure 3 5 Status Layer 2 Page 1 3 4 3 MORE MORE is a menu item which is used when there are more menu items on a layer than will fit on one screen It will take you to the next screen...

Page 61: ...e 3 6 PA Temperature Metering HOME METERING C A C Example 2 You want to check or possibly change the Maximum High Power Setting This falls under the category of CONFIGURATION but this menu item only s...

Page 62: ...t in the Main Menu Pressing Fault will take you to the screen shown in Figure 3 8 This screen gives you a choice of resetting the transmitter faults and fault log and clearing any red indicators or vi...

Page 63: ...A should be taken out turned over and re inserted placing the bad PA in a different foursome For example if PA amplifiers B1 and B2 have failed pull out the A2 B2 PA module turn it over and plug it ba...

Page 64: ...ss HOME STATUS D C This will bring up the screen shown in Figure 3 10 Pressing D will toggle between the two exciters Figure 3 10 Exciter Status Screen HOME STATUS D C 3 7 Manual IPA Switching The act...

Page 65: ...Figure 3 12 Automatic Mode When AUTO mode is selected the transmitter will automati cally optimize the efficiency every 12 hours if there are not faults present This is the recommended mode of operat...

Page 66: ...ease transmitter efficiency However if any fault occurs the fan will automatically switch to high speed until the fault is no longer active The fan can also be forced to HIGH speed using the configura...

Page 67: ...shown on this diagram is the control and monitoring associated with the advanced Controller and Diagnostics system 4 2 1 Exciters It starts with the built in dual exciter option in other words the sw...

Page 68: ...4 2 888 2408 002 WARNING Disconnect primary power prior to servicing Overall System Theory Figure 4 1 RF System Block Diagram...

Page 69: ...s provides the necessary 8 drive signal for the 8 PAs connected to Z Plane A The PAs are labeled A1 A8 for Z Plane A and B1 B8 for Z Plane B PAs 1 4 on each Z Plane are located in the front of the tra...

Page 70: ...g paragraphs 4 3 1 Exciter Operation The exciter output is basically fixed and should not require adjustment The exciter power output is set using the controls on the front of the exciter and should b...

Page 71: ...IPA Power Output The power output of the IPA determines the power output of the transmitter and is varied by changing the gate bias on the IPA amplifiers MOSFETs The gate bias for the IPA is adjusted...

Page 72: ...t relay K2 If EXCITER SELECT goes high K1 will be energized and switches to the Exciter 2 RF output This switching will take place automatically if an exciter fault is detected by the Master Controlle...

Page 73: ...he screen in Figure 4 3 Pressing the D function key will now toggle K2 and K3 switching from IPA_AB1 to IPA_AB2 or vise versa 4 3 3 3 IPA Monitoring The IPA Backplane Board provides for monitoring and...

Page 74: ...s gives the controller time to shut off the IPAs via the IPA gate voltage IPA1_GATE so that the connector contacts do not arc 4 3 3 6 IPA Power Divider 3dB Hybrid The IPA power divider is actually a 3...

Page 75: ...t on an output the Wilkinson circuit and the load resistors act to keep the input impedance of the splitter near the nominal value of 50 ohms Each output from each 8 Way Divider is fed to the input of...

Page 76: ...r 4 3 4 4 Power Amplifier PA See Figure 4 4 The RF drive from the IPA enters the PA Amplifier Boards at Pin C The RF input level for each amplifier is typically 15 20 watts TL1 C1 and C2 allow the inp...

Page 77: ...x without the need for a blocking capacitor Maximum RF output is 425 watts Typical output level is 300 to 340 watts The power module is designed for single amplifier field replacement In the event an...

Page 78: ...002 WARNING Disconnect primary power prior to servicing Overall System Theory Figure 4 5 PA Compartment Front View Figure 4 6 PA Compartment Rear View A1 A2 A3 A4 IPA_AB1 IPA_AB2 B1 B2 B3 B4 B5 B6 B7...

Page 79: ...in the ratings of the modules The effects are minimized by the 2 way combiner and its isolation resistor which will tend to absorb imbalances and by the characteristics of the 3dB hybrid combiner whic...

Page 80: ...forward output power and one coupler arranged to provide a sample of the reflected output power The isolation or directivity of the couplers is better than 30dB with 40dB typical NOTE Note that the re...

Page 81: ...lly The 3 Phase 3 wire and 4 wire supplies have all of the same components but have a different wiring harness The PA power supplies whether 3 Phase or Single Phase are regulated by reliable tap switc...

Page 82: ...he 16 PAs Four of these are on Z Plane A and four on Z Plane B Therefore PS 2 provides power for the remaining 8 PAs There is only one PS Controller for both supplies however each supply still operate...

Page 83: ...charge Circuit 4 4 1 1 1 PA Power Supply Discharge The PA Power Supply Discharge circuit also uses the Soft Start resistor to discharge the 52Vdc PA supply The discharge circuit is activated when the...

Page 84: ...secondary windings has 4 output taps each of which are connected through an SCR to ground The SCRs act as both tap switches activating the tap which gives the appropriate DC voltage output and as rec...

Page 85: ...ter the 6 second soft start the resistor is bypassed by activating the normal run mode SCRs which are also attached to the lowest voltage output tap but connect directly to ground This allows the supp...

Page 86: ...AC contactor 4 5 Detailed Power Supply Descriptions 4 5 1 3 Phase PA Power Supply Refer to the Overall System Block Diagram in the schematic package for the following discussion The transmitter 3 pha...

Page 87: ...888 2408 002 4 21 WARNING Disconnect primary power prior to servicing Overall System Theory Figure 4 11 3 Phase Power Supply Simplified Diagram of Transformer and Rectifier Connections...

Page 88: ...ere originally made as one board which is broken apart for assembly Therefore there is an A side and a B side both of which are shown on the same schematic The left side of the schematic is the B side...

Page 89: ...forward biases diodes CR4 CR8 and CR12 on the B side and CR13 CR17 and CR21 on the A side This turns on the associated SCRs Q4 Q8 and Q12 for the B side and Q13 Q17 and Q21 on the A side Each of the...

Page 90: ...ly and Soft Start from being activated while the DISCHARGE signal is active b Second it allows the base of Q37 to pull high shutting it off R62 will then pull the gates of Q29 and Q31 low turning them...

Page 91: ...lation approximately 2Vdc change per tap to compensate for AC line variations 4 5 2 1 Rectifier Board The SCRs for the single phase are required to carry a much larger amount of current than the 3 Pha...

Page 92: ...tivates SCRs for 48V tap J4 3 DRIVER 2 activates SCRs for 50V tap J4 5 DRIVER 3 activates SCRs for 52V tap J4 7 DRIVER 4 activates SCRs for 54V tap NOTE The circuit for the 48V tap will be explained h...

Page 93: ...al is active low and comes from the PS Controller Board When low it causes the output of U2 14 to go high This does two things a First it reverse biases CR31 which allows the gate of Q33 to pull high...

Page 94: ...proper reporting to the Master Controller The PS Controller will not allow 2 IDs to be the same The jumper configurations are given below These jumpers are located on the Rectifier Boards on both the...

Page 95: ...e active low FAN_SPEED_SELECT signal from the Life Support Board A19K3 activates the fan speed select relay K2 mounted next to the AC mains contactor on the cabinet wall K2 is shown on the Overall Sys...

Page 96: ...e firmware The Controller consists of the following boards Master Controller Board PA Controller 1 PA Controller 2 Power Supply Controller 1 Power Supply Controller 2 Optional Life Support Board Displ...

Page 97: ...EEPROM U39 The Master Controller has 3 memories ROM firmware RAM volatile and an EEPROM non volatile U39 When the low voltage is applied to the controller it loads up the program from ROM to RAM and...

Page 98: ...l be reduced which will in turn reduce the PA RF output If the forward power output goes down the IPA RF output will be increased which will increase the PA RF output to compensate The APC loop starts...

Page 99: ...al if there are no System Mutes present Due to the low impedance of the circuit the Manual PWR REF pot R25 has little or no effect on the circuit CR4 and R30 shift the positive APC voltage to a propor...

Page 100: ...fe Support Power Level CAUTION IN LIFE SUPPORT MODE THERE IS LIMITED OVERLOAD PROTECTION AND NO FOLDBACK FUNCTIONS ADJUSTING R25 TO MORE THAN 25 RATED POWER WILL CAUSE THE TRANSMITTER TO SHUT OFF AND...

Page 101: ...press C The edit controls should now show up on the screen CAUTION ENTERING A WRONG VALUE IN ONE OF THESE SCREENS COULD CAUSE SERIOUS DAMAGE TO THE TRANSMITTER OR EXTERNAL SYSTEMS IT IS RECOMMENDED T...

Page 102: ...PWR CAL screen to 5kW and calibrating we are telling the micro that 806 represents 5kW The micro now calculates the Forward Factor by dividing the 5kW by the square of 806 or Forward Factor FWD PWR CA...

Page 103: ...C_Factor The Operating APC Factor is frequency compensated based on the slope of the coupler output and is the factor calculated above If the transmitter is operating at the same frequency at which it...

Page 104: ..._MAX UPS SET kW APC_Factor DAC_MAX HOME MORE CONFIGURATION C B is the display variable which will contain one of the above numbers depending on which mode the transmitter is in Once these are set the...

Page 105: ...ed on the Master Controller and then A D converted in the micro for metering This A D value shows up as A D_RFL_PWR HOME MORE CONFIGURATION C B which at 2 1V should be very close to 700 the A D conver...

Page 106: ...e input to the open loop gain differential amplifer U7 13 is the calibrated voltage from the reflected coupler from Life Support Board As long as there is little or no reflected power the voltage at U...

Page 107: ...ond timer is started b Strike 2 If another fault is detected before the 10 seconds is up the transmit ter will again mute for 3 or 6 seconds start the 10 second timer again and slowly ramp the power u...

Page 108: ...hes located on the isolation boards which are associated with the PAs under its control Crossover protection the ability to mute the PAs which are controlled by the other PA Controller Board in case o...

Page 109: ...s a temperature sensor on each PA which sends a tem perature sample voltage to one of the PA Controllers The temperature of each individual PA can be checked by pressing METERING C A then C or D to ch...

Page 110: ...e loss of one power supply will create the same scenario as loss of one PA Controller the loss of 2 PA per foursome 4 7 4 4 PA Controller Faults For a complete listing of the faults associated with th...

Page 111: ...ded the contactor has been activated and the Master Controller is operating normally This will first activate the SOFT_START outputs at J1 8 and J2 8 This allows the supplies to charge slowly limiting...

Page 112: ...plies are fully active again or shut off by the PS_DISABLE signal 4 7 5 4 Discharge Protection Circuit The discharge protection circuit protects the power supply and the discharge circuit components f...

Page 113: ...ng However they are also digitally filtered by the micro by two filters The first is a 50 to 60 HZ band pass filter whose output is used to detect a loss of a rectifier fuse on the transformer seconda...

Page 114: ...connects via AND gates all signals from the Master Controller and allows the transmitter to stay on the air at 1 4 power with minimal fault protection and no visible monitoring for the operator Transm...

Page 115: ...e must be a closed connection between J4 10 and J4 7 GND on the Life Support Board or between TB1 7 and TB1 6 on the Remote Control Interface terminal strip This will activate the optical isolator U24...

Page 116: ...g the trans mitter to turn on In summary the signal at U33 12 CONTACTOR_ON BAR will not allow a second turn on pulse to be deliv ered while the transmitter is still running and in Life Support Mode b...

Page 117: ...there is a jumper from TB1 8 to TB1 10 ground b It can also be connected directly to the Life Support Board to J4 7 and J4 8 Be very careful when connecting to these terminals The pressure necessary t...

Page 118: ...to relay K1 13 as the exciter mute and to inverter U13 7 as an IPA mute a Exciter Mute K1 directs the mute signals SOFTSTART MUTE and SYSTEM_MUTE to the on air exciter K1 is shown in the RESET or Exc...

Page 119: ...F output Exciter switching is done by latching relay K1 EXCITER1_SELECT is a pulsed signal which will go high to select exciter 1 This will make U12 8 high if the Master Controller is working MSTR_NOR...

Page 120: ...e IPA output level The IPA output level is controlled by the signal MSTR_IPA_CTL which is an analog voltage variable DC which will control the IPA gate voltage Varying the gate voltage will vary the I...

Page 121: ...If the coupler is connected the line is pulled low and no fault occurs When disconnected the line will pull high and the Master Controller will mute the transmitter 4 7 6 1 10Reflected Power The refle...

Page 122: ...PA control signal to the active IPA When the Master Controller fails MASTER_NORMAL will go low opening the U5 13 switch The MANUAL PWR REF pot R25 now controls the transmitter power output This is fac...

Page 123: ...e exciters K1 applies AC to the contactor coil while K2 applies AC to the exciters 2 The high at U26 13 enables the XMTR_ON_LOW pushbutton on the front panel overlay when in Life Support Mode to enabl...

Page 124: ...Life Support Mode It is cleared by the MASTER_NORMAL BAR signal when the Master Controller is opera tional The Master Controller normally takes care of this function via the SYSTEM_MUTE line d MASTER_...

Page 125: ...the MASTER_NORMAL line This line will be high only if the Master Controller has failed which is the case here for Life Support Mode Therefore the LS_SYST_FAULT will cause U6 3 to go high Next OR gates...

Page 126: ...PAC 1 This cross numbering is due to the fact that Z Plane B is inverted compared to Z Plane A The seventh column is actually the intermediate step between the PAs and the PA Controllers and gives the...

Page 127: ...lethal voltages are shielded behind doors or clear lexan shields which require a tool to be opened Shut off all power before servicing the transmitter other than replacement of modules The Front and r...

Page 128: ...information to be recorded and analyzed to provide a database for a failure reporting system is as follows DISCREPANCY Describe the nature of the malfunction Include all observable symptoms and perfor...

Page 129: ...mperature Monitoring press METERING C A then select the desired Z Plane Keeping a regular log of the PA temperatures versus Ambient temperature will give a quick indication of a possible problem or th...

Page 130: ...hut off the transmitter and disconnect primary power at the wall breaker Remove a PA module to allow access to the Z Plane connectors Connect the common lead of the meter to the chassis and check pins...

Page 131: ...Log the abort screen will read VSWR high During the test the HIGH ON and LOW ON buttons will not work The test can be started at any time and any power level above 50 If a fault is detected during th...

Page 132: ...he Z5 one for each Z Plane The boards are mounted on each side of the 5kW power block 5 5 1 1 Isolation Board Removal a There are 2 ribbon cables connecting to each Isolation assembly The cables shoul...

Page 133: ...with the thermistor already attached as this is very critical to proper transmitter operation 5 5 1 3 Installation of Isolation Assembly If a new Isolation Board is being installed be sure to set the...

Page 134: ...le which attaches to it NOTE The directional couplers are held in place on the harmonic filter with 2 hose clamps Be sure to place the clamps as far toward the edge of the coupler body as possible and...

Page 135: ...g the Raise and Lower buttons STEP 2 To enter a new MAX HIGH setting go to the MAX HIGH SET screen HOME MORE CONFIGURATION B B change to the new maximum power level and press BACK to save the changes...

Page 136: ...TPO as well MAX HIGH sets the maximum power level when the HIGH ON button is pressed while MAX LOW sets the maximum power level when the LOW ON button is pressed 5 10 Setting Life Support Power Level...

Page 137: ...ard Power Calibration procedure requires an external power meter to be used as the calibration reference STEP 1 Shut the transmitter off Press HOME MORE CONFIGURATION D and set your operating frequenc...

Page 138: ...MORE CONFIGURATION C A D C STEP 6 Set R127 on the Life Support Board maximum CW STEP 7 Turn the transmitter on Make sure the exciter power is on and un muted STEP 8 Press HOME MORE CONFIGURATION C B T...

Page 139: ...left of the display to calibrate the FWD power and save the new information The display will flash Calibration Done very quickly at the bottom of the Diagnostics Display The external meter and the FWD...

Page 140: ...the VSWR Foldback screen Set the VSWR FOLDBACK to 1 49 Press BACK to save the settings STEP 4 Press HOME MORE CONFIGURATION C A B Set the value of REFLECT FACTOR to 0 000306 see Figure 5 7 To access t...

Page 141: ...djust R128 until the A D RFL PWR reading is 700 Go slowly the adjustment is sensitive Figure 5 8 A D RFL PWR Screen HOME MORE CONFIGURATION C B STEP 9 Set the Transmitter LCD meter the right hand disp...

Page 142: ...PC BOARDS OR IC S TO PREVENT DAMAGE TO THE COMPONENTS 5 13 1 Replacement of the Life Support Board If the Life Support Board is replaced the following procedure should be performed STEP 1 Turn off the...

Page 143: ...eration in Life Support Mode Adjust R24 on the Life Support Board for 2 1Vdc at U3 5 This sets the fault threshold to 150 Watts of reflected power when Life Support Mode is active STEP 10 Set R127 Max...

Page 144: ...pins 1 2 d JP2 pins 1 2 5 13 3 Replacing a PA Controller Board Replacement of a PA Controller Board requires no analog adjustments Set all dip switches and jumpers to the same position as the board be...

Page 145: ...ower from the transmitter STEP 2 Remove the defective Master Controller Board STEP 3 Carefully remove U39 from the new Master Controller Board and replace with the EEPROM from the defective Master STE...

Page 146: ...only the EEPROM U39 is being replaced then exchange U39 with the new one re install the Master Controller Board and skip to STEP 6 If the Master Controller Board is also being replaced then proceed w...

Page 147: ...should appear on the screen STEP 8 Press the HIGH ON button and then quickly press and hold the LOWER button for 10 seconds This will turn the transmitter on at zero power output STEP 9 Proceed to 5 1...

Page 148: ...ut with AC power applied from the wall breaker The REMOTE DISABLED LED should be lit on the front panel of the transmitter For the following setup refer to the Diagnostics Display Menu Tree for more d...

Page 149: ...n kW which is to be displayed as 100 on the FWD PWR meter Default is 05 00KW b MAX HIGH SET This screen will let you set the upper limit the transmitter will be allowed to go to in the High Mode of op...

Page 150: ...Firmware ICs Each of the controller boards with the exception of the Life Support Board have 2 Firmware IC s which contain the software for the microcontrollers It is possible that these may need to...

Page 151: ...rers do make a special extraction tool for these type of IC s but it has been found that a sharp meter lead or ice pick actually works better for extracting them Place the sharp tool point into one of...

Page 152: ...5 26 888 2408 002 WARNING Disconnect primary power prior to servicing Maintenance and Alignment Table 5 2 Z5 Minimum Recommended Transmitter Log Readings...

Page 153: ...omponent level troubleshooting is not an option But due to the complexity of the circuitry and the use of surface mount components especially in the controller boards which are multi layer boards as w...

Page 154: ...TS NATURE AND OF THE NECESSARY SAFETY PRECAUTIONS AFTER USE DISPOSE OF AS CHEMICAL OR SPECIAL WASTE ACCORDING TO THE REGULATIONS APPLY ING AT THE LOCATION OF THE USER IT MUST NEVER BE THROWN OUT WITH...

Page 155: ...re are still 2 failed PAs B1 and A2 but now each one is in a different foursome This will restore balance to the system and the transmitter will still be able to operate at near full power output by a...

Page 156: ...r will issue the TX_RESTART command and try to return the transmitter to normal operation after any fault has occurred Note that this will not reset or erase any of the faults stored in the Fault Log...

Page 157: ...p again Strike 3 A third fault detected within this 10 seconds will cause the transmitter to be muted until the operator gives the transmitter an ON command High or Low locally or by remote If the cau...

Page 158: ...the display and ABCD to the right To avoid confusion every line from one screen to the next is labelled A B C or D where it leaves a screen to correspond with the keypress required on the actual disp...

Page 159: ...t Reset Note the warning asking if you really want to erase the faults in the log just in case this screen was reached by accident Pressing YES D will erase any of the faults in the Fault Log which ar...

Page 160: ...Table 6 5 provide a quick reference containing a complete listing of all of the faults which can show up on the Diagnostics Display Menu including their effect on transmitter operation and a brief com...

Page 161: ...educe the transmitter power to 40 of nameplate TPO 2kW and will be going through a MUTE cycle for each of the 16 PAs The antenna VSWR must be 1 2 1 or less with no faults present in order to run the t...

Page 162: ...e Z Planes or Isolation Boards The following sequence of tests make up the SYSTEM TEST PA Muting Test PA ISO Resistor and Thermistor Test PA RF Switch Test 6 7 1 1 PA Muting Test Each PA will be muted...

Page 163: ...e PA may be failed since the switch is grounding the its output A normal PA current would rule this out c The ISO resistor is open which means it would not draw any current and would not get hot These...

Page 164: ...r if the Master Controller needs to be replaced If it fails the test U39 will have to be replaced and a complete System Configuration and Calibration will have to be done per the procedure in Section...

Page 165: ...eens can be extremely helpful in determining where to start looking for the source of the fault This screen will only show a YES status if the front panel FOLDBACK LED is illuminated 6 8 2 Turning the...

Page 166: ...ircuit becomes open the detector input goes high which gives a cold temperature reading This leaves the device to which the thermistor is connected unprotected from an over temperature condition Once...

Page 167: ...considered to be invalid or out of tolerance and was replaced with a Default value from the firmware prom This fault is an indication that the EEPROM U39 should be replaced Refer to Section V Mainten...

Page 168: ...wer level while staying below the foldback threshold The Foldback light on the front of the controller will be illuminated The VSWR Fault threshold is set via software in the Diagnostics Display Menu...

Page 169: ...n the AC power returns no operator intervention required 6 9 9 LOW_AIR Fault Nominal air flow for the Z5 is 350 cfm The aiflow reading should be near 100 at high fan speed and is typically around 60 f...

Page 170: ...e current is not less than 1 amp then the system does not have the ability to shut off the IPA and will mute the system by shutting off the PAs and the exciter 6 9 13 IPA_AB _LOW Power Fault If one of...

Page 171: ...o the fault condition All power supply meter readings will be replaced with an asterisk 6 9 20 PAC _COMM Fault This is a communications fault between one of the PA Controllers and the Master Controlle...

Page 172: ...temperature goes below 115 C the foldback will be reversed and the power will be very slowly increased until the power output is back to normal or until the load temperature again rises to 115 C at wh...

Page 173: ...n the fault log and on the front panel fault light Action will not be taken until an exciter low power condition is detected The controller will delay 10 seconds to give the exciter time to recover th...

Page 174: ...eference of these faults is given in Table 6 4 on page 6 37 6 11 1 General PA Troubleshooting As a general rule the first step in troubleshooting any PA or IPA problem is to swap the PA or the entire...

Page 175: ...at is less than 10 of the average current of the other three the system will be muted for 120mS the isolation switch for that PA activated removing the PA from the combiner and the mute released on th...

Page 176: ...de of the PA Normally the ISO resistors have minimal current flow through them and run about 40 100 C If the amplifier connected to the ISO resistor has a difference in phasing or amplitude compared t...

Page 177: ...led down then it is probably a failure of the RF Switch To locate the correct RF Switch and or ISO Load get the A or B _ISO there should also be one of these in the Fault Log fault number and use Tabl...

Page 178: ...will protect the system if the Master Controller is not operational or if the foldback routine fails to reduce the load temperature The foldback description is in the Master Controller Faults under Sy...

Page 179: ...ontroller at J1 J2 J11 and J12 J1 and J2 connect to the Isolation Boards while J11 and J12 connect to the Z Planes The PA Controller boards have ID jumpers to select the board as PA Controller 1 or PA...

Page 180: ...only other easy troubleshooting would be to swap out the controller card if a spare is available This also requires setting the ID switches on the new PS Controller board to the same as the one being...

Page 181: ...rt Discharge resistor or failed SCRs and or SCR fuses 6 12 2 2 PS _HS_TEMP Rectifier Heatsink Temperature There is a thermistor temperature sensor mounted on each of the rectifier heat sinks on top of...

Page 182: ...ault is not used in the single phase transmitter It is also important to note that there could be several other faults show up as a result of a phase loss PAC _VOLTS IPA_LOW EXC _AFC These faults are...

Page 183: ...oking at the DC input voltage data from the PA Power Supply 52Vdc It is interpreted as an indication of a transformer secondary fault which could be a fuse or SCR If one of the taps has been detected...

Page 184: ...Fuses TAP 1 48V Q13 F13 Q4 F4 CR4 F4 Q17 F17 Q8 F8 CR8 F8 Q21 F21 Q12 F12 TAP 2 50V Q14 F14 Q3 F3 CR3 F3 Q18 F18 Q7 F7 CR7 F7 Q22 F22 Q11 F11 TAP 3 52V Q15 F15 Q2 F2 CR2 F2 Q19 F19 Q6 F6 CR6 F6 Q23 F...

Page 185: ...888 2408 002 6 33 WARNING Disconnect primary power prior to servicing Troubleshooting Figure 6 7 3 Phase Power Supply Component Locator Top View...

Page 186: ...6 34 888 2408 002 WARNING Disconnect primary power prior to servicing Troubleshooting Figure 6 8 Single Phase Power Supply Rectifier Assembly Component Locator Top View...

Page 187: ...AC power supply failed 20V power supply on Life Support Board is less than 12V Mute XMTR save fault time Transmitter will automatically return to operation when power returns LOW_AIR Low air flow fau...

Page 188: ...lt PAC1_COMM Communication lost between Master and the PA controller Request another controller to mute ISO_AB Reject Load ISO_AB on the 3dB hybrid is 145o C Will follow 3 Strike Routine described in...

Page 189: ...nd release the mute on the rest of the amplifiers A _OUT B _OUT The designated PA is not properly seated in the connector Make sure the module is properly inserted and the thumbscrews on the PA module...

Page 190: ...OAB Designated ISO load Temp 145o C Means ISO_APC foldback has failed to reduce temperature of the load Fold back level is 135 o C NOTE This is the load on the 5kW 3dB hybrid which is combining the Z...

Page 191: ..._TAP1 Tap 1 failed One or more of the secondary SCRs for the 48V tap have failed on the designated Power Supply Tap1 fault indication PSC will automatically switch to Tap2 if it is not faulted If Tap2...

Page 192: ...6 40 888 2408 002 WARNING Disconnect primary power prior to servicing Troubleshooting...

Page 193: ...888 2408 002 7 1 WARNING Disconnect primary power prior to servicing Parts List 7 1 Part List Index...

Page 194: ...7 2 888 2408 002 WARNING Disconnect primary power prior to servicing Parts List...

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