FAX 5/10/20/30/40KW Transmitter Series

FAX 5/10/20/30/40KW Transmitter Series
TECHNICAL MANUAL
FAX 5/10/20/30/40KW
Transmitter Series
Revision J
888-2720-001
Harris Broadcast is an independent company not affiliated with Harris Corporation.
TECHNICAL MANUAL
888-2720-001
Flexiva™ FAX 5/10/20/30/40K
Transmitter Series
© Copyright Harris Broadcast 2013
All rights reserved
October 28, 2013
Rev J
Harris Broadcast
9800 S Meridian Blvd, Ste 300
Englewood, CO 80112 U.S.A
Copyright ©2013, Harris Broadcast. Proprietary and Confidential.
This document and its contents are considered proprietary and confidential by Harris
Broadcast. This publication, or any part thereof, may not be reproduced in any form,
by any method, for any purpose, or in any language other than English without the
written consent of Harris Broadcast. A reasonable number of copies of this document
may be made for internal use only. All others uses are illegal.
This publication is designed to assist in the use of the product as it exists on the date
of publication of this manual, and may not reflect the product at the current time or an
unknown time in the future. This publication does not in any way warrant description
accuracy or guarantee the use for the product to which it refers.
Harris Broadcast reserves the right, without notice to make such changes in
equipment, design, specifications, components, or documentation as progress may
warrant to improve the performance of the product.
Harris Broadcast is an independent company not affiliated with Harris Corporation.
Trademarks
Flexiva and Maxiva are trademarks of Harris Broadcast or its subsidiaries.
Microsoft® and Windows® are registered trademarks of Microsoft Corporation.
All other trademarks and trade names are the property of their respective companies.
Support Contact Information
For domestic and international support contact information, See:
•
Support Contacts: http://harrisbroadcast.com/support
•
eCustomer Portal: http://support.harrisbroadcast.com
WARNING: Disconnect primary power prior to servicing.
Manual Revision History
Flexiva FAX 5/10/20/30/40kW Transmitter Series
REV.
DATE
ECN
Pages Affected / Description
Preliminary
Feb 2011
B
April 9, 2012
P52641
Update all sections
C
May 23, 2012
P52961
Added 30/40kW models, general updates in all sections
D
Aug 23, 2012
P53607
Updates to all sections
E
Feb 18, 2013
P54586
Updates to all sections
F
Mar 05, 2013
P54684
Update Title Page, MRH-1 and Section-1
H
May 01, 2013
P54930
Updates to all sections
J
Oct 28, 2013
P55668
Full Revision with new software GUI
Preliminary - in process
MRH-1
WARNING: Disconnect primary power prior to servicing.
Technical Assistance
Technical and troubleshooting assistance for Harris Broadcast products is available from the field service department during normal business hours 8:00AM to 5:00PM CST. Telephone +1‐217‐222‐8200, FAX +1‐217‐221‐7086, email tsupport@harrisbroadcast.com.
Emergency service is available 24 hours a day, seven days a week, by telephone only.
Online assistance, including technical manuals, software downloads, and service bulletins, is available at http://www.harrisbroadcast.com/servicesandsupport/default.asp. Address written correspondence to Field Service Dept. Harris Broadcast P.O. Box 4290 Quincy, IL 62305‐4290, USA. For global service contact information, visit: http://www.harrisbroadcast.com/contactus.
NOTE: For all service and parts correspondence, please provide the sales order number, as well as the serial number for the transmitter or part in question. Record those numbers here:
___________________________________/___________________________________
Provide these numbers for any written request, or have these numbers ready in the event you choose to call regarding any service or parts requests. For warranty claims it will be required. For out of warranty products, this will help us identify what hardware shipped.
Replaceable Parts Service
The service parts department is available from 7:00AM to 5:00 PM CST Monday ‐ Friday, and 8:00AM to 12:00PM CST on Saturday. Telephone +1‐217‐221‐7500 or email servicepartsreq@harrisbroadcast.com.
Emergency parts are available 24 hours a day, seven days a week, by telephone only.
Unpacking
Carefully unpack the equipment and perform a visual inspection to determine if any damage was incurred during shipment. Retain the shipping materials until it has been verified that all equipment has been received undamaged. Locate and retain 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, straps, and packing materials prior to initial turn on.
Returns And Exchanges
No equipment can be returned unless written approval and a return authorization is received from Harris Broadcast. Special shipping instructions and coding will be provided to assure proper handling. Complete details regarding circumstances and reasons for return are to be included in the request for return. Custom equipment or special order equipment is not returnable. In those instances where return or exchange of equipment is at the request of the customer, or convenience of the customer, a restocking fee will be charged. All returns will be sent freight prepaid and properly insured by the customer. When communicating with Harris Broadcast, specify the Harris Broadcast order number or invoice number.
WARNING: Disconnect primary power prior to servicing.
WARNING: Disconnect primary power prior to servicing.
Item
______________________________
Quantity
Part Number
________________________________
______________________________
Ref Des
e.g. C21,
R100, etc.
Item Used On Assembly if Known e.g.
C21 used on 992-8025-001
& Schematic 839-8038-991
Comments
Guide for Ordering Parts: Please provide as much information as possible to facilitate part
substitution as required. Equipment name, part number and serial number is found on a metal
ID plate on the rear of the unit. Describe the unit using the parts list if possible. Include
schematic information, schematic number, or number of next higher assembly. The next higher
assembly usually has a part number that begins with a 9xx-xxxx-xxx.
Shipping Method : ________________________
Preferred
FAX:
Telephone: ______________________________
________________________________
________________________________
________________________________
Address: ________________________________
Description of Part Part’s Name, Description, and
Specification from Parts List
Equipment Serial Number:___________________
Equipment Part Number:____________________
Frequency & Channel: ______________________
Payment Method : ________________________
Preferred
FAX:
Telephone: ______________________________
________________________________
________________________________
________________________________
Address: ________________________________
Shipping Information
Phone: 217-22-00
FAX: 217-221-70
Ship To (If different from billing information):
PARTS ORDER FORM
Billing Information
Customer Name: ________________________
Harris Broadcast
PO Box 4290
3200 Wismann Lane 62305
!
WARNING:
THE CURRENTS AND VOLTAGES IN THIS EQUIPMENT ARE DANGEROUS. PER‐
SONNEL MUST AT ALL TIMES OBSERVE SAFETY WARNINGS, INSTRUCTIONS AND REGULATIONS.
This manual is intended as a general guide for trained and qualified personnel who are aware of the dangers inherent in handling potentially hazardous electrical/electronic circuits. It is not intended to contain a complete statement of all safety precautions which should be observed by personnel in using this or other electronic equipment.
The installation, operation, maintenance and service of this equipment involves risks both to personnel and equipment, and must be performed only by qualified personnel exercising due care. Harris Broadcast shall not be responsible for injury or damage resulting from improper procedures or from the use of improperly trained or inexperienced personnel performing such tasks. During installation and operation of this equipment, local building codes and fire protection standards must be observed.
The following National Fire Protection Association (NFPA) standards are recommended as reference:
‐ Automatic Fire Detectors, No. 72E
‐ Installation, Maintenance, and Use of Portable Fire Extinguishers, No. 10
‐ Halogenated Fire Extinguishing Agent Systems, No. 12A
!
WARNING:
ALWAYS DISCONNECT POWER BEFORE OPENING COVERS, DOORS, ENCLO‐
SURES, GATES, PANELS OR SHIELDS. ALWAYS USE GROUNDING STICKS AND SHORT OUT HIGH VOLTAGE POINTS BEFORE SERVICING. NEVER MAKE INTER‐
NAL ADJUSTMENTS, PERFORM MAINTENANCE OR SERVICE WHEN ALONE OR WHEN FATIGUED.
Do not remove, short‐circuit or tamper with interlock switches on access covers, doors, enclosures, gates, panels or shields. Keep away from live circuits, know your equipment and don’t take chances.
!
WARNING:
IN CASE OF EMERGENCY ENSURE THAT POWER HAS BEEN DISCONNECTED.
IF OIL FILLED OR ELECTROLYTIC CAPACITORS ARE UTILIZED IN YOUR EQUIPMENT, AND IF A LEAK OR BULGE IS APPARENT ON THE CAPACITOR CASE WHEN THE UNIT IS OPENED FOR SERVICE OR MAINTENANCE, ALLOW THE UNIT TO COOL DOWN BEFORE ATTEMPTING TO REMOVE THE DEFECTIVE CAPACITOR. DO NOT ATTEMPT TO SERVICE A DEFECTIVE CAPACITOR WHILE IT IS HOT DUE TO THE POSSIBILITY OF A CASE RUPTURE AND SUBSEQUENT INJURY.
WARNING: Disconnect primary power prior to servicing.
WARNING: Disconnect primary power prior to servicing.
FIRST‐AID
Personnel engaged in the installation, operation, maintenance or servicing of this equipment are urged to become familiar with first‐aid theory and practices. The following information is not intended to be complete first‐aid procedures, it is a brief and is only to be used as a reference. It is the duty of all personnel using the equipment to be prepared to give adequate Emergency First Aid and there by prevent avoidable loss of life.
Treatment of Electrical Burns
1. Extensive burned and broken skin
a. Cover area with clean sheet or cloth. (Cleanest available cloth article.)
b. Do not break blisters, remove tissue, remove adhered particles of clothing, or apply any salve or ointment.
c. Treat victim for shock as required.
d. Arrange transportation 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 him a weak solution of salt and soda: 1 level teaspoonful of salt and 1/2 level teaspoonful of baking soda to each quart of water (neither hot or cold). Allow victim to sip slowly about 4 ounces (a half of glass) over a period of 15 minutes. Discontinue fluid if vomiting occurs. (Do not give alcohol.)
2. Less severe burns ‐ (1st & 2nd degree)
a. Apply cool (not ice cold) compresses using the cleanest available cloth article.
b. Do not break blisters, remove tissue, remove adhered particles of clothing, or apply salve or ointment.
c. Apply clean dry dressing if necessary.
d. Treat victim for shock as required.
e. Arrange transportation to a hospital as quickly as possible.
f. If arms or legs are affected keep them elevated.
REFERENCE:
ILLINOIS HEART ASSOCIATION
AMERICAN RED CROSS STANDARD FIRST AID AND PERSONAL SAFETY MANUAL (SECOND EDITION)
WARNING: Disconnect primary power prior to servicing.
Guide to Using Parts List Information
The Replaceable Parts List Index portrays a tree structure with the major items being left most in the index. The example below shows the Transmitter as the highest item in the tree structure. If you were to look at the bill of materials table for the Transmitter you would find the Control Cabinet, the PA Cabinet, and the Output Cabinet. In the Replaceable Parts List Index the Control Cabinet, PA Cabinet, and Output Cabinet show up one indentation level below the Transmitter and implies that they are used in the Transmitter. The Controller Board is indented one level below the Control Cabinet so it will show up in the bill of material for the Control Cabinet. The tree structure of this same index is shown to the right of the table and shows indentation level versus tree structure level.
Example of Replaceable Parts List Index and equivalent tree structure:
Transmitter
995 9283 001
Replaceable Parts List Index Part Number Page Table 7‐1. Transmitter
995 9283 001 7‐2
Table 7‐2. Control Cabinet
981 9244 002 7‐3
Table 7‐3. Controller Board 901 8344 002 7‐6
Table 7‐4. PA Cabinet
981 9400 002 7‐7
Table 7‐5. PA Amplifier
971 7894 002 7‐9
Table 7‐6. PA Amplifier Board 901 7904 002 7‐10
Table 7‐7. Output Cabinet
981 9450 001 7‐12
Control Cabinet
981 9244 002
PA Cabinet
981 9400 002
Controller Board
901 8344 002
PA Amplifier
971 7894 002
Output Cabinet
981 9450 001
PA Amplifier Board
901 7904 002
The part number of the item is shown to the right of the description as is the page in the manual where the bill for that part number starts. Inside the actual tables, four main headings are used:
•
•
•
•
Table #‐#. ITEM NAME ‐ PART NUMBER ‐ this line gives the information that corresponds to the Replace‐
able Parts List Index entry;
PART NUMBER column gives the ten digit Harris Broadcast part number (usually in ascending order);
DESCRIPTION column gives a 25 character or less description of the part number;
REF. SYMBOLS/EXPLANATIONS column 1) gives the reference designators for the item (i.e., C001, R102, etc.) that corresponds to the number found in the schematics (C001 in a bill of material is equivalent to C1 on the schematic) or 2) gives added information or further explanation (i.e., “Used for 208V operation only,” or “Used for HT 10LS only,” etc.).
NOTE: Inside the individual tables some standard conventions are used:
•
•
•
A # symbol in front of a component such as #C001 under the REF. SYMBOLS/EXPLANATIONS column means that this item is used on or with C001 and is not the actual part number for C001.
In the ten digit part numbers, if the last three numbers are 000, the item is a part that has been purchased and has not manufactured or modified. If the last three numbers are other than 000, the item is either manufactured or is purchased from a vendor and modified for use in the Harris Broadcast product.
The first three digits of the ten digit part number tell which family the part number belongs to ‐ for exam‐
ple, all electrolytic (can) capacitors will be in the same family (524 xxxx 000). If an electrolytic (can) capaci‐
tor is found to have a 9xx xxxx xxx part number (a number outside of the normal family of numbers), it has probably been modified in some manner at the factory and will therefore show up farther down into the individual parts list (because each table is normally sorted in ascending order). Most Harris Broadcast made or modified assemblies will have 9xx xxxx xxx numbers associated with them.
The term “SEE HIGHER LEVEL BILL” in the description column implies that the reference designated part number will show up in a bill that is higher in the tree structure. This is often the case for components that may be frequency determinant or voltage determinant and are called out in a higher level bill structure that is more customer dependent than the bill at a lower level.
WARNING: Disconnect primary power prior to servicing.
Table of Contents
Section‐1 Introduction
Initial Turn On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐13
User Remote Control Connection . . . . . . . . . . . . . 2‐15
Purpose of This Manual . . . . . . . . . . . . . . . . . . . . . . 1‐1
Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐1
FAX Options and Spare Parts Kits . . . . . . . . . . . . . . . 1‐2
FAX5/10 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐2
FAX20 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐2
FAX30 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐3
FAX40 Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐3
Exciter Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1‐3
FAX Spare Parts Kits . . . . . . . . . . . . . . . . . . . . . . . . 1‐4
FAX Transmitter Description and Features . . . . . . . 1‐4
FAX5/10 Photos/Mechanical/Cooling/Electrical Data1‐5
FAX20 Photos/Mechanical/Cooling/Electrical Data 1‐9
FAX30 Photos/Mechanical/Cooling/Electrical Data1‐12
FAX40 Photos/Mechanical/Cooling/Electrical Data1‐15
FAX Specifications(All Models) . . . . . . . . . . . . . . . .1‐18
Selecting Location for Transmitter Placement . . .1‐19
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1‐19
Grounding Requirements . . . . . . . . . . . . . . . . . . . .1‐21
AC Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . .1‐21
Surge Suppression Devices . . . . . . . . . . . . . . . . .1‐21
Voltage Regulation . . . . . . . . . . . . . . . . . . . . . . . .1‐21
RF Line Requirements . . . . . . . . . . . . . . . . . . . . . . .1‐22
Section‐3 Operation
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐1
Controls and Indicators . . . . . . . . . . . . . . . . . . . . . . 3‐1
Front Panel Controls and Indicators. . . . . . . . . . . 3‐1
Internal Controls and Indicators . . . . . . . . . . . . . . . 3‐3
RF Sample and RTAC Ports . . . . . . . . . . . . . . . . . . 3‐5
Front Panel Operation . . . . . . . . . . . . . . . . . . . . . . . 3‐5
ON/OFF Operation. . . . . . . . . . . . . . . . . . . . . . . . . 3‐6
Power Raise/Lower Procedure . . . . . . . . . . . . . . . 3‐6
Remote Enable/Disable Buttons . . . . . . . . . . . . . 3‐6
LCD Navigation Tutorial . . . . . . . . . . . . . . . . . . . . . . 3‐7
Power Button Menu . . . . . . . . . . . . . . . . . . . . . . . . 3‐9
Status Button Menus . . . . . . . . . . . . . . . . . . . . . . . . 3‐9
STATUS >LOG Menu . . . . . . . . . . . . . . . . . . . . . . . 3‐12
STATUS>EXCITER Menu . . . . . . . . . . . . . . . . . . . . 3‐13
STATUS>Drive Chain Menu . . . . . . . . . . . . . . . . . 3‐13
STATUS>POWER AMP Menu. . . . . . . . . . . . . . . . 3‐14
STATUS>OUTPUT Menu . . . . . . . . . . . . . . . . . . . 3‐14
STATUS>POWER SUPPLIES Menu . . . . . . . . . . . . 3‐16
STATUS>SYSTEM Menu . . . . . . . . . . . . . . . . . . . . 3‐16
STATUS>>SW REVISIONS . . . . . . . . . . . . . . . . . . . 3‐17
STATUS>>TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐17
SET‐UP Button. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐18
Transmitter Setup/Configuration and Calibration 3‐20
SETUP>TX CONTROL Menu. . . . . . . . . . . . . . . . . 3‐20
SETUP>SYSTEM SETUP Menu . . . . . . . . . . . . . . . 3‐21
SETUP>TX CONFIGURATION . . . . . . . . . . . . . . . 3‐21
SETUP>TX CALIBRATE . . . . . . . . . . . . . . . . . . . . . 3‐21
SETUP>TX CALIBRATE>TX POWER CAL Menu . . 3‐21
SETUP>TX CALIBRATE>POWER SUPPLY SET. . . . 3‐22
SETUP>TX CALIBRATE>AIRFLOW SET . . . . . . . . . 3‐22
SETUP>TX CALIBRATE>PWR BLOCK CAL . . . . . . 3‐23
SETUP>TX CALIBRATE>REJ LOAD CAL. . . . . . . . . 3‐24
SETUP>TX CALIBRATE>CAL RESTORE . . . . . . . . . 3‐24
SETUP>EXCITER SETUP . . . . . . . . . . . . . . . . . . . . 3‐24
SETUP>NETWORK SETUP . . . . . . . . . . . . . . . . . . 3‐25
SETUP>DISPLAY MODE . . . . . . . . . . . . . . . . . . . . 3‐26
SETUP>RESTORE DEFAULTS. . . . . . . . . . . . . . . . . 3‐26
Remote Graphical User Interface (GUI) . . . . . . . . 3‐26
GUI HOME SCREEN . . . . . . . . . . . . . . . . . . . . . . . 3‐28
Event Log Menu . . . . . . . . . . . . . . . . . . . . . . . . . . 3‐29
System>System Setup Menu . . . . . . . . . . . . . . . 3‐30
Section‐2 Installation
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐1
Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐1
Returns and Exchanges . . . . . . . . . . . . . . . . . . . . . . . 2‐1
Transmitter Documentation . . . . . . . . . . . . . . . . . . . 2‐1
Installation and Outline Drawings. . . . . . . . . . . . . 2‐1
Personnel and Equipment Protection . . . . . . . . . . . 2‐2
Safety Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐2
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐3
Remove Shipping Materials . . . . . . . . . . . . . . . . . . 2‐3
Setting Transmitter in Place. . . . . . . . . . . . . . . . . . 2‐3
Rack Mounting FAX5/10 . . . . . . . . . . . . . . . . . . . . . 2‐4
Equipment Ground . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐5
Exciter‐Transmitter Interconnection . . . . . . . . . . . . 2‐6
Installing A Non‐Harris Broadcast Exciter . . . . . . . 2‐7
RF Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2‐9
AC Power Requirements and Connection . . . . . . . . 2‐9
AC Connection without Distribution Panel . . . .2‐10
AC Connection with Distribution Panel . . . . . . .2‐13
Cooling Installation . . . . . . . . . . . . . . . . . . . . . . . . .2‐13
1
Copyright ©2013, Harris Broadcast. Table of Contents
System>System Setup>System Service Menu. . 3‐30
System>System Setup>System Config Menu . . 3‐31
System>System Setup>Network Menu . . . . . . . 3‐31
System>System Setup>Network>SNMP Menu. 3‐32
System>System Setup>Network>NTP Menu . . 3‐32
SYSTEM>System Setup>Network>ISP Menu. . . 3‐33
Reject Load Calibration (Power/Fan Speed) FAX20/30/40 Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5‐20
Backup Control Mode Power Setting . . . . . . . . .5‐21
UPS Mode Power Setup . . . . . . . . . . . . . . . . . . . .5‐21
IPA Bypass FAX 5/10 Only . . . . . . . . . . . . . . . . . . .5‐21
Board and Assembly Replacement Procedures . .5‐22
Backplane Board Replacement . . . . . . . . . . . . . .5‐22
System Interface Control Board Replacement . .5‐23
Multi Unit System Interface Board Replacement5‐25
Control and Display Board Replacement . . . . . .5‐26
14‐Way Power Splitter Assembly Replacement . 5‐27
14‐Way Combiner Assembly Replacement . . . .5‐28
Section‐4 Theory
FAX Transmitter Configurations . . . . . . . . . . . . . . . 4‐1
10kW RF Block Diagram Description . . . . . . . . . . 4‐1
FAX5 RF Block Diagram . . . . . . . . . . . . . . . . . . . . . 4‐3
FAX20 RF Block Diagram . . . . . . . . . . . . . . . . . . . . 4‐4
FAX30 RF Block Diagram . . . . . . . . . . . . . . . . . . . . 4‐5
FAX40 RF Block Diagram . . . . . . . . . . . . . . . . . . . . 4‐6
System APC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4‐6
PA Module Description . . . . . . . . . . . . . . . . . . . . . 4‐8
Power Supply System Description . . . . . . . . . . . . 4‐9
Fan Control Board Description . . . . . . . . . . . . . . 4‐10
Front Panel Control/Display Board Description 4‐11
System Interface Control Board Description . . . 4‐12
Section‐6 Diagnostics
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐1
Troubleshooting Tables . . . . . . . . . . . . . . . . . . . . . . . 6‐1
LED Indicator Explanation . . . . . . . . . . . . . . . . . . . 6‐1
Transmitter Front Panel Controller LED Indicators6‐1
System Interface Control Module LED Indicators 6‐3
Telnet Session . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6‐6
Section‐5 Maintenance
Section‐7 Parts List
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐1
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . 5‐1
Dipswitch Settings . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐1
Transmitter Cleaning . . . . . . . . . . . . . . . . . . . . . . . . 5‐7
Air Filter Replacement Procedure . . . . . . . . . . . . 5‐8
PA Module Cleaning Procedure . . . . . . . . . . . . . . 5‐8
Periodic Cleaning and Inspection . . . . . . . . . . . . 5‐9
Date and Time Battery . . . . . . . . . . . . . . . . . . . . . . 5‐10
PA/PS Replacement . . . . . . . . . . . . . . . . . . . . . . . . 5‐11
Changing PA, IPA, & Power Supply Modules . . . 5‐11
Power Supply Module Replacement Procedure 5‐12
Configuration File, Fault Logs and Software Upload5‐13
Config File Save/Upload . . . . . . . . . . . . . . . . . . . 5‐13
Save Config File . . . . . . . . . . . . . . . . . . . . . . . . . . 5‐13
Upload Config File . . . . . . . . . . . . . . . . . . . . . . . . 5‐14
Software Update Procedure . . . . . . . . . . . . . . . . 5‐14
Retrieving/Printing Fault Logs . . . . . . . . . . . . . . 5‐15
System Calibration Procedures . . . . . . . . . . . . . . . 5‐16
System Forward/Reflected Power Calibration . 5‐16
Power Block Power Calibration FAX20/30/40 Only5‐17
Transmitter Air Flow Calibration . . . . . . . . . . . . 5‐18
Exciter Power Calibration/Switchover Threshold5‐19
Power Supply Voltage Set . . . . . . . . . . . . . . . . . . 5‐20
Exploded View 10 kW Power Block . . . . . . . . . . . . . 7‐1
AC Distribution Panel Parts (All Models) . . . . . . . . . 7‐4
FAX20/30/40 Specific Parts . . . . . . . . . . . . . . . . . . . . 7‐4
Reject Load Parts . . . . . . . . . . . . . . . . . . . . . . . . . . 7‐5
Splitters/Combiners . . . . . . . . . . . . . . . . . . . . . . . . 7‐5
2
Copyright ©2013, Harris Broadcast. 1‐1
FAX 5/10/20/30/40KW
October 28, 2013
1
1.1
Section-1 Introduction
Purpose of This Manual
This manual provides important information for the proper installation, operation and maintenance of the Flexiva FAX Series of transmitters including the 5kW, 10kW, 20kW, 30kW, and 40kW systems. The various sections of the manual provide the following types of information.
•
Section 1: Identifies the options available including spare parts kits. Provides detailed information required prior to the installation of the transmitter, including mechanical, cooling and electrical data, Ground‐
ing, AC Mains requirements and RF transmission line information.
•
•
•
•
•
Section 2: Details the proper steps to install the transmitter and putting it on the air for the first time.
Section 3: Provides detailed information on how to properly operate the transmitter.
Section 4: Details the Theory of Operation of the transmitter.
Section 5: Maintenance, detailed steps to clean, calibrate and change modules in the transmitter.
Section 6: Troubleshooting, included as a service aid to be used along with sections 4 and 5 by qualified person‐
nel to identify and correct an equipment malfunction.
1.2
Technical Support
Harris Broadcast offers 24 hour telephone technical support for all radio and television products from the United States. To get the best assistance as quickly as possible please have the transmitter model and serial number ready when calling or sending an email.
24‐hour Technical Support and Parts Phone ‐ 1‐217‐222‐8200 (follow prompts)
24‐hour Technical Support and Parts FAX ‐ 1‐217‐221‐7086 (follow prompts)
Technical Support Email Address ‐ tsupport@harrisbroadcast.com
Website ‐ www.harrisbroadcast.com
Customer portal access can be obtained via www.harrisbroadcast.com/servicesandsupport. Customers must register with a username and password to gain access to; technical documentation, software upgrades and service bulletins.
Offices around the Globe:
North America
Harris Broadcast
3200 Wismann Lane
Quincy, Illinois USA 62301
telephone: +1 217 222 8200 facsimile: +1 217 221 7086 e‐mail: tsupport@harrisbroadcast.com 888‐2720‐001
Europe
Harris Broadcast Communications Eskdale Road, Winnersh
Wokingham, Berkshire, U.K. RG41 5TS
telephone: +44 (0) 118 964 8100
facsimile: +44 (0) 118 964 8054
e‐mail: supporttx.emea@harrisbroadcast.com
WARNING: Disconnect primary power prior to servicing.
Copyright ©2013, Harris Broadcast
1‐2
Section-1 Introduction
October 28, 2013
Asia
Harris Communications (Shenzhen) Ltd. R3‐B2, High‐Tech Industrial Park, Nanshan Dist., Shenzhen China 518057 Telephone: +86 (0) 755 663 7928. facsimile: +86 (0) 755 663 7048 e‐mail: Dpan@harrisbroadcast.com 1.3
Harris Communications (China)
Rm 3711, CITIC Square
1168 Nanjing Road (W)
Shanghai, China 200041
Telephone: +86 (0) 21 5292 5660
facsimile: +86 (0) 21 5292 5955 e‐mail: Jmei@harrisbroadcast.com FAX Options and Spare Parts Kits
This section summarizes the options that are available for purchase with the Harris Broadcast FAX transmitters. The FAX can incorporate any available Harris Broadcast exciter in both single and dual exciter configurations. There are also a number of spare parts kits available, some of which are model dependant. Please see 843‐5614‐102 in front section of the drawing package for your model transmitter for a complete listing.
1.3.1
FAX5/10 Options
FAX5/10 is a single power block and can be purchased as a standalone transmitter and racked in a customer rack. It may also be purchased in a Harris Broadcast rack. Harris Broadcast can provide three different model racks for the FAX5/10 transmitter.
Documentation Package Part Number ‐ 943‐5614‐093 Units manufactured prior to August 2012
Documentation Package Part Number ‐ 943‐5614‐476 Units manufactured after to August 2012
Harris Broadcast Basic Rack ‐ 981‐0136‐012 ‐ 37RU Rack with rear door
Harris Broadcast Basic Rack ‐ 981‐0136‐011 ‐ Basic Rack, plus RF Line to top Harris Broadcast Deluxe Rack ‐ 981‐0136‐004 ‐ Basic rack plus AC Power Distribution Panel
3‐Phase Delta ..... 971‐0054‐035
3‐Phase Wye....... 971‐0054‐036
1‐Phase............... 971‐0054‐037
220 VAC Strip...... 253‐0253‐000
120 VAC Strip ..... 253‐0254‐000
Vented Rear Door ‐ 943‐5602‐481 ‐ Replaces solid panel door
Air Plenum Kit ‐ 981‐0031‐027G ‐ Fits front of Harris Broadcast Rack only
Remote Control Breakout Board ‐ 901‐0218‐201GT ‐ Converts connections from dB‐25 to Screw terminals
1.3.2
FAX20 Options
The FAX20 requires a Harris Broadcast rack due the mounting of the power block combiner and associated reject load. The basic rack comes with the RF line installed to top of the rack. The AC distribution is an option in the deluxe rack.
Documentation Package Part Number ‐ 943‐5614‐187 Units manufactured prior to August 2012
Documentation Package Part Number ‐ 943‐5614‐321 Units manufactured after to August 2012
3‐Phase Delta ..... 971‐0054‐038
3‐Phase Wye....... 971‐0054‐039
1‐Phase............... 971‐0054‐040
220 VAC Strip...... 253‐0253‐000
120 VAC Strip...... 253‐0254‐000
Vented Rear Door ‐ 943‐5602‐481 ‐ Replaces solid panel door
Air Plenum Kit ‐ 981‐0031‐052 ‐ Fits front of Harris Broadcast Rack only
Remote Control Breakout Board ‐ 901‐0218‐201GT ‐ Converts connections from dB‐25 to Screw terminals
Copyright ©2013, Harris Broadcast
WARNING: Disconnect primary power prior to servicing.
888‐2720‐001
FAX 5/10/20/30/40KW
October 28, 2013
1.3.3
1‐3
FAX30 Options
The FAX30 requires a Harris Broadcast rack due the mounting of the power block combiners and associated reject loads. The basic rack comes with the RF line installed to top of the rack and can be purchased without the AC Distribution Panel. No single phase AC Distribution Panel available for this model. To use single phase to the FAX30, use three feeds with breakers in a wall mounted panel external to the transmitter rack.
Documentation Package Part Number ‐ 943‐5614‐341 Units manufactured prior to August 2012
Documentation Package Part Number ‐ 943‐5614‐478 Units manufactured after to August 2012
3‐Phase Delta ..... 971‐0054‐041
3‐Phase Wye....... 971‐0054‐042
220 VAC Strip...... 253‐0253‐000
120 VAC Strip...... 253‐0254‐000
Vented Rear Door ‐ 943‐5602‐481 ‐ Replaces solid panel door (2 required)
Air Plenum Kit ‐ 981‐0031‐052 ‐ Fits front of Harris Broadcast Rack only (2 required)
Remote Control Breakout Board ‐ 901‐0218‐201GT ‐ Converts connections from dB‐25 to Screw terminals
1.3.4
FAX40 Options
The FAX40 requires a Harris Broadcast rack due the mounting of the power block combiners and associated reject loads. The basic rack comes with the RF line installed to top of the rack and can be purchased without the AC Distribution Panel. No single phase AC Distribution Panel available for this model. To use single phase to the FAX40, use four feeds with breakers in a wall mounted panel external to the transmitter rack.
Documentation Package Part Number ‐ 943‐5614‐342 Units manufactured prior to August 2012
Documentation Package Part Number ‐ 943‐5614‐478 Units manufactured after to August 2012
3‐Phase Delta ..... 971‐0054‐043
3‐Phase Wye....... 971‐0054‐044
220 VAC Strip...... 253‐0253‐000
120 VAC Strip...... 253‐0254‐000
Vented Rear Door ‐ 943‐5602‐481 ‐ Replaces solid panel door (2 required)
Air Plenum Kit ‐ 981‐0031‐052 ‐ Fits front of Harris Broadcast Rack only (2 required)
Remote Control Breakout Board ‐ 901‐0218‐201GT ‐ Converts connections from dB‐25 to Screw terminals
1.3.5
Exciter Options
The following Exciters are available for installation into any of the FAX models. These can be in single or dual exciter configurations. There is also an option for mounting the exciter external to the FAX rack either 25 or 50 feet away. Please see exciter manual for the various options available for each model. For the FAX transmitter to operate in any HD mode or in Split Level Combined mode, a Harris Broadcast FlexStar Exciter with correct options is required.
FAX50 ‐ 995‐0093‐001
Flexstar HD Exciter ‐ 995‐0012‐001
Digit DFM Exciter ‐ 994‐9410‐005
Micromax Exciter ‐ HARMICROMAXANALOG
Micromax Exciter ‐ HARMICROMAXDIGITAL (AES Audio capable)
Single exciter cables (for adding second exciter) Standard length ‐ 952‐9266‐015
Dual exciter cables Standard length ‐ 952‐9266‐016
External mount 25 foot cables (Single exciters) ‐ 952‐9266‐067
External mount 50 foot cables (Single exciters) ‐ 952‐9266‐068
External mount 25 foot cables (Dual exciters) ‐ 952‐9266‐069
External mount 50 foot cables (Dual exciters) ‐ 952‐9266‐070
888‐2720‐001
WARNING: Disconnect primary power prior to servicing.
Copyright ©2013, Harris Broadcast
1‐4
Section-1 Introduction
October 28, 2013
1.3.6
FAX Spare Parts Kits
The following spares kits are available.
FAX Spare Parts Kit (ALL MODELS):
Module Spares ‐ 990‐1201‐001 ‐ Contains 1 each PA and PS modules
FAX Spare Parts Kit FAX20/30/40:
Board Spares 20K ‐ 990‐1201‐010 ‐ Contains 1 each of the control and interface boards
FAX Spare Parts Kit FAX5/10:
Board Spares 10K ‐ 990‐1201‐002 ‐ Contains 1 each of the control and interface boards
Basic Spares 10K ‐ 990‐1201‐003 ‐ Contains fuses and a fan
FAX Spare Parts Kit FAX20:
Basic Spares 20K ‐ 990‐1201‐004 ‐ Contains fuses, 2 fans, and reject load resistor
FAX Spare Parts Kit FAX30/40:
Basic Spares 30/40K ‐ 990‐1201‐007 ‐ Contains fuses, 2 fans, and reject load resistor
1.4
FAX Transmitter Description and Features
The Flexiva FAX series transmitters are built based on a 10 kW building power block. The FAX 10 transmitter has one power block, the FAX 5 uses the same power block as a FAX10 but fewer PA modules and power supplies. For the higher power transmitters FAX20/30/40, multiple 10 kW power blocks are combined using hybrid combiners to achieve their rated power. All transmitters utilize the same control cards and software. FAX Transmitter Features
•
•
•
•
•
•
•
•
•
•
FM air‐cooled transmitter
Quad Mode operation in FM, FM+HD, HD and DRM+
Broadband design and frequency agile across the FM Band 88‐108 MHz
Hot Pluggable Power Supplies and Power Amplifiers
Incorporates multiple Harris Broadcast exciter models as well as other manufacturers ‐ dual exciter capability
Control via Parallel I/O, Ethernet and SNMP
RoHS 7 CE Compliant
Typical efficiency AC to RF of 70%
Has backup hardware control if Micro Module would fail
SFN, Main/Alt and N+1 Systems available
Copyright ©2013, Harris Broadcast
WARNING: Disconnect primary power prior to servicing.
888‐2720‐001
FAX 5/10/20/30/40KW
October 28, 2013
1.5
1‐5
FAX5/10 Photos/Mechanical/Cooling/Electrical Data
Exciter B
Exciter A
Flexiva
FAX 10kW
Transmitter
10kW
Transmitter
Figure 1-1 FAX5/10 Transmitter System Front View
The FAX10 transmitter system shown is setup with dual exciters to provide redundancy for additional on‐air reliability. Exciter A in the lower position in the rack is always the main exciter in the system. The upper Exciter B is always the backup exciter in the system. These positions hold true for all model of high power FAX Transmitters.
The FAX5 is the same chassis and hardware but contains four less power amplifiers and three less power supply modules. See Section 4 for detailed differences between FAX 5 and FAX10.
Note
For Outline drawing and Rack mechanical information see drawing 843-5614-103 in the documentation
package. The Electrical and HVAC contractors should be provided a copy of this drawing for reference.
888‐2720‐001
WARNING: Disconnect primary power prior to servicing.
Copyright ©2013, Harris Broadcast
1‐6
Section-1 Introduction
October 28, 2013
Figure 1-2 FAX5/10 in Harris Broadcast Deluxe Rack Rear View
Copyright ©2013, Harris Broadcast
WARNING: Disconnect primary power prior to servicing.
888‐2720‐001
FAX 5/10/20/30/40KW
October 28, 2013
1‐7
ELECTRICAL / COOLING / MECHANICAL DATA
HARRIS FAX 5K, 5 kW FM TRANSMITTER
All table values referenced to maximum power from FCC type notification range and minmum efficiency values.
PARAMETER NAME
VALUE
ELECTRICAL
5000 W (FM)
Nominal output power
FCC type-notified output
power range
Minimum (W)
Maximum(W)
FM+HD
FM Only
550
5500
HD Only
-20 dBc
-14 dBc
-10 dBc
-20 dBc
-14 dBc
-10 dBc
550
4500
550
3500
550
2650
550
2000
550
1850
7563
8127
550
1550
Typical (W)
Power consumption
(5.5 kW output in FM mode)
Maximum (W)
0.99 Typical
AC power factor
Overall efficiency, AC input
to RF output
FM
Minimum
Typical
-20 dBc
67%
72%
60%
FM + HD (Typical)
-14 dBc
-10 dBc
53%
50%
-20 dBc
HD Only (Typical)
-14 dBc
-10 dBc
42%
42%
42%
AC mains configuration
Three/Four-wire M5 screw terminal lugs. #14 - #6 Gauge screw lugs supplied single-phase, delta, or wye service, as factory configured.
Customer supplied circuit breaker/disconnect panel.
AC input voltage (nominal)
190-264VAC 50Hz/60Hz single-phase, 3ph delta, or 330-460VAC four wire 3PH WYE
AC protection size (Notes 1)
FM
FM+HD
HD Only
3PH
1PH
3PH
1PH
3PH
1PH
208-240VAC
330-460VAC
30A
20A
2 x 2P 25A
30A
20A
2 x 2P 25A
20A
10A
2 x 2P 15A
Recommended AC
Conductor Size, #THHW
Wire (NOTE 2)
3PH
1PH
3PH
1PH
3PH
208-240VAC
#10 AWG (6mm )
380-415VAC
#12 AWG (4mm2)
MAX Line Amps per phase
208VAC
380VAC
Grounding/Earthing
FM
2
FM+HD
2
2 x #12 AWG (4mm )
2
HD Only
2
#10 AWG (6mm )
2 x #12 AWG (4mm )
#12 AWG (4mm2)
FM
1PH
2
2
#12 AWG (4mm )
#14 AWG (2.5mm )
#14 AWG (2.5mm2)
FM+HD
HD Only
3PH
1PH
3PH
1PH
3PH
1PH
23A
12A
39A
21A
12A
36A
13A
7A
23A
AC safety ground via third wire of mains inlets (PE green wire). AC safety ground should have unbroken connection back to earth post at mains
distribution panel. Threaded ground stud provided on rear of amplifier chassis for connection to rack buss-bar where required by prevailing safety
norms. Connection should be via unpainted surfaces and soldered/brazed for low resistance.
COOLING
3
Cooling air volume
500 cfm (14.2 m /min) maximum
Cool air enters via front panel door with integral air filter. Heated air exhausts via four ventilated areas on amplifier rear door. Each air outlet has
Air inlet/outlet size
approximately 150 mm diameter (6“). One replacement inlet air filter shipped with each unit. Customized rack with ducted air output and/or input
See note 3 for dimensions available as option.
Heat loads at MAX Output
Watts
BTU / h
Tons
2709
9251
0.8
HD
FM + HD
FM
-20dBc
-14dBc
-10dBc
-20dBc
-14dBc
-10dBc
3000
10245
0.9
3104
10599
0.88
2650
9050
0.75
2762
9432
0.79
2555
8725
0.73
2140
7310
0.61
MECHANICAL
Transmitter size
Width
Depth
Height
Weight
Harmonic filter
RF output connector
Remote control connections
Inches
19
29
27.97
Empty Less PAs and Power Supplies
Millimeters
(16RU)
145 lbs 66 kg
Full
482.6
736.6
710.4
205 lbs
93
kg
Internal harmonic filter that meets or exceeds all FCC, CCIR and ITU requirments
1-5/8” EIA unflange, male, upper left rear of cabinet
Parallel remote control interface 25-pin female ‘D-sub’ connector. Optional ‘D-sub’ connector to terminal board kit available. Web-based
control/SNMP available via RJ45 connector interfaces located on rear of amplifier chassis and front door.
NOTES:
1. Wall-mounted circuit breakers are customer-supplied item. Note: IEC “B” curve = 3x-5x inrush current.
2. Wiresize recommendations based on 90oC THHW and 50oC ambient derating factor. All transmitter wiring should be done in conformance with prevailing electrical codes.
3. See Harris drawing 8435614383 for complete dimensional information
RJH 9/12/12
888‐2720‐001
WARNING: Disconnect primary power prior to servicing.
Copyright ©2013, Harris Broadcast
1‐8
Section-1 Introduction
October 28, 2013
ELECTRICAL / COOLING / MECHANICAL DATA
HARRIS FAX 10K, 10 kW FM TRANSMITTER
All table values referenced to maximum power from FCC type notification range and minmum efficiency values.
PARAMETER NAME
VALUE
ELECTRICAL
10000 W (FM)
Nominal output power
FCC type-notified output
power range
Minimum (W)
Maximum(W)
FM+HD
FM Only
1000
11000
HD Only
-20 dBc
-14 dBc
-10 dBc
-20 dBc
-14 dBc
-10 dBc
1000
9000
1000
7000
1000
5300
1000
4000
1000
3700
15125
16254
1000
3100
Typical (W)
Power consumption
(11 kW output in FM mode)
Maximum (W)
0.99 Typical
AC power factor
Overall efficiency, AC input
to RF output
AC mains configuration
FM
Minimum
Typical
-20 dBc
67%
72%
60%
208-240VAC
330-460VAC
42%
42%
FM
FM+HD
HD Only
3PH
1PH
3PH
1PH
3PH
1PH
2 x 2P 50A
60A
30A
2 x 2P 50A
35A
20A
2P 35A
FM
3PH
#6 AWG (16mm )
380-415VAC
#8 AWG (10mm2)
Grounding/Earthing
-10 dBc
42%
60A
35A
208-240VAC
208VAC
380VAC
50%
HD Only (Typical)
-14 dBc
190-264VAC 50Hz/60Hz single-phase, 3ph delta, or 330-460VAC four wire 3PH WYE
Recommended AC
Conductor Size, #THHW
Wire (NOTE 2)
MAX Line Amps per phase
53%
-20 dBc
Three/Four-wire M5 screw terminal lugs. #14 - #6 Gauge screw lugs supplied single-phase, delta, or wye service, as factory
configured. Customer supplied circuit breaker/disconnect panel.
AC input voltage (nominal)
AC protection size (Notes 1)
FM + HD (Typical)
-14 dBc
-10 dBc
FM+HD
1PH
2
3PH
2
2 x #6 AWG (16mm )
HD Only
1PH
2
#6 AWG (16mm )
3PH
2
2 x #8 AWG (10mm )
#8 AWG (10mm2)
FM
1PH
2
#8 AWG (10mm )
2
2 x #8 AWG (10mm )
#10 AWG (6mm2)
FM+HD
HD Only
3PH
1PH
3PH
1PH
3PH
1PH
46A
25A
79A
42A
23A
73A
27A
15A
46A
AC safety ground via third wire of mains inlets (PE green wire). AC safety ground should have unbroken connection back to earth post at mains
distribution panel. Threaded ground stud provided on rear of amplifier chassis for connection to rack buss-bar where required by prevailing
safety norms. Connection should be via unpainted surfaces and soldered/brazed for low resistance.
COOLING
3
Cooling air volume
1000 cfm (28 m /min) maximum
Cool air enters via front panel door with integral air filter. Heated air exhausts via four ventilated areas on amplifier rear door. Each air outlet has
Air inlet/outlet size
approximately 150 mm diameter (6“). One replacement inlet air filter shipped with each unit. Customized rack with ducted air output and/or input
See note 3 for dimensions available as option.
Heat loads at MAX Output
Watts
BTU / h
Tons
5418
18502
1.5
HD
FM + HD
FM
-20dBc
-14dBc
-10dBc
-20dBc
-14dBc
-10dBc
6000
20490
1.7
6208
21199
1.77
5300
18100
1.51
5524
18864
1.57
5110
17449
1.45
4281
14619
1.22
MECHANICAL
Transmitter size
Width
Depth
Height
Weight
Harmonic filter
RF output connector
Remote control connections
Inches
19
29
27.97
Empty Less PAs and Power Supplies
Millimeters
(16RU)
150 lbs 68 kg
Full
482.6
736.6
710.4
276 lbs
125
kg
Internal harmonic filter that meets or exceeds all FCC, CCIR and ITU requirments
1-5/8” EIA unflange, male, upper left rear of cabinet
Parallel remote control interface 25-pin female ‘D-sub’ connector. Optional ‘D-sub’ connector to terminal board kit available. Web-based
control/SNMP available via RJ45 connector interfaces located on rear of amplifier chassis and front door.
NOTES:
1. Wall-mounted circuit breakers are customer-supplied item. Note: IEC “B” curve = 3x-5x inrush current.
2. Wiresize recommendations based on 90oC THHW and 50oC ambient derating factor. All transmitter wiring should be done in conformance with prevailing electrical codes.
3. See Harris drawing 8435614383 for complete dimensional information
DGV 8/22/12
Figure 1-3 FAX10 Cooling/Mechanical/Electrical Data
Copyright ©2013, Harris Broadcast
WARNING: Disconnect primary power prior to servicing.
888‐2720‐001
FAX 5/10/20/30/40KW
October 28, 2013
1.6
1‐9
FAX20 Photos/Mechanical/Cooling/Electrical Data
Figure 1-4 FAX20 Transmitter Front View
The FAX20 transmitter is comprised of two 10 kW Power Blocks combined to make 20 kW. The FAX20 comes standard in a Harris Broadcast deluxe rack with RF line to the top of the rack and the AC Power Distribution panel installed. All FAX Models covered in this manual have dual exciter capability.
Note
For Outline drawing and Rack mechanical information see drawing 843-5614-103 in the documentation
package. The Electrical and HVAC contractors should be provided a copy of this drawing for reference.
888‐2720‐001
WARNING: Disconnect primary power prior to servicing.
Copyright ©2013, Harris Broadcast
1‐10
Section-1 Introduction
October 28, 2013
Figure 1-5 FAX20 Transmitter Rear View
Copyright ©2013, Harris Broadcast
WARNING: Disconnect primary power prior to servicing.
888‐2720‐001
FAX 5/10/20/30/40KW
October 28, 2013
1‐11
ELECTRICAL / COOLING / MECHANICAL DATA
HARRIS FAX20, 20 kW FM TRANSMITTER
All table values referenced to maximum power from FCC type notification range and minmum efficiency values.
VALUE
PARAMETER NAME
ELECTRICAL
20000 W (FM)
Nominal output power
FCC type-notified output
power range
FM Only
Minimum (W)
Maximum(W)
FM+HD
HD Only
-20 dBc
-14 dBc
-10 dBc
-20 dBc
-14 dBc
-10 dBc
2000
2000
2000
2000
2000
2000
2000
22000
18000
14000
10700
8000
7400
30250
32507
6200
Typical (W)
Power consumption
(22 kW output in FM mode)
Maximum (W)
0.99 Typical
AC power factor
Overall efficiency, AC input
to RF output
AC mains configuration
FM
Minimum
Typical
-20 dBc
67%
72%
60%
FM + HD (Typical)
-14 dBc
53%
-10 dBc
-20 dBc
50%
42%
HD Only (Typical)
-14 dBc
42%
-10 dBc
42%
Single-phase, delta, or wye service, as factory configured. Customer supplied circuit breaker/disconnect panel.
190-264VAC 50Hz/60Hz single-phase, 3ph delta, or 330-460VAC four wire 3PH WYE
AC input voltage (nominal)
AC protection size per phase
(Notes 1)
208-240VAC
330-460VAC
3PH
FM
1PH
3PH
1PH
3PH
1PH
125A
70A
200A
110A
60A
200A
70A
40A
125A
Recommended AC
Conductor Size, #THHW
Wire (NOTE 2)
3PH
1PH
3PH
1PH
3PH
FM
2
208-240VAC
#1 AWG (50mm )
330-460VAC
#4 AWG (25mm2)
208VAC
380VAC
HD Only
FM+HD
2
2
#4/0 (120mm )
#2 AWG (35mm )
HD Only
2
#4/0 (120mm )
#6 AWG (16mm2)
FM
Line amps per phase
Grounding/Earthing
FM+HD
1PH
2
#4 AWG (25mm )
#1 AWG (50mm2)
#8 AWG (10mm2)
FM+HD
HD Only
3PH
1PH
3PH
1PH
3PH
1PH
91A
50A
158A
84A
46A
146A
53A
29A
93A
AC safety ground via third wire of mains inlets (PE green wire). AC safety ground should have unbroken connection back to earth post at mains distribution
panel. Threaded ground stud provided on rear of amplifier chassis for connection to rack buss-bar where required by prevailing safety norms. EIA rack
housing transmitter should be connected via copper strap to station RF ground. Connection should be via unpainted surfaces and soldered/brazed for low
resistance.
COOLING
2000 cfm (56 m3/min) maximum
Cooling air volume
Air inlet/outlet size
See note 3 for dimensions
Cool air enters via 2 front panel doors with integral air filter. Heated air exhausts via two ventilated areas on top of rack. 34.5cm (13.6”) x 28.2cm (11.1”)
Two replacement inlet air intake filters shipped with each unit. Ducted air output and/or input available as option.
Heat loads at MAX Output
Watts
BTU / h
Tons
Cabinet size
Width
Depth
Height
Weight
Harmonic filter
RF output connector
HD
FM + HD
FM
10836
37004
3.1
-20dBc
-14dBc
-10dBc
-20dBc
-14dBc
-10dBc
12000
40980
3.4
12415
42398
3.53
10700
36541
3.05
11048
37728
3.14
10219
34898
2.91
8562
29239
2.44
MECHANICAL
Inches
22
37.52
83.12
Empty Less PAs and Power Supplies
717
(44RU)
lbs 325 kg
Millimeters
Full
558.8
953.0
2111.2
1002 lbs
455 kg
Internal harmonic filter that meets or exceeds all FCC, CCIR and ITU requirments
3-1/8” EIA flanged, with un-flanged adapter. Top, left rear corner of rack
Parallel remote control interface 25-pin female ‘D-sub’ connector. Web-based control/SNMP over IP (Static or DHCP) via RJ45 connector interfaces located
Remote control connections on rear of amplifier chassis and front door. Front door RJ45 (static IP via DHCP server) for service.
NOTES:
1. Wall-mounted circuit breakers are customer-supplied item. Note: IEC “B” curve =3x-5x inrush current.
o
o
2. Wiresize recommendations based on 90 C THHW and 50 C ambient derating factor. All transmitter wiring should be done in conformance with prevailing electrical codes.
3. See Harris drawing 8435614493 for complete dimensional information
DGV 8/2/12
Figure 1-6 FAX20 Cooling/Mechanical/Electrical Data
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Section-1 Introduction
October 28, 2013
1.7
FAX30 Photos/Mechanical/Cooling/Electrical Data
Figure 1-7 FAX 30kW Transmitter Front View
The FAX30 transmitter is comprised of three 10 kW Power Blocks combined to make 30 kW. The FAX30 comes standard in a Harris Broadcast deluxe rack with RF line to the top of the rack and the AC Power Distribution panel installed. All FAX Models covered in this manual have dual exciter capability.
Note
For Outline drawing and Rack mechanical information see drawing 843-5614-308 in the documentation
package. The Electrical and HVAC contractors should be provided a copy of this drawing for reference.
Copyright ©2013, Harris Broadcast
WARNING: Disconnect primary power prior to servicing.
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October 28, 2013
1‐13
Figure 1-8 FAX30 Transmitter Rear View
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Copyright ©2013, Harris Broadcast
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Section-1 Introduction
October 28, 2013
ELECTRICAL / COOLING / MECHANICAL DATA
HARRIS FAX 30K, 30 kW FM TRANSMITTER
All table values referenced to maximum power from FCC type notification range and minmum efficiency values.
VALUE
PARAMETER NAME
ELECTRICAL
30000 W (FM)
Nominal output power
FCC type-notified output
power range
FM Only
Minimum (W)
Maximum(W)
FM+HD
HD Only
-20 dBc
-14 dBc
-10 dBc
-20 dBc
-14 dBc
-10 dBc
3000
3000
3000
3000
3000
3000
3000
33000
27000
21000
15900
12000
11000
45375
49500
9300
Typical (W)
Power consumption
(33 kW output in FM mode)
Maximum (W)
0.99 Typical
AC power factor
Overall efficiency, AC input
to RF output
AC mains configuration
FM
Minimum
Typical
FM + HD (Typical)
-20 dBc
-14 dBc
66%
72%
59%
52%
-10 dBc
-20 dBc
50%
42%
HD Only (Typical)
-14 dBc
42%
42%
3-phase delta or 4 wire wye service, as factory configured. Customer supplied circuit breaker/disconnect panel.
190-264VAC 50Hz/60Hz 3ph delta, or 330-460VAC four wire 3PH WYE
AC input voltage (nominal)
AC protection size per phase
(Notes 1)
208-240VAC 3PH
330-460VAC 3PH
Recommended AC
Conductor Size, #THHW
Wire (NOTE 2)
FM
FM+HD
HD Only
175A
100A
150A
80A
100A
50A
FM+HD
HD Only
FM
2
330-460VAC
#3/0 (95mm )
#2 AWG (35mm2)
#2/0 (70mm2)
#4 AWG (25mm2)
#2 AWG (35mm2)
#6 AWG (16mm2)
Line amps per phase
208VAC
380VAC
FM
FM+HD
HD Only
139A
76A
128A
70A
80A
44A
208-240VAC
Grounding/Earthing
-10 dBc
AC safety ground via third wire of mains inlets (PE green wire). AC safety ground should have unbroken connection back to earth post at mains
distribution panel. Threaded ground stud provided on rear of amplifier chassis for connection to rack buss-bar where required by prevailing safety norms.
EIA rack housing transmitter should be connected via copper strap to station RF ground. Connection should be via unpainted surfaces and
soldered/brazed for low resistance.
COOLING
2400 cfm (68 m3/min) maximum
Cooling air volume
Air inlet/outlet
Heat loads at MAX Output
Watts
BTU / h
Tons
Cabinet size
Width
Depth
Height
Weight
Harmonic filter
RF output connector
Cool air enters via 3 front panel doors with integral air filter. Heated air exhausts via three ventilated areas on top of rack. Three replacement inlet air
intake filters shipped with each unit. Customized rack with ducted air output and/or input available as option.
FM + HD
FM
17000
58055
4.8
HD
-20dBc
-14dBc
-10dBc
-20dBc
-14dBc
-10dBc
18763
64075
5.3
19385
66198
5.52
15900
54299
4.52
16571
56591
4.72
15190
51875
4.32
12843
43858
3.65
Inches
47.1
37.52
83.12
Complete Rack
MECHANICAL
Millimeters
(44RU)
771.107 kg
1700 lbs
1196.3
953.0
2111.2
Internal harmonic filter that meets or exceeds all FCC, CCIR and ITU requirments
3-1/8” EIA flanged, with un-flanged adapter. Top, left rear corner of rack
Parallel remote control interface 25-pin female ‘D-sub’ connector. Web-based control/SNMP over IP (Static or DHCP) via RJ45 connector interfaces
Remote control connections located on rear of amplifier chassis and front door. Front door RJ45 (static IP via DHCP server) for service.
NOTES:
1. Wall-mounted circuit breakers are customer-supplied item. Note: IEC “C” curve = 5x-10x inrush current.
2. Wiresize recommendations based on 90oC THHW and 50oC ambient derating factor. All transmitter wiring should be done in conformance with prevailing electrical codes.
3. See Harris drawing 8435614308 for complete dimensional information
DGV 8/2/12
Figure 1-9 FAX30 Cooling/Mechanical/Electrical Data
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FAX 5/10/20/30/40KW
October 28, 2013
1.8
1‐15
FAX40 Photos/Mechanical/Cooling/Electrical Data
Figure 1-10 FAX40 Transmitter Front View
The FAX40 transmitter is comprised of four 10 kW Power Blocks combined to make 40 kW. The FAX40 comes standard in a Harris Broadcast deluxe rack with RF line to the top of the rack and the AC Power Distribution panel installed. All FAX Models covered in this manual have single exciter capability.
Note
For Outline drawing and Rack mechanical information see drawing 843-5614-309 in the documentation
package. The Electrical and HVAC contractors should be provided a copy of this drawing for reference.
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Section-1 Introduction
October 28, 2013
Figure 1-11 FAX 40kW Transmitter Rear View Doors Open
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October 28, 2013
1‐17
ELECTRICAL / COOLING / MECHANICAL DATA
HARRIS FAX 40K, 40 kW FM TRANSMITTER
All table values referenced to maximum power from FCC type notification range and minmum efficiency values.
VALUE
PARAMETER NAME
ELECTRICAL
40000 W (FM)
Nominal output power
FCC type-notified output
power range
FM Only
Minimum (W)
Maximum(W)
FM+HD
HD Only
-20 dBc
-14 dBc
-10 dBc
-20 dBc
-14 dBc
4000
4000
4000
4000
4000
4000
4000
44000
36000
28000
21200
16000
14800
60500
66000
12400
Typical (W)
Power consumption
(44 kW output in FM mode)
Maximum (W)
0.99 Typical
AC power factor
Overall efficiency, AC input
to RF output
AC mains configuration
-10 dBc
FM
Minimum
Typical
FM + HD (Typical)
-20 dBc
-14 dBc
66%
72%
59%
52%
-10 dBc
-20 dBc
50%
42%
HD Only (Typical)
-14 dBc
42%
42%
3-phase delta or 4 wire wye service, as factory configured. Customer supplied circuit breaker/disconnect panel.
190-264VAC 50Hz/60Hz 3ph delta, or 330-460VAC four wire 3PH WYE
AC input voltage (nominal)
AC protection size per phase
(Notes 1)
208-240VAC
330-460VAC
Recommended AC
Conductor Size, #THHW
Wire (NOTE 2)
FM
FM+HD
HD Only
250A
125A
225A
125A
150A
80A
FM
FM+HD
2
HD Only
330-460VAC
300kcmil (150mm )
#1 AWG (50mm2)
250kcmil (150mm )
2
#1 AWG (50mm )
#2/0 (70mm2)
2
#4 AWG (35mm )
Line amps per phase
208VAC
380VAC
FM
FM+HD
HD Only
185A
101A
171A
94A
107A
58A
208-240VAC
Grounding/Earthing
-10 dBc
2
AC safety ground via third wire of mains inlets (PE green wire). AC safety ground should have unbroken connection back to earth post at mains
distribution panel. Threaded ground stud provided on rear of amplifier chassis for connection to rack buss-bar where required by prevailing safety norms.
EIA rack housing transmitter should be connected via copper strap to station RF ground. Connection should be via unpainted surfaces and
soldered/brazed for low resistance.
COOLING
3
Cooling air volume
Air inlet/outlet
Heat loads at MAX Output
Watts
BTU / h
Tons
Cabinet size
Width
Depth
Height
Weight
Harmonic filter
RF output connector
3200 cfm (90.6 m /min) maximum
Cool air enters via 3 front panel doors with integral air filter. Heated air exhausts via three ventilated areas on top of rack. Four replacement inlet air
intake filters shipped with each unit. Customized rack with ducted air output and/or input available as option.
FM + HD
FM
22667
77407
6.5
HD
-20dBc
-14dBc
-10dBc
-20dBc
-14dBc
-10dBc
25017
85433
7.1
25846
88265
7.36
21200
72398
6.03
22095
75455
6.29
20438
69796
5.82
17124
58478
4.87
Inches
47.1
37.52
83.12
Complete Rack
MECHANICAL
(44RU)
839.146 kg
1850 lbs
Millimeters
1196.3
953.0
2111.2
Internal harmonic filter that meets or exceeds all FCC, CCIR and ITU requirments
4-1/16” EIA flanged, with un-flanged adapter. Top, left rear corner of rack
Parallel remote control interface 25-pin female ‘D-sub’ connector. Web-based control/SNMP over IP (Static or DHCP) via RJ45 connector interfaces
Remote control connections located on rear of amplifier chassis and front door. Front door RJ45 (static IP via DHCP server) for service.
NOTES:
1. Wall-mounted circuit breakers are customer-supplied item. Note: IEC “B” curve = 3x-5x inrush current.
2. Wiresize recommendations based on 90oC THHW and 50oC ambient derating factor. All transmitter wiring should be done in conformance with prevailing electrical codes.
3. See Harris drawing 8435614309 for complete dimensional information
DGV 7/19/12
Figure 1-12 FAX40 Cooling/Mechanical/Electrical Data
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Section-1 Introduction
October 28, 2013
1.9
FAX Specifications(All Models)
For AC mains/power consumption, mechanical and other model specific specifications and information see the ECM sheets in this section. For All audio specs and frequency stability see exciter manual that came with the transmitter.
Table 1-1 Specifications for all models transmitters
Frequency Range
87.5‐108 MHz
Operating Modes
"Quad‐Mode", FM Only, FM+HD, HD Only,Split Level
Power Stability
±0.25 dB
Asynchronous AM
55 dB Minimum below equivalent 100% amplitude modulation by 400 Hz using 75 µSec de‐emphasis
Synchronous AM
50 dB minimum below equivalent 100% amplitude modulation using 75 µSec de‐
emphasis and 400 Hz high‐pass filter (FM Deviation ±75 kHz by a 1 kHz sinewave). Measured at wideband input
RF Harmonic and Spurious Suppression
Meets or exceeds all FCC, CCIR and ITU requirements
VSWR
Protected against open or short circuit at all phase angles. Foldback user adjustable from 1.3 to 1.5:1. VSWR shutdown at 1.5:1
Altitude
Maximum 9,843 feet (3000 M) elevation above sea level
Ambient Temperature Range
32° to 113° F (0 to 45° C), derated 35.6° F (2° C) per 1000 feet (300m) elevation
Humidity
95% Non‐condensing
Parallel Control
dB‐25 female connector, Status outputs open collector max 24 VDC/200 mA. Command inputs TTL opto‐isolated. Analog outputs 0 to 5 VDC.
Web Interface
Ethernet rear port user configurable; front port local use (DHCP Server)
SNMP
SNMP Ver 1,2 compliant, Harris Broadcast Base MIB and IRT MIB available
Exciter
Capable of using any Harris Broadcast or non‐Harris Broadcast exciter
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October 28, 2013
1‐19
1.10 Selecting Location for Transmitter Placement
Selecting a good location for the transmitter to be placed is very important. There are several points that should be considered if the transmitter is in a new location or being moved to a new building. Read through each point to ensure a proper and safe installation.
•
Make sure doors into the site are large enough to accommodate the transmitter. Doorway height can some‐
times be a problem. If the doors are not tall enough extra manpower may be required to get the transmitter tipped down to clear the door.
•
Ensure the floor where the transmitter is to be placed can support the weight of the transmitter. See the ECM sheets in this section for dimensions and weight of your model.
•
The location should be selected so there is enough clearance around the transmitter with the doors open to meet local electrical and safety codes.
•
Breakers and or disconnects should be within sight of the transmitter. If possible the best location is directly behind the transmitter on the wall.
•
Proper lightning protection should be installed in the building by a professional electrical contractor. Ensure that it is installed as close to the AC Mains entrance into the building as well as close to the station reference ground.
•
If the transmitter is installed in a high RF environment, it is a good practice to utilize cable ferrites on all con‐
ductors to minimize RF interference.
•
Do not install the transmitter in places where it may be exposed to mechanical shocks, excessive vibration, dust, water, salty air, or acidic gas. •
If outside air is brought into the building it should be well filtered to keep dirt out of the building and the transmitter. See Section 1.11 Cooling for further details.
•
Ambient temperature and relative humidity should always range between the following limits at the installa‐
tion location:
Ambient temperature: 0 to +45oC
Relative humidity: 5 to 95% non‐condensing
Note
Failure to follow these installation instructions may void the warranty.
•
Plan the RF transmission line runs so that a minimum number of elbows are required, this will allow for best performance. It is usually best to install the RF line first, since it is easier to work around it with the AC con‐
duits and the air handling duct.
1.11 Cooling
Flexiva series transmitters use forced air cooling provided by multiple internal blowers to remove the heat generated by the signal generation and amplification processes.To avoid operational problems due to excessive temperature, the blower openings must not be blocked. The transmitter Outline Drawing 843‐5614‐103 provides an indication of the relative location of the transmitter blowers and the necessary clearances to respect. Air input is from the transmitter front with hot air exhaust at the rear of the amplifier. When factory rack integration has been provided, the exhaust air exits through a vent at the top of the rack. An optional intake plenum is available for Harris Broadcast supplied racks to permit connection to an external ducted air system at the top of the rack if desired.
When the transmitter components are mounted in a customer supplied rack, care must be taken not to overheat the other pieces of equipment already installed in the rack. The exhaust from the Flexiva amplifier chassis will typically be 10oC to 20oC hotter than the ambient air. In many cases, this may necessitate use of a vented rear rack door or removal of rear rack door altogether. Additionally, sufficient rear clearance must be left behind the Flexiva amplifier chassis exhaust ports, typically 15cm (6 in.) or greater. 888‐2720‐001
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Section-1 Introduction
October 28, 2013
Figure 1-13 Cooling Intake/Exhaust
Note
Consult the data sheets in this section of the manual for details of cooling requirements for each FAX
model.
In general, transmitter cooling systems fall into two categories:
An open system in which the heated transmitter exhaust passes through a dedicated duct to the outside of the transmitter building. The transmitter may receive fresh outside air directly through a separate intake duct or may receive ambient air from the transmitter hall, with the transmitter hall being supplied make‐up air from outside via a filtered inlet vent. With an open system, it is imperative to correctly balance the input and output air flow volumes, paying particular attention to the pressure drops in external ducts and providing external blowers to overcome these losses and ensure correct air flow. The Flexiva transmitter internal air system is designed to supply sufficient air at the required static pressure to cool the transmitter only and all external duct losses must be compensated for by external blowers (this includes the optional intake plenum). Outside air containing salt or pollution must have those items removed by an adequate filtration system, and any pressure drops caused by filtration must also be considered.
A closed system in which the transmitter exhausts and inputs air directly to and from the transmitter room. The transmitter room is closed to outside air and makes use of air conditioning units to remove the resulting heat buildup. This type of system is recommended in geographic areas with especially salty, sulfuric, or otherwise polluted air. With a closed system, it is imperative to correctly balance the heat load. That is, to size and position the air conditioning units properly to handle the heat generated by the transmitter, ancillary equipment, building lighting, and even solar radiation entering through windows. In may also be desirable to oversize the air conditioning system to include the heat dissipated by the station test load, when in operation. Figures for both the transmitter heat load and air flow volume are provided in the transmitter Outline Drawing 843‐
5614‐103. Consult a professional heating and ventilation expert in your area for help in designing the building cooling system.
When the installation is to be made at a high altitude, it will be necessary to derate the upper temperature range. The Harris Broadcast transmitter is rated to operate from 0° to +45°C at sea level. The upper temperature range must be derated by 2°C per 300 meters (1000 feet) above sea level. Copyright ©2013, Harris Broadcast
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October 28, 2013
1‐21
1.12 Grounding Requirements
Two separate ground connections are required for the Flexiva FAX series transmitter: an AC safety ground and an RF earth ground.
The AC safety ground prevents an electrocution hazard should a dangerous potential from inside the unit accidentally contact an exposed metal surface. This is done by ensuring all metal surfaces have an uninterrupted connection back to the physical earth (PE) terminal at the AC mains service entrance. A physical earth (PE) connection is typically tied to the return current terminal either indoors at the main distribution panel or outside “at the pole” (as dictated by local codes), thus allowing any fault current to safely return to the power source.
The AC safety ground connection is made automatically for the exciter and other Harris Broadcast auxiliary equipment via the green/yellow wire on the third prong of the AC input cord. When the exciter and any auxiliary equipment are connected directly to a user‐supplied outlet box or distribution panel, the green‐yellow wire from the AC input cord(s) must terminate at the PE terminal at the AC mains source. In the case of a Harris Broadcast‐supplied AC distribution chassis, the green/yellow earth wire from the incoming AC mains service terminates at the PE terminal of the AC distribution chassis (ground symbol inside circle). The individual subassemblies making up the transmitter connect via the green/yellow wire of their mains cords to the same PE terminal on the AC distribution chassis. When present, a rack buss‐bar will also connect to the PE terminal. Individual panels making up the rack cabinet without a solid, permanent connection back to the PE terminal that might be exposed to unsafe voltages (e.g. doors on hinges) will connect to the PE terminal via a wire jumper connection to the buss‐bar.
The RF earth ground prevents damage to the equipment during lightning‐induced transients and reduces RF interference to low level circuits in general. An RF ground strap attachment point is located at the rear of the FAX transmitter and exciter chassis. This connection is suitable for use in a single point grounding system, with the ground strap attached to the equipment rack and the rack, in turn, to a common grounding plate. A minimum 2" copper strap is recommended.
Note
Observe this important distinction: The AC safety ground ensures that energy originating at the AC mains
source is always safely returned to the AC mains source (i.e. prevents electrocution), whereas the RF earth
ground ensures that energy “originating in the earth,” such as lightning, safely returns to the earth. Confusion may arise in some cases because the AC safety and RF earth ground circuits may share the same
conductor or connection point(s) in some situations. To prevent confusion, some sources refer to the AC
safety ground as “bonding” and the RF earth ground as “earthing.”
1.13 AC Requirements
1.13.1
Surge Suppression Devices
Harris Broadcast strongly recommends the use of surge protection devices on the incoming AC mains lines. These devices protect against damages due to transients arising from both natural and man‐made sources. (e.g. lightning and inductive load switching). Clear preference is to be given to “series” type surge protection devices ‐‐ featuring protection by both a series inductance / shunt capacitor filter and shunt threshold device ‐‐ over simple shunt‐only clamping devices. The surge protector must be sized to handle the full amperage of the load it is protecting (plus a nominal safety margin) and be connected to the building ground system by short, direct connections. In the case where the shunt protection elements are protected by a fuse, it is necessary to periodically check the integrity of the fuse to ensure continued transient protection. Consult the manufacturer of these products for best device to be used in each installation.
1.13.2
Voltage Regulation
If voltage variations in excess of the transmitter specified range are anticipated, the transmitter power input must be equipped with an AVR (automatic voltage regulators) (optional equipment) capable of correcting the mains voltage. There are several factors that need to be taken into consideration when selecting the proper AVR. All these factors should be discussed with the manufacturer prior to purchasing a unit.
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Section-1 Introduction
October 28, 2013
•
•
•
•
•
•
•
•
Amount of line variation expected
Line Voltage and frequency
Single or three phase
Current output required
Correction type (individual or all three phases)
Bypass switch required or not
Input and output breakers required
Surge arrestor devices installed
The regulator should be sized taking into account the transmitters worst case power consumption, all associated equipment to be ran from the AVR plus 25% headroom. This will ensure the AVR stays in regulation and not trip breakers under heavy loads and start up. For 3‐Phase applications, it is preferred that the AVR correct on the individual phases, this will provide phase to phase regulation and better dependability of the equipment.
1.14 RF Line Requirements
The RF output connector on FAX transmitter depends on the model. The FAX5/10 has a 1‐5/8" EIA unflanged output connector. If the FAX5/10 is racked in a Harris Broadcast rack, the RF connector at the top will be a 1‐5/8" EIA flanged connector that includes a adapter to a unflanged connection. There is an optional adapter to allow for a 3‐1/8" EIA unflanged connection for models with 1‐5/8 EIA output. All transmitter models have a RF output impedance of 50 ohms unbalanced. There are two major factors in selecting the correct transmission line for the application, line loss and line power handling capability. Air dielectric lines tend to be more efficient but require pressurization. Foam dielectric lines tend to be less efficient (more loss). When considering the power handling capability requirement of the line, consider peak voltages not just the power of the transmitter. Also the environment to be installed in, extremely high heat will degrade the power handling characteristics of the line.
All air dielectric transmission lines should be pressurized to the line or antenna manufacturers recommendations.
Consult manufacturer to determine best product for each system.
Figure 1-14 FAX5/10 Transmitter 1-5/8 RF Output Connector (rear of amplifier)
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October 28, 2013
1‐23
Figure 1-15 FAX 3-1/8" Cabinet Output Flanged Connection
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Section-1 Introduction
October 28, 2013
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2‐1
FAX 5/10/20/30/40KW
October 28, 2013
Section-2 Installation
2
2.1
Introduction
This section details the procedures for installation and the steps required for the initial turn‐on of the FAX series transmitters. All steps should be followed in order to ensure the installation and turn on process are completed properly. Please refer to the exciter manual for more detailed information about the model installed in the transmitter.
2.2
Unpacking
When the transmitter is delivered to the site, the shipment should be inspected and inventoried before installation is begun. Each transmitter shipment will be accompanied by a packing check‐list identifying which items are packed in the various crates or boxes. Be sure to locate and save this document when the shipment arrives.
The contents of the shipment should be as indicated on the packing list. Carefully unpack the transmitter and perform a visual inspection to assure that no apparent damage was incurred during shipment. Retain the shipping materials until it has been determined that the unit has not been damaged. If the contents are incomplete, or if the unit is damaged electrically or mechanically, notify the carrier and Harris Broadcast immediately.
2.3
Returns and Exchanges
Damaged or undamaged equipment should not be returned unless written approval and a Return Authorization is received from Harris Broadcast. Special shipping instructions and coding will be provided to assure proper handling. Complete details regarding circumstances and reasons for return are to be included in the request for return. Custom equipment or special‐order equipment is not returnable. In those instances where return or exchange of equipment is at the request of the customer, or convenience of the customer, a restocking fee will be charged. All returns must be sent freight prepaid and properly packed and insured by the customer. When communicating with Harris Broadcast, specify the Harris Broadcast order number or invoice number and serial number.
2.4
Transmitter Documentation
Prior to installation, this technical manual, the factory test data, and the accompanying drawing package should be studied carefully to obtain a thorough understanding of the principles of operation, circuits, and nomenclature used in the Flexiva FAX series transmitter. This will facilitate proper installation and commissioning. Store the documentation, including the factory test data, in a secure location for future reference.
Note
The information contained in the drawing package should be considered the most accurate in the case of
a discrepancy. Document any changes and all external connections, sign and date them, and keep this info
with the doc package.
2.4.1
Installation and Outline Drawings
In Section 100 of the accompanying documentation package there are several drawings that will aid in the installation and initial turn‐on of the transmitter. It is always a good practice to locate and review all documentation prior to continuing. In the case that both generic and custom drawings are provided, the generic drawings are superseded by site/
model‐specific drawings.
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Section-2 Installation
October 28, 2013
Before continuing please be sure that the site AC mains and cooling are adequate for the installation of your transmitter. Pre‐Installation information and data for each FAX model can be found in Section 1 of this manual. 2.5
Personnel and Equipment Protection
All electrical equipment can pose a safety hazard if not operated properly or if proper safety precautions are not taken. Every care should be taken during the site planning process to maximize personnel protection on site, both during the installation and once the transmitter has been placed into operation. Below is a collection of recommendations to follow to enhance personnel safety on site. •
•
•
•
•
•
•
•
Post first aid procedures in a visible location.
Maintain a well‐stocked first aid kit in a visible location.
Post emergency phone numbers next to all site telephones.
Install fire extinguishers appropriate for extinguishing electrical fires.
Maintain a file of Material Safety Data Sheets (MSDS) for any hazardous chemicals on premises. Restrict site access to unauthorized personnel and post applicable high voltage and non‐ionizing radiation hazard warnings.
Secure all equipment racks to prevent tip over hazards, especially at sites prone to seismic activity. When mounting Flexiva transmitting equipment in a pre‐existing rack, be sure to mount equipment low enough in relation to rack center of gravity to prevent a tip over hazard.
•
Install mains safety disconnects (pull box or emergency off button) in sight of transmitter so as to permit visual verification of mains status at all times while performing maintenance.
•
Provide a means to lock out AC mains while performing maintenance to prevent inadvertent electrocution by a second party. 2.5.1
Safety Circuits
The Flexiva FAX series transmitter has provisions for the following safety connections, see Section 2.13 for further details of circuit operation:
> RF mute:
The RF MUTE signal line is available on pin 7 of J1 USER REMOTE connector at the rear of the transmitter. If the RF MUTE line is unconnected (open) to ground, the power control circuits within the amplifier chassis force its RF output to zero, but the 50V DC circuits and cooling fans continue to operate. An example of a possible connection point for this line would be the position switch in a coaxial switch. The transmitter mutes its output when the switch is in travel, then quickly returns to full power once the transition is complete. This can be enabled/disabled by Dipswitch S2‐5 on the System Interface/Multi‐Unit Interface Board. Shipped from factory as disabled.
> External Interlock:
The EXTERNAL INTERLOCK signal is available on pins 24 and 25 of J1 USER REMOTE connector at the rear of the transmitter. The interlock pin must have a continuous connection between these two pins to turn on the FAX transmitter. The transmitter is shipped with a “dummy” D‐sub 25 connector (Part number 952‐9266‐071) to defeat this circuit for initial turn on. This interlock requires a manual or remote "TX ON" command for the transmitter to restart.
> Equipment Interlock:
The EQUIPMENT INTERLOCK signal is available on pin 9 of J1 USER REMOTE connector at the rear of the transmitter. This input is user configurable for Active Hi or Active Low operation. See dipswitch S14 settings for the System Interface Board in Section 5 of this manual. Once this input is returned to it non‐faulted state the transmitter will automatically turn on.
> Emergency Off(Optional):
In certain circumstances, the Flexiva FAX transmitter system may be equipped with an optional emergency shut off button. This button is typically a large red plunger/pushbutton surrounded by a contrasting yellow border. The switch terminal connections of this button may be connected to the external interlock connection described above or brought outside the transmitter cabinet to an AC shutdown mechanism (e.g. contactor or shunt‐trip circuit breaker) in the customer’s AC mains panel.
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October 28, 2013
2.6
2‐3
Installation
Note
It should be noted that any remote control, status or analog meter connections be made only after the
transmitter has been initially turned on and operation verified.
This transmitter installation section provides instructions on proper cabinet placement, inter‐cabinet wiring where applicable, grounding, AC power connections, RF out connection, and static checks required before application of AC power.
The later part of the installation process involves the initial turn‐on procedure and initial equipment checks to assure proper operation.
Note
All connections referred to in this installation procedure should be verified using the schematic diagrams
supplied with the transmitter. The schematic diagrams should be considered the most accurate document in case of a discrepancy.
2.6.1
Remove Shipping Materials
In preparation to remove the cabinets from the shipping skids, it may be necessary to remove any tape, foam, and supports used for shipping. Remove these materials at this time.
The base of the cabinet may be bolted to a skid in the two front corners and the two rear corners with carriage bolts, flat washers, lock washers, and nuts. When it is desired to remove the cabinets from the skids, remove this hardware. A socket wrench, a short extension, and a 9/16‐inch deep‐socket are required.
2.6.2
Setting Transmitter in Place
If your transmitter is a FAX30/40 and was shipped with the cabinets split, it will be necessary to re‐assemble the cabinets. The instructions for cabinet re‐assembly are located in Appendix a of this manual. Complete the procedure prior to continuing with this section.
Prior to removing the bolts, move the transmitter as close as possible to the final location. Once the bolts are remove the transmitter cabinet can be taken off the skid and be set into its final position. See Section 1‐11 of this manual for site selection information.
•
•
•
•
•
888‐2720‐001
Carefully inspect the transmitter for loose hardware, loose or unconnected wires, and any debris in the rack
Level the cabinets
Secure rack to the floor and neighboring racks if required
Install all power amplifier modules in the location per the factory test data. This can be found on page 3 under "PA Serial Number Assignments". This step, while not necessary, helps to ensure the transmitter performs as close as possible as in the factory test. See Figure 2‐1 for slot locations in the power block.
Install all power supply modules. These can be installed in any location.
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2‐4
Section-2 Installation
October 28, 2013
Figure 2-1 Slot Locations (FAX20 Power Block 1 Shown)
Note
Figure 2-1 is Power Block 1 in FAX20/30/40. The Multi-Unit Controller will not be installed in FAX5/10.
2.6.3
Rack Mounting FAX5/10
In some instances the FAX5/10 transmitter will ship without a mounting rack. It is the customer’s responsibility to properly support and mount the equipment in the racks. The FAX transmitter will fit in any 19" EIA compatible rack that has adequate space available. See the ECM sheets or the accompanying documentation package for dimensions.
Another consideration when installing in a customer supplied rack is proper ventilation, read through the following checks and see Section 1.11 of this manual to ensure that all equipment has adequate cooling: Check Point 1: Transmitter cooling is accomplished by the multiple blower fans on the back of the transmitter cabinet. It is important that nothing obstructs this air flow such as a closed back rack mount door or blank rack mount panels. The fans should be able to blow air freely into the room. Check Point 2: If the transmitter is placed in an equipment rack with a solid back door that has to be closed, there must be large exhaust ports in the top of the rack to allow venting of the transmitter fan air. (Another option is to add exhaust fans to the top of the equipment rack).
Check Point 3: Often peripheral equipment such as exciters, processors, controllers, etc., may take in air through their sides or back panels. Do not allow the flow of the transmitter exhaust air to flow into their intake vents. This may cause over heating of the peripheral units. Added peripheral equipment may require a cover or partition to protect it.
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October 28, 2013
2.7
2‐5
Equipment Ground
The FAX transmitter is equipped with a RF/Safety ground lug connection on the upper left rear panel, see Figure 2‐
2. When shipped without a rack, this safety ground must be connected to either the ground bar/strap inside the rack or directly to the site ground system. A 2" wide copper ground strap is recommended.
Figure 2-2 FAX RF/Safety Ground Connection
When FAX transmitters are in a Harris Broadcast cabinet, there will already be a copper ground strap connected to the copper ground buss bar/strap that runs down the left side of the cabinet (when viewing from cabinet rear). The exciter will also be grounded to this buss bar as well. The rack mount cabinet buss bar/strap must be grounded to the site ground system. A minimum 2" wide copper ground strap is recommended. The strap should be attached to the site ground system at the bottom of the cabinet copper ground buss bar.
Figure 2-3 Cabinet Ground Buss Bar/Strap
Caution
WHEN INSTALLING ANY ADDITIONAL EQUIPMENT IN THE TRANSMITTER
RACK, BE SURE TO CONNECT A SEPARATE GROUND WIRE FROM EACH
COMPONENT TO THE BUSS BAR. NEVER RUN "DAISY CHAIN" GROUND
WIRES ACROSS MULTIPLE COMPONENTS AND THEN GROUND TO BUSS
BAR. THIS CAN CREATE A POSSIBLE GROUND LOOP.
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Section-2 Installation
October 28, 2013
2.8
Exciter-Transmitter Interconnection
Most installations will utilize a Harris Broadcast exciter and will be prewired at the factory. Ensure all connections are secure. When installing an exciter in the field or from another manufacturer, refer to Section 2.8.1 of this manual for details on the correct interface cable and jumper settings. See Section 1.3.5 for part numbers of Exciter Interconnect Cables.
The following information illustrates the interconnection wiring for the FAX transmitter (all models of FAX). Figure 2‐4 shows the Exciter Interface on the back of the transmitter. Exciter connections are always made to Power Block 1 in the FAX20/30/40. If the transmitter was ordered with dual exciters, exciter A will be the lower exciter and B will be the upper exciter in the rack.
Exciter A connections are made to the top connectors, J2 is Control Exciter A, J4 is RF for Exciter A and J6 is RTAC Exciter A. Exciter B connections are made to the lower connectors, J3 is Exciter B Control, J5 is RF Exciter B and J7 is RTAC Exciter B.
Figure 2-4
FAX Exciter Interface
Note
To run the FAX transmitter in FM+HD or HD only modes, a Harris Broadcast FlexStar or FAX Exciter
and HD Exporter are required. Please refer to the HD Exporter and the Exciter manuals for proper interconnection and setup. The HD carriers will not be present until these connections are made and the
interface between this equipment is running properly.
When the exciter is in the FM+HD or HD only mode, RTAC samples are required for the FlexStar and FAX exciters to correct the output signal properly. Figure 2‐5 shows the location of RTAC RF Sample that connects to the input of the Exciter. These will be connected and setup for proper levels to the exciter when tested at the factory.
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October 28, 2013
2‐7
Figure 2-5 RTAC RF Sample Input on back of Exciter.
2.8.1
Installing A Non-Harris Broadcast Exciter
When an exciter is not supplied at the time of purchase, the customer is responsible for fashioning a cable to interface the exciter to the FAX transmitter. There are some requirements that the cable must comply to to ensure safety and proper operation. The exciter interface at the rear of the transmitter goes to the System Interface Board, see its schematic diagram for more information. Also refer to Section 5 of this manual for help in setting the dipswitches for exciter/transmitter interface.
Warning
ENSURE THAT THE EXCITER IS SETUP FOR A MAXIMUM OF 2 WATTS PRIOR TO
CONNECTION TO THE FAX TRANSMITTER. EXCEEDING 5 WATTS COULD CAUSE
DAMAGE TO THE PA MODULES. THE TRANSMITTER MAY REQUIRE SLIGHTLY
MORE THAN 5 WATTS TO GET FULL RATED POWER FROM THE TRANSMITTER
BUT USE THIS AS A STARTING POINT TO BE SAFE.
•
J2 (J3) Pin 4 must always be grounded and Pins 5 and 6 must be unconnected at the transmitter end to signal a permanent FM mode (S3‐8 on System interface/Multi‐unit Interface should be set to ON)
•
J2 (J3) Pin 9 sends the Mute command to the exciter. The Mute from the transmitter can be a logic HI or LO depending on the dipswitch setting. See Section 5 of this manual for dipswitch settings and Sheet 8 of 801‐
0234‐051 System Interface/Multi‐Unit Interface Board schematic for detailed information on the exciter inter‐
face.
•
If the exciter has an external APC input to control RF power this connection must be made and the "Exciter Type" must be set to CUST DRV in the FAX setup. The FAX transmitter will output a linear APC voltage in the range of 0 (Minimum Power) to 3.3 or 4.75 VDC (set by dipswitch S2‐1 on Sys Inf Bd) to the exciter. The exciter must have a sufficient APC response time for proper operation. If the exciter does not have the exter‐
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Section-2 Installation
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nal APC input this connection is not required and the Exciter Type must be set to CUST IPA(APC to internal IPA) in the FAX setup. If using CUST IPA dipswitch S1‐5 on PA Backplane board 1(top board) where the IPA plugs in must be set to ON. This passes the APC voltage to the IPA.
•
The transmitter will display forward power from the exciter based on a DC voltage from the exciter that is proportional to it RF output. If the exciter does not have this analog output that transmitter will still operate but will not display exciter forward power. For dual exciters automatic switchover is done by using this volt‐
age, if not available the exciter will be forced to the other exciter in auto mode. See Section 5 of this manual for exciter power calibration procedure.
•
Ensure the exciter RF power output is set to approximately 2 Watts for safe initial turn on of the transmitter.
Refer to Section 5 of this manual and the exciter manual for proper dipswitch settings internal to the FAX transmitter.
Table 2-1 EXCITER INTERFACE (J2,J3 D-sub 15, amplifier rear)
Designation
Remarks
Pin
GND
Signal ground
1
EXCITER FORWARD POWER SAMPLE
Exciter forward power reading 0‐4 VDC for 0 ‐ 100% power out of the exciter
2
Input
RS 485 +
Used for FAX exciter only
3
Bi‐Directional
FM_ON_STATUS
Exciter grounds pin to tell PA that mode is FM ONLY (continuous closure)
4
Input
HD_ON_STATUS
Exciter grounds pin to tell PA that Exciter Mode is HD (continuous closure).
5
Input
EXCITER FAULT Exciter grounds pin to signal it has internal alarm
6
Input
N/C
No connection
7
Spare
APC OUTPUT
Analog voltage from transmitter to control exciter output power. 0 ‐ 3.3 (or 0‐4.75 VDC Sys Inf Bd Dipswitch S2‐1 sets range) VDC linear 0 VDC = Min power
8
Output
MUTE
Mute Output logic can be Hi or Lo to mute exciter. See switch settings in Section 5 of this manual to configure.
9
Output
N/C
No Connection
10
Spare
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Type
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2‐9
Table 2-1 EXCITER INTERFACE (J2,J3 D-sub 15, amplifier rear)
Designation
Remarks
Pin
Type
RS 485 ‐
Used for FAX exciter only
11
Bi‐Directional
N/C
No Connection
12
Spare
Exciter A Active
Used by main/alt exciter switcher to inform web remote which exciter is selected.
logic high = exciter B selected logic low = exciter A selected
13
Output
N/C
No Connection
14
Spare
EXCITER_READY
Pin is High when Exciter is Not Ready
15
Input
2.9
RF Connections
Prior to operation of the transmitter, the RF output must be connected to a known good test load or antenna. Connect the load/antenna using the correct size connector and transmission line for your model of transmitter. It is a good practice to use the minimum number of elbows to get the best performance from your transmitting system. If there is a patch panel or an RF Switch for a load/antenna, an interlock connection is required to J1 of the FAX. See Table 2‐3 for correct pins. These can be installed in the dummy connector supplied by Harris Broadcast.
Note
Initial testing into a 50 ohm test load is recommended. The VSWR of the load should be no greater than
1.05:1. The VSWR of the antenna should be no greater than 1.1:1.
2.10
AC Power Requirements and Connection
The following instructions cover both a customer mounted stand alone 10kW transmitter and all FAX transmitter models mounted in a cabinet with or without an AC Distribution Panel installed. The FAX series of transmitters can be connected to 3 types of AC sources. The voltage ranges are as follows:
•
•
•
Single‐phase 190V ‐ 264V
Three‐phase 190V ‐ 264V (No Neutral)
Three‐phase 330V ‐ 460V (Neutral Required)
If the 3‐Phase voltage is in the 190‐264 VAC(Line‐to‐Line or Line‐to‐Neutral) range either WYE or Delta can be used. In the case of Wye the Neutral will not be used. See Table 2‐2, Figure 2‐7 and Figure 2‐8 below for correct straps.
Table 2-2 AC Mains Connection Chart (See 843-5614-482)
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Voltage
Service
Connections
Comments
190‐264 VAC
1‐PH
L1,L2,GND
Set straps for 1‐Phase
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Section-2 Installation
October 28, 2013
Table 2-2 AC Mains Connection Chart (See 843-5614-482)
Voltage
Service
Connections
Comments
190‐264 VAC
Delta
L1,L2,L3,GND
Set straps for Delta
190‐264 VAC
Wye
L1,L2,L3,GND
TX will be strapped for Delta and no Neutral required. Neutral bar will not be installed.
330‐460 VAC
Wye
L1,L2,L3,Neu,GND
Transmitter will be strapped for WYE and Neutral required
Note
This chart is correct for all FAX models with or without AC Distribution Panel.
Please read all the following Warnings and Cautions prior to preceding with this section. Warning
DISABLE AND LOCK OUT STATION PRIMARY POWER BEFORE PRIMARY POWER CABLES
ARE CONNECTED TO THE EQUIPMENT.
Caution
CHECK THE AC POWER FEEDING THE FAX. IT MUST BE WITHIN THE VOLTAGE RANGES
SPECIFIED ON THE MAINS INTERCONNECT WIRING DIAGRAM Table 2-2. ANY VOLTAGE
OUTSIDE THIS RANGE WILL CAUSE DAMAGE TO THE EQUIPMENT. THE VOLTAGE SHOULD
BE MEASURED LINE TO LINE, AND IF A NEUTRAL IS USED, LINE TO NEUTRAL.
Warning
AN EXTERNAL CIRCUIT PROTECTION DEVICE (BREAKER OR FUSE) IS REQUIRED FOR
EACH AC LINE INPUT. THIS IS PROVIDED BY THE CUSTOMER IN ACCORDANCE WITH THE
AC INTERCONNECT DRAWING OR BY HARRIS BROADCAST IF AN IN-RACK AC DISTRIBUTION CHASSIS IS PURCHASED (OPTIONAL). IN THE LATTER CASE, AN EXTERNAL CIRCUIT
PROTECTION DEVICE TO HANDLE THE ENTIRE TRANSMITTER LOAD AT THE MAIN AC DISTRIBUTION POINT IS STILL REQUIRED, IN ACCORDANCE WITH PREVAILING LOCAL SAFETY
NORMS.
Warning
THE NEUTRAL WIRE SHOULD NOT GO THROUGH THE EXTERNAL BREAKER.
2.10.1
AC Connection without Distribution Panel
AC power is connected to the stand‐alone FAX or to a cabinet that does not contain a Harris Broadcast supplied AC Distribution Panel by running the AC power wires through the AC Mains input hole provided on the upper right rear corner of the transmitter. See Figure 2‐7, the wires can go in the top as shown or the white hole plug can be removed and the wires can be fed through there.
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2‐11
Figure 2-6 AC Mains in Amplifier
If a FAX20/30/40 is ordered without the AC Distribution panel, a breaker must be supplied for each power block and one for each exciter. The breaker and wire size for each power block will be the same as a FAX10. Follow the AC connection procedure for a stand‐alone transmitter and repeat for each power block.
Note
When connecting to a 3-Phase Wye configuration and the voltage is in the range of 190 - 264 VAC, use
the 3-Phase Delta strapping and the Neutral is not connected to the transmitter and the safety ground
connects to E7. See drawing 843-5614-482.
Caution
WHEN CONNECTING THE TRANSMITTER TO A 3-PHASE WYE CONFIGURATION
AND THE VOLTAGE IS IN THE RANGE OF 330-460 VAC, THE NEUTRAL MUST BE
CONNECTED TO THE E4-E5-E6-N TERMINAL POST TO STABILIZE THE
VOLTAGES. FAILURE TO CONNECT THE NEUTRAL CAN CAUSE DAMAGE TO THE
TRANSMITTER AND VOID THE WARRANTY. SAFETY GROUND CONNECTS TO E7.
Caution
WHEN THE SINGLE PHASE INPUTS TO THE TRANSMITTER ARE DERIVED FROM
A WYE (STAR) MAINS SERVICE, SPECIAL CARE MUST BE PAID TO THE NEUTRAL
CONNECTION, AS THE NEUTRAL CONNECTION SERVES AS THE COMMON
VOLTAGE REFERENCE TO ALL THREE PHASES. SHOULD THE NEUTRAL
CONNECTION BREAK, THE LINE-TO-LINE VOLTAGE OF EACH PHASE WILL
BECOME UNSTABLE AND INVARIABLY RESULT IN SEVERE DAMAGE TO ALL
LOADS FROM AN OVERVOLTAGE CONDITION. ACCORDINGLY, ALL NEUTRAL
CONNECTIONS SHOULD BE DOUBLE CHECKED FOR INTEGRITY, ESPECIALLY
WHEN MODULAR MAINS DISCONNECT PLUGS ARE IN USE. NEVER ALLOW THE
NEUTRAL TO BE BROKEN BEFORE THE INDIVIDUAL LINE CONNECTIONS. THIS
RECOMMENDATION HOLDS FOR ALL SINGLE-PHASE EQUIPMENT WITH A 380415V WYE-DERIVED FEED, NOT JUST THE HARRIS BROADCAST FAX
TRANSMITTER.
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Section-2 Installation
October 28, 2013
Note
It is not necessary to observe a certain phase rotation or even phase balance in three phase transmitters.
Additionally, the amplifier chassis can operate indefinitely (at a reduced power) with one or two of the
mains phases missing. The internal power supplies connected to each input will continue to operate provided the incoming mains power at that input falls within 190-300VAC.
•
Remove the cover near the upper right corner of the transmitter as in Figure 2‐7.
Figure 2-7 AC Cover Removed (Delta Strapping Shown)
•
Figure 2-8 AC Mains Strapping in Power Blocks
Figure 2‐8 shows the proper strapping for the AC input depending on the type of service. The straps were placed at the factory based on the information given at the time of order, please verify the straps are correct for your service prior to proceeding.
Note
For 3-Phase Wye service in the 190-264 VAC range Delta strapping must be used and no Neutral is
required. If set to Wye in this voltage range the transmitter will use Line to Neutral which will be insufficient voltage to operate the transmitter.
•
Route the AC wires in to the transmitter and secure to the lugs as shown in Figure 2‐7. The lugs shown are supplied by Harris Broadcast but other lugs can be used.
•
•
•
Make sure all wires, including the safety ground wire, and lugs are secure and replace the cover.
Repeat these steps for each power block in the transmitter if necessary.
A separate AC service will need to be supplied for the exciter and peripheral equipment as well. Refer to each piece of equipment user manual for detailed information on its AC requirements.
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October 28, 2013
2.10.2
2‐13
AC Connection with Distribution Panel
When the FAX is installed in a Harris Broadcast cabinet with the AC Distribution Panel option installed, there is only one AC service connection required. Figure 2‐9 shows the AC Distribution panel which provides a breaker to each power block in the transmitter as well as an outlet strip for the exciter and peripheral equipment. However there will need to be a properly sized breaker external to the transmitter that is customer provided. If this has not been installed please refer to Section 1 of this manual to determine the correct breaker and wire size for your model. However, ensure all local electrical codes are followed.
Figure 2-9 AC Input Terminal Block (3-Phase Delta Shown)
Review the following checklist before continuing.
•
•
•
Confirm presence of safety ground wire connection as shown in Figure 2‐9.
The AC Mains wires for Line and Neutral(Neutral used on Wye only at 330‐460 VAC range) are in correct loca‐
tion and tight.
Be sure all AC covers are replaced.
Note
If using a 3-Phase Wye service in the range of 190-264 VAC the transmitter will be strapped internally for
delta. The AC Distribution panel will not have a Neutral bar. If the Neutral Bar is required to meet the
electrical code in your area please contact Harris Broadcast Service to obtain a terminal barrier strip
Qty-1 part number 614-0988-000.
2.11
Cooling Installation
Now that the AC and the RF line has been installed any cooling duct work can be installed. See Section 1 of the manual for detailed guidelines on installing a closed‐loop or open‐loop cooling system.
2.12
Initial Turn On
At this point in the installation the following items should be completed. If not then please go back to the related section and complete the task before continuing with turning on the transmitter.
•
•
888‐2720‐001
AC Mains and safety ground should be connected and all safety covers replaced
Transmitter cabinet should be grounded to the building ground using at least 2" copper strap
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Section-2 Installation
October 28, 2013
•
•
•
•
•
RF transmission line should be attached and connectors tightened to proper torque
Cooling system should be installed and running
J1 should have special connector attached to defeat the Interlock
Exciters should be connected and all connections tight
If transmitter is running a HD mode the Exporter should be connected to the exciter Exgine via IP connection. Refer to the exporter and exciter manuals for setup.
Note
If unit is a FAX5 and has dual exciters, Exciter A will operate in to the high power input and Exciter B will
operate in to the internal IPA and will operate at a much lower power. See Section 4.1.2 for detailed operation of the FAX5.
Initial Turn‐On Procedure:
STEP 1
STEP 2
STEP 3
Turn the AC on at the wall breaker. Verify the voltages are correct at the transmitter input.
If an AC Distribution Panel is installed in the Harris Broadcast rack turn all the breakers on. The LCD on the front of the transmitter should now be on and sitting at the home screen. The exciters should be powered up.
Verify the model and mode at the top of the home screen is correct. Figure 2‐
10 shows a FAX10 in FM only mode. The other possible modes are "FM+HD" and "HD".
Figure 2-10 FAX Home Screen for FAX10 running FM mode
STEP 4
STEP 5
STEP 6
STEP 7
If the transmitter is to be ran in the HD mode go to the Flexstar exciter and verify the connection to the Exporter is running with no errors. Once this step is complete return to the turn on procedure. Consult the Exciter and Exporter manuals to verify operation.
Open the front door of each power block and verify the right most LED on each power supply module is green and no other power supply LED’s are on
Connect the audio program source to the exciter. Refer to the exciter manual for correct location and level setup.
Using the front panel ON button, turn the transmitter on and verify the following actions take place:
a.Fans on power blocks turn on
b.Forward power on the LCD indicates full power that the transmitter was calibrated to at the factory. Refer to test data front page TPO.
c.Reflected power on the LCD is less than 1.1:1 for your transmitter model.
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October 28, 2013
2‐15
d.Front Panel "OUTPUT" status LED turns green
e.There are no red LED’s on the front or inside any of the power blocks.
STEP 8
STEP 9
STEP 10
STEP 11
STEP 12
STEP 13
STEP 14
STEP 15
2.13
Allow the transmitter to operate for 30 minutes to warm up.
Inspect all transmission line for any localized heating.
If an infrared temperature measurement device is available, check all AC connections and breakers for excess heating
After 30 minutes of operation, verify that the PA meter readings are close to the factory test data. All the meter readings can be found under the "Status" menu button. See Section 3 of this manual for further details on menus and operation of the transmitter.
Verify Spectrum for HD carriers and the RTAC is correcting the output signal and it meets the compliance mask. If RTAC is not correcting refer to the exciter manual for help.
If transmitter is equipped with dual exciters, go to SETUP>>TX CONTROL on the LCD menu and switch to the backup exciter. Verify the transmitter operation.
Once satisfactory performance of the transmitter has been verified the USER REMOTE can now be connected. See Section 2.13 for detailed information.
If a Network connection is to be made for use with a remote computer or control go to Section 3 of this manual for setup information.
User Remote Control Connection
Figure 2-11 FAX Rear Panel Remote Control Connector J1
The 25 pin female connector is labeled J1 "User Remote" is located on the rear panel of the transmitter. This is on power block 1 for FAX20/30/40. It can be used for remote control and monitoring on all FAX transmitter systems. The Table 2‐3 provides the pinout for control, status, and metering functions. The special connector that was used to defeat the interlock for the initial turn on of the transmitter can be replaced with the new cable. However, "EXTERNAL INTERLOCK" must have a continuous ground to satisfy the interlock, J1‐24 to J1‐25, so the transmitter will operate.
Figure 2‐12 and Figure 2‐13 shows the circuits and maximum voltage and current for Status Outputs. The remote control circuitry is located on the System Interface board, on Revision K boards the Status Output circuit was changed to allow for an external voltage of up to 24 VDC. Some Command Inputs require a Continuous Ground and some inputs are momentary Ground, see Table 2‐3. Status Outputs are open collector outputs and require an external pull up. All Status Outputs are active low unless otherwise stated in Table 2‐4.
Remote must be enabled for inputs to respond unless noted in table.
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Section-2 Installation
October 28, 2013
There is an optional Remote Control Breakout Board ‐ 901‐0218‐201GT ‐ Converts connections from dB‐25 to Screw terminals
Figure 2-12 User Remote Inputs and Outputs Rev J and earlier boards
Note
If the unit in operation has a Rev J or older circuit board and external pull-up goes to a voltage higher
than 5 VDC, remove F3 from the System Interface (FAX5/10) or Multi-Unit Interface (FAX20/30/40)
board.
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October 28, 2013
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Figure 2-13 User Remote Inputs and Outputs Rev K and Later boards
Table 2-3 REMOTE CONTROL (D-sub 25, amplifier rear) J1- Inputs
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Designation
Remarks
Pin
Type
TX ON COMMAND
Momentary. Ground pin to turn transmitter on.
1
Input
TX OFF COMMAND
Momentary. Ground pin to turn transmitter off. This input can be configured to operate regardless of Remote enable/disable status. See Section 5 for S2‐2 description.
2
Input
POWER RAISE COMMAND
Momentary
Ground pin to raise output power
3
Input
POWER LOWER COMMAND
Momentary
Ground pin to lower output power. 4
Input
DRIVE CHAIN (IPA) "A" SELECT
Momentary
Ground to activate
5
Input
DRIVE CHAIN (IPA) "B" SELECT
Momentary
Ground to activate
6
Input
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Table 2-3 REMOTE CONTROL (D-sub 25, amplifier rear) J1- Inputs
RF MUTE
Continuous Ground pin to unmute RF output
When open, RF output is muted to zero power. This is defeatable by dip switch S2‐5 on System Interface Bd. Shipped from factory as Defeated.
7
Input
UPS LOW Power MODE
Continuous Ground pin to put transmitter into UPS Power Mode (Default 1/4 power). Enabled regardless of Remote enable/disable status. See Section 5 to setup Power out in this mode.
8
Input
EQUIPMENT INTERLOCK
Configurable Active Hi/Lo by S14‐1,2 on Sys Inf Bd; Continuous connection Hi/Low required to activate Interlock Enabled regardless of Remote enable/disable status. Transmitter return to operation once Interlock in OK state
9
Input
GROUND
Ground; Can be used for Command Inputs and Status Outputs
23
GND
EXTERNAL INTERLOCK
Continuous Ground to satisfy interlock loop
When released, requires a manual TX ON command to turn TX back ON. Enabled regardless of Remote enable/disable status.
24
Input
EXTERNAL INTERLOCK GROUND
Ground for External Interlock
25
GND
Table 2-4 REMOTE CONTROL (D-sub 25, amplifier rear) J1- Status and
Metering Outputs
SYSTEM ON
Hi ‐ SYSTEM is OFF; Low ‐ System is ON
10
Output
DRIVE CHAIN "B"
Hi ‐ Indicates IPA A selected; Low ‐ IPA B
11
Output
SUMMARY FAULT
All faults in the system are summed together. Low ‐ System Fault; Hi ‐ System Normal
12
Output
OUTPUT SUMMARY
Hi ‐ Output OK; Lo ‐ VSWR or RF Low (Below Fault Threshold)
13
Output
POWER AMP SUMMARY
Hi ‐ PA OK; Lo ‐ PA Fault
14
Output
PROG 1 FAULT
Status output is programmable via GUI only. Hi ‐ OK; Low ‐ Fault
15
Output
PROG 2 FAULT
Status output is programmable via GUI only. Hi ‐ OK; Low ‐ Fault
16
Output
PROG 3 FAULT
Status output is programmable via GUI only. Hi ‐ OK; Low ‐ Fault
17
Output
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Table 2-4 REMOTE CONTROL (D-sub 25, amplifier rear) J1- Status and
Metering Outputs
888‐2720‐001
PROG 4 FAULT
Status output is programmable via GUI only. Hi ‐ OK; Low ‐ Fault
18
Output
FORWARD POWER
3.5VDC = 100% calibrated power, Linear scale
19
External
Metering
Output
REFLECTED POWER
3.5VDC = 1.5:1 VSWR; 1.3 VDC=1.3:1 VSWR
20
External
Metering
Output
PA VOLTAGE
PA Drain Voltage 14.63 VDC/V output
21
External
Metering
Output
PA CURRENT
Total PA Current 4.1 VDC = Max current (Model Dependant)
22
External
Metering
Output
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Section-2 Installation
October 28, 2013
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3‐1
FAX 5/10/20/30/40KW
October 28, 2013
Section-3 Operation
3
3.1
Introduction
This section contains normal day‐to‐day operational procedures and information pertaining to the function of the Flexiva FAX 5/10/20/30/40 Transmitters. The information contained in this section assumes the transmitter has been installed correctly and is in proper working order. See Section 2 of this manual for installation and initial turn on steps. It is important that the operator be aware of normal transmitter operation and performance and note any changes or fault indications. Changes in operation may indicate a need for maintenance or corrective action before a more serious problem develops. Refer to the Factory Test Data (FTD) which includes meter readings, measured performance data, information and data measured with external equipment, and adjustments specifically for each transmitter’s operating frequency and power level.
3.2
Controls and Indicators
The following section identifies the location and function of all front‐of‐transmitter controls and indicators for operation of the FAX Transmitters.
Remote
ENABLE/DISABLE
Power
RAISE/ LOWER
Navigation Buttons
“Enter” is Black Circle
¼ VGA
Display
Status Menu
Button/LED
Power Menu
Button/LED
Setup Menu
Button/LED
ON / OFF
Buttons/LEDs
Summary
Status LEDs
Figure 3-1 Front Panel Controls and Indicators
Note
IP address shown in the LCD is the rear Ethernet port.
3.2.1
Front Panel Controls and Indicators
Table 3‐1 describes the functions of the front panel control buttons as well as what each LED represents. More detailed information can be found later in this section.
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Table 3-1 Front Panel Control Buttons
Button
Explanation
STATUS
Displays the Status Menu including the Event Log and meter readings
POWER
Displays model, forward/reflected power levels and system voltage and current readings
SETUP
Displays the setup menus on the LCD, includes configuration and calibration of the transmitter
UP/DOWN/LEFT/RIGHT
Used for LCD menu navigation. The up and down buttons are used to move the arrow cursor, which indicates the menu line that will be activated by pressing the black enter button. The left button is primarily used as a back button to return to a previous menu selection
ENTER
This is the black button in the center of the UP/DOWN/LEFT/RIGHT buttons. Used to select(highlight) or expand LCD menu items
REMOTE ENABLE
Allows remote control of the FAX (IP, SNMP and Parallel I/O); Disables Local control including front Ethernet port and LCD control/config
REMOTE DISABLE
Disables remote control of the FAX (IP, SNMP and Parallel I/O); Enables Local Control including front Ethernet port and LCD control/config
POWER RAISE
Raises the RF power output
POWER LOWER
Lowers the RF power output
ON
Turns Transmitter RF ON
OFF
Turns Transmitter RF OFF
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3‐3
Table 3-2 Front Panel Status Indicators
Status LEDs
States
Explanation
EXCITER
Green = OK
Amber/Yellow = Auto‐ Switched
Red = Fault Represents the status of the On‐air Exciter and Auto‐Switching relay
DRIVE CHAIN
Green = OK
Amber/Yellow = Auto‐
Switched
Red = Fault
Represents the status of all IPA’s in the transmitter and Auto‐
Switching relay(s)
POWER AMP
Green = OK
Red = Fault
Represents a summary status of the all PA Modules in the transmitter
POWER SUPPLY
Green = OK
Red = Fault
Represents a summary status of the Power Supplies in the transmitter
OUTPUT
Green = OK
Amber/Yellow = Warning
Red = Fault
Represents the status of the RF Output system. When the transmitter is switched off, the OUTPUT LED is off Green: The transmitter is switched on, and the RF output level is within +/‐10% of calibrated power
Yellow: The transmitter is switched on and an Output warning exists; either VSWR or power is below warning threshold
Red: The transmitter has an Output Fault (VSWR) or power is below fault threshold
SYSTEM
Green = OK
Amber/Yellow = Warning
Red = Fault
Represents a summary status of the transmitter system control and cooling. Green: System Normal
Yellow: A Control or Cooling Warning exists
MUTE
Green = OK
Red = RF Muted
Green: Indicates the transmitter is OFF or the transmitter is ON and un‐muted
Red: A Control or Cooling Fault exists
Red: Indicates the transmitter is switched on, but the RF output is presently muted.
3.3
Internal Controls and Indicators
The following figures show the System Interface (in all power blocks) and the Multi‐Unit Interface (in power block 1 only FAX20/30/40). The hardware for these boards is identical, however there are several dipswitch settings that distinguish the boards from being a system controller or a power block controller. When a Multi‐Unit controller is present, it connects to all key circuits within the transmitter system as well as multiplexing data from the power blocks back to the Mirco Module.
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Figure 3-2 System Interface Board
When the board is configured as a Power Block Controller (FAX20/30/40), none of the switches function.There are 6 LED status indicators on the board. With the exception of the “Remote Enable” LED, all the LED’s are active on both cards. In a FAX20/30/40 the “Remote Enable” LED is not active on the System Interface because it pertains to the overall transmitter not the specific power block.
•
•
•
•
•
•
SYSTEM ON: Illuminates when transmitter is ON
RF OUTPUT OK: Illuminates when RF Output is within 10% and no VSWR faults
REMOTE ENABLE: Illuminates when front panel Remote Enable button is pressed DRV B ACTIVE: Illuminates when IPA “B” is activated. Off when IPA “A” activated.
RF MUTE: Illuminates when any RF Mute action occurs
BACKUP MODE: Illuminates RED when upper NORMAL/BACKUP switch selects BACKUP or when Micro fails
Note
If the IPA switch mode is set to AUTO, the manual DRV buttons still function.
Figure 3-3 RF Switch Board Indicators
Green LED (Left) ‐ Indicates RF Out of IPA into the splitter is at Normal level. This LED will turn OFF when the IPA drops below 30 % of the TPO of the transmitter. When the IPA level drops below the threshold and Drive Chain Switching is set to Auto, the relay on the RF Switch board will switch the other IPA. The Drive Chain LED on the front panel will turn Amber and a Fault will be logged. If Drive Chain Switching is set to Manual no switching will occur and the transmitter will run at a reduced or zero power. In a FAX 5 the RF switch board becomes the exciter switcher, see Section 4 for detailed RF Chain path for the FAX5.
Amber LED (Right) ‐ Indicates that IPA B is on the air. If this LED is off IPA A is on the air.
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3‐5
Figure 3-4 Multi-Unit Interface Board FAX20/30/40 Only
The Manual DRV A SELECT/DRV B SELECT buttons select the IPA path for all power blocks simultaneously. When the transmitter is in Normal control mode and an IPA fault occurs the switching will happen automatically. Backup is a term used to describe one of the control modes for the FAX. If a fault should occur in the Micro Module or the Control/Display board, the transmitter will automatically go to BACKUP control mode, and the transmitter will continue operation. This button forces the transmitter into the BACKUP control mode and allows for setting the power in this mode via the PWR SET pot next to the switch. This switch should only be used to set the power for BACKUP mode and otherwise remain in NORMAL.
3.3.1
RF Sample and RTAC Ports
In the factory test data there is an entry labelled “Sample Port Coupling Factors”. These port locations are different depending on the model of transmitter. The last page of the factory test data lists the coupling factor of each port over frequency, this data is taken directly at the port with no cables attached. However the coupling factors noted on page three are for the frequency the transmitter was tested at only and take into account the cable loss to each port. For a FAX5/10 the RF Sample on the front door, which is indicated on the test data as “Front”, includes the loss of the splitter and cable. The Modulation Monitor on the rear panel is indicated as “Rear”, and includes the cable loss (no splitter in line) to it as well.
For the FAX20/30/40 the RF Sample on the front door of each power block is a sample from the directional coupler in each power block and is not indicated on the test data.
Refer to Figure 3‐3 above, the RF Sample port on the Multi‐Unit Panel inside power block one is the “Front” sample port indicated on the test data. This port comes from the transmitter directional coupler at the output which is a sample of the combined power. It includes the cable and splitter loss.
For the FAX20/30/40 “Rear Sample port, this is J5 directly on the output directional coupler. The RTAC sample ports are located on the rear panel of Power Block 1 in all the FAX models. These samples are taken from the output directional coupler in the system and through a 3‐way splitter. The level of the signal will likely be to high for direct connection to the exciter. Ensure that the level is padded correctly before connection to the exciter to prevent damage to the RTAC input.
3.4
Front Panel Operation
The following information is to tutor the first time user on how to navigate through the screens to observe operation data, perform setup and calibration procedures via the front panel LCD.
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Figure 3-5 Front Panel LCD Display Controller after Pressing ON
3.4.1
ON/OFF Operation
To turn the transmitter ON from the front panel press the Green ON button. The following should occur:
•
•
•
•
•
Green ON button LED should illuminate
Power supply internal fans turn on
Fans on rear door of each power block should turn on
Exciter should un‐mute
RF should ramp up from 0 watts to TPO To turn the transmitter OFF from the front panel press the Red OFF button. The following should occur:
•
•
•
•
•
Red OFF button LED should illuminate
Power supply fans turn off
Fans on rear door of each power block should turn off
Exciter should mute
RF should ramp down from TPO to 0 watts
3.4.2
Power Raise/Lower Procedure
To raise or lower power, press and hold the RAISE or LOWER button until the desired power level is reached.
Note
Small time delay: When pressing the RAISE or LOWER buttons, a small delay occurs before the transmitter power actually changes. The same is true when releasing the RAISE or LOWER button. The output
power will continue to change momentarily upon release. This is normal. The control circuits are scanning all of the critical functions and parameters of the transmitter to protect it from an overload. This creates the slight delay. When setting the power out to a very specific level, release the buttons before the
desired power level is reached. Then give short momentary presses to nudge the power to the exact level
desired.
3.4.3
Remote Enable/Disable Buttons
Pressing the Remote Enable button allows the transmitter to be controlled by a customer provided remote control system from off‐site. When using the GUI or SNMP via Rear Ethernet port, no changes can be made unless the Remote is ENABLED.
The front panel Ethernet port and LCD menus are considered a Local port on the transmitter, therefore the Remote must be Disabled for changes to made made. This port should never be connected to a network, it is a DHCP server.
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3‐7
Note
Prior to August 2013 the software required that the Remote be “Enabled” for both front and rear Ethernet
ports to be enabled for changes to be made. The Remote Enable LED can be RED or GREEN depending
on a dipswitch setting on the Control/Display board. The user can also set a dipswitch on the Control/
Display board to lock out the front panel when the Remote is enabled. See Section 5 of this manual for
details.
Caution
WHENEVER WORK IS BEING PERFORMED ON THE TRANSMITTER SYSTEM,
ALWAYS DISABLE THE REMOTE CONTROL SYSTEM BY PRESSING THE DISABLE
BUTTON. THIS WILL PREVENT ANOTHER OPERATOR FROM TURNING THE
TRANSMITTER ON WHILE WORK IS BEING PERFORMED ON IT.
Caution
ALWAYS CHECK TO VERIFY THE REMOTE ENABLED LIGHT IS ILLUMINATED
BEFORE LEAVING THE TRANSMITTER SITE. A REMOTE CONTROL SYSTEM
CANNOT GAIN CONTROL OF THE TRANSMITTER IF THE DISABLED LIGHT IS
ILLUMINATED. THIS IS AN IMPORTANT SAFETY FEATURE. IF NO REMOTE
CONTROL SYSTEM IS UTILIZED, THEN LEAVE THE TRANSMITTER IN THE
“REMOTE DISABLE” MODE.
3.5
LCD Navigation Tutorial
The navigation button is comprised of 5 separate buttons, Left, Right, Up, Down, and the center Black ENTER button. These buttons allow the user to navigate through the menu screens, POWER,STATUS and SETUP by scrolling up or down, and left and right to select different pages. The left button sometimes works as a “Back” button to go back one screen (page).
Looking at Figure 3‐6 left screen, there is an arrow on the left side by TX CONTROL. The arrow indicates there are more menus or information that can be viewed under TX CONTROL by pressing the ENTER button.
In the case of a diamond shape on the left side of the screen as in Figure 3‐6 right screen, this indicates there is more information that can be viewed by using the UP/DOWN button.
Caution
THERE IS A DIPSWITCH SETTING ON THE CONTROL/DISPLAY BOARD THAT
LOCKS THE FRONT PANEL OUT WHEN REMOTE IS ENABLED. IF THE SWITCH
IS SET TO FRONT PANEL DISABLE, NO CHANGES TO SETUP CAN BE MADE
UNTIL THE REMOTE IS DISABLED. SEE SECTION 5 DIPSWITCH SETTINGS FOR
DETAILS.
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Figure 3-6 LCD Screen Navigation
In the SETUP menu there are several selections that can be made to configure, control and calibrate the transmitter. When navigating the SETUP menu the following steps can be used as an example how to make changes. In this example the Date will be changed. After pressing the SETUP button, scroll down to SYSTEM SETUP, press ENTER and the display should be as shown in Figure 3‐7 left screen.
Figure 3-7 Date Setup
The DATE screen will display the current date (month/day/year) information. If you press the ENTER button when the arrow is next to the selection you wish to change, the selection will be highlighted like the APPLY DATE in Figure 3‐7 right screen. To change the MONTH, ensure arrow is next to MONTH highlight it by pressing ENTER, use the up or down buttons to correct the displayed month and then press ENTER. However, to actually change the date in memory the APPLY DATE must be pressed. Use the UP or DOWN buttons until the arrow is next to DATE, press the ENTER button to highlight DATE, the ENTER button must be pressed again with the selection highlighted, once the highlight clears the date is saved.
In some cases such as DUAL EXCITERS setup, it will be required to change from NO to YES. The screen shows “DUAL EXCITERS: YES” as in Figure 3‐8, in this case when the screen is highlighted the UP/DOWN buttons (either will work) can change the entry from YES to NO and then press the ENTER button to save the change.
The menu tree for the POWER, STATUS and SETUP menus follow this section. Only the SETUP allows the user to make changes, POWER and STATUS are view only menus. Following the example above will allow the user to get comfortable with navigation of the menus. Copyright ©2013, Harris Broadcast
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3‐9
Figure 3-8 YES/NO Change Example
3.6
Power Button Menu
The Power Button light illuminates automatically whenever the transmitter AC is turned on, this is the default home screen. It provides the operator very basic information about how the transmitter is operating. To view this screen whenever another screen is being displayed, simply press the POWER button. The POWER menu is information only, no configuration settings are available in this menu.
Figure 3-9 POWER Menu
Figure 3‐10 Shows all of the information available when the POWER button is pressed. These readings are all system readings. The PA AMPS is the total DC current being drawn form all of the power supplies in the system.
POWER
FWD:10.0KW
RFLD:0W
PAVOLTS:43.8V
PAAMPS:408A
TXFAULTS:OK
EXCONAIR:A
PWRMODE:NORM
Figure 3-10 POWER Button Menu Tree
3.7
Status Button Menus
Pressing the Status button will bring up the screen shown in Figure 3‐11. This allows the user access to specific status information including the transmitter Event LOG and meter readings among other status information. The STATUS menu like the POWER menu is information only.
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Figure 3-11 STATUS menu
Figure 3‐12 and Figure 3‐13 are the menu tree for the STATUS button. Details of each sub‐menu are describe in this section. Any readings given in this manual should not be assumed correct for your transmitter. The Factory Test Data should be consulted for correct readings for the transmitter being operated.
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3‐11
Status
Log___________
F/W,DESC,OCCURTIME
Exciter_____________EXCONAIR:A
EXCSWMODE:AUTO
EXCAUTOSW:READY
MODULATION FM
MODULATION:FM
EXCITERA:OK
EXCITERB:OK
EXCAPWR:2119mW
EXCBPWR:0mW
APCV:2.84
Modulator>>_____________________________
AudioPresent
AudioStatus
ExciterStatus
e C a _________
O
DriveChain_________IPAON:A
IPASWMODE:AUTO
IPAAUTO:READY
PWRBLK1IPA>>_____________________________ IPAA:OK
IPAB:OK
IPAPOWER:13.4W
PWRBLK2IPA>>_________IPAA:OK
IPAB:OK
IPAVDC:43.4
IPAPOWER:13.4W
IPAAAMPS:3.5A
IPAVDC:43.4
IPABAMPS:0.0A
IPA A AMPS:3 5A
IPAAAMPS:3.5A
IPA TEMP:33 4C
IPATEMP:33.4C
IPABAMPS:0.0A
IPATEMP:33.4C
PowerAmp_________PABLOCK1>>________________________________PASUMMARY:OK
PBAVGV:44.2V
PBTOTALI:192.3A
PABLOCK2>>___________ PASUMMARY:OK
PBAVGV:44.2V
PA1A:OK
PBTOTALI:192.3A
PA1B:OK
PA1A:OK
PA1VDC:44.2V
(PAMetersrepeatedforall7PAmodules)
PA1B:OK
PA1AAMPS:13.8A
PA1VDC:44.2V
PA1BAMPS:13.1A
PA1AAMPS:13.8A
PA1TEMP:45.3C
PA1BAMPS:13.1A
PA2A:OK
PA1TEMP:45.3C
PA2B:OK
PA2A:OK
PA2VDC:44.2V
PA2B:OK
PA2AAMPS:13.8A
PA2VDC:44.2V
PA2BAMPS:13.1A
PA2AAMPS:13.8A
PA2TEMP:45.3C
PA2BAMPS:13.1A
PA2TEMP:45.3C
ModulatorSubmenusareforFAXExciterONLY
SeeFAXExciterManual
(Therecanbeupto4PowerBlocks)
(Therecanbeupto4PowerBlocks)
Output____________ OUTPUT:OK
FORWARD9901W
REFLECTED:0W
VSWR:OK
VSWR FLDBK OK
VSWRFLDBK:OK
PWRLIMIT:OK
REJLEVEL:0%
REJLOAD:OK
PABLOCK1>>________________________________FORWARD:5.35KW
REFLECTED:0W
VSWR:OK
PABLOCK2>>___________ FORWARD:5.39KW
REFLECTED:0W
VSWRFLDBK:OK
VSWR:OK
PWRLIMIT:OK
VSWRFLDBK:OK
PWRLIMIT:OK
Figure 3-12 Status Menu Tree Page 1
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Section-3 Operation
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StatusContinued
PowerSupplies_____PABLOCK1>>___________________________________________________ PSSUMMARY:OK
ACMAINS:OK
PBAVGV:44.2V
PABLOCK2>>___________ PSSUMMARY:OK
ACMAINS:OK
PBTOTALI:192.5A
PBAVGV:44.2V
PSMETERS>>__________PBAVGV:44.2
PBTOTALI:192.5A
PS1:OK
PBTOTALI:192.5A
PS2:OK
PS1VDC:44.2V
PSMETERS>>_________ PBAVGV:44.2
PS1:OK
PBTOTALI:192.5A
PS3:OK
PS2VDC:44.2V
PS2:OK
PS1VDC:44.2V
PS4:OK
PS3VDC:44.2V
PS3:OK
PS2VDC:44.2V
PS5:OK
PS4VDC:44.2V
PS4:OK
PS3VDC:44.2V
PS6:OK
PS5VDC:44.2V
PS5:OK
PS4VDC:44.2V
PS7:OK
PS6VDC:44.2V
PS6:OK
PS5VDC:44.2V
PS7VDC:44.2V
PS7:OK
PS6VDC:44.2V
CONTROL:
PS7VDC:44.2V
+5V:4.62V
CONTROL:
+3.3V:3.30V
+5V:4.62V
+3.3V:3.30V
System___________ SYSSUM:OK
APCSTATUS:ON
APCMODE:DRIVE
CTRLMODE:NORM
PWRMODE:NORM
INTERLOCK:OK
RFMUTE:NO
REMOTEMUTE:NO
EQUIPINTLK:OK
SYSTEMMETERS>>_______________________________________________APCREF:3.50V
APCOUT:3.53V
PABLOCK1>>________________________________FANS:OK
PWRLIMIT:0.00V
AIRFLOWSTAT:OK
FRONTTEMP:41.0C
REARTEMP:34.9C
PABLOCK2>>___________ FANS:OK
AIRFLOWSTAT:OK
AIRFLOW:83%
REARTEMP:36.1C
AIRFLOW:90%
SWRevisions______ Application:
0018,May8,2012
GUI:
2.2.5May07,2012
Bootloader:
0035,Mar29,2012
TEST______________TESTMODE
Figure 3-13 Status Menu Tree Page 2
3.7.1
STATUS >LOG Menu
The Log displays information about events and faults that have occurred in the transmitter. The faults can be both active and cleared faults. On the LCD the active faults will be highlighted, pressing the ON button on the front panel will clear any faults that are no longer active but may show up highlighted in the log. If the fault returns after pressing the ON button they are still active faults. Once the log is full, the oldest entries will drop out as new ones are entered.
There are four possible entries in the LOG:
F = Fault; W = Warning; I=Information; A = Action or Event
The following is a typical fault:
F C1 PA6 OUT 9/28 13:10
C1 = Cabinet 1 (FAX20/30/40 only) FAX30/40 has 2 cabinets and 3/4 power blocks
PA6 OUT = Description of fault
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9/28 13:10 = Time and date fault occurred or cleared
If this fault was highlighted it would be an active fault
3.7.2
STATUS>EXCITER Menu
The Exciter submenu displays the status, switching mode and meter readings for the Exciter(s) installed in the FAX transmitter. Table 3-3 STATUS>EXCITER Menu Description
Menu
Description
EXC ON AIR:A
Displays On‐Air Exciter A or B
EXC SW MODE:AUTO
Displays dual exciter switching mode: Auto on Manual
EXC ATUTO SW:READY
Displays the exciter Switchover relay status:Ready or Tripped; If Tripped manual reset required by pressing ON button
MODULATION:FM
Displays Exciter Mode:FM, HD,FM+HD,SLC; Also displayed on LCD HOME screen; Mode set by exciter which changes the transmitter operating mode between Class C and Class AB
EXCITER A:OK
Displays status of Exciter A Fault Line: OK,Fault
EXCITER B:OK
Displays status of Exciter B Fault Line: OK,Fault
EXC A PWR:2119mW
Displays Exciter A power level in milliwatts; Calibrated to DC voltage from exciter interface.
EXC B PWR:2119mW
Displays Exciter B power level in milliwatts;Calibrated to DC voltage from exciter interface.
APC V:2.84
Displays APC voltage from FAX to Exciters (Typically about 0.1 Volts less at exciter)Range 0 ‐ 4.75 VDC(Configurable on System Interface S2‐1)
3.7.3
STATUS>Drive Chain Menu
The Drive Chain submenu displays the status, switching mode and meter readings for the IPA’s in each power block. The IPA is always in top left slot in each power block, refer to Figure 2‐1. The IPA has 2 amplifiers, side A and side B. Only one side of the IPA operates, the other is in standby and ready for operation if the on‐air side faults. Note that on IPA switchover the IPA’s in each Power Block will switch at the same time. For example if IPA A fails in Power Block 3, all IPA’s in the transmitter will switch to IPA B.
STATUS>Drive Chain Menu Description
888‐2720‐001
Menu
Description
IPA ON: A
Displays the IPA that is on‐air; All IPA’s in transmitter will be A or B (no individual power block switching)
IPA SW MODE: AUTO
Displays drive chain (IPA) switching mode: Auto on Manual
IPA AUTO: READY
Displays the Drive Chain (IPA) relay status:Ready or Tripped; If Tripped manual reset required by pressing ON button; Trip is on IPA RF Level only which is detected oon RF Switch bd. Trip level is 500 mV out of detector which is approximately 30 % of TPO. WARNING: Disconnect primary power prior to servicing.
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Section-3 Operation
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STATUS>Drive Chain Menu Description
Menu
Description
PWR BLK 1 IPA>>
Displays Fault status and meter readings for IPA in power block 1
PWR BLK 2 IPA>>
Displays Fault status and meter readings for IPA in power block 2 (If used)
PWR BLK 3 IPA>>
Displays Fault status and meter readings for IPA in power block 3 (If used)
PWR BLK 4 IPA>>
Displays Fault status and meter readings for IPA in power block 4 (If used)
3.7.4
STATUS>POWER AMP Menu
The Power Amp submenu displays the status and meter readings for the power amplifier modules in each power block. Included in the meter readings is the Summary Fault, PA voltage and total PA DC Current for the power block. The readings for each module (except for the three power block readings) are repeated for all seven power amplifier modules in the power block. There can be up to four power blocks in the transmitter.
\
Table 3-4 STATUS>POWER AMP Menu Description
Menu
Field
Description
PA BLOCK 1
PA SUMMARY:OK
Displays PA Summary Fault: OK or Fault; Faults are OVR TEMP, OVR CUR, OVR DRV,VSWR,MOD PRESENT,UDR VOLTS for all modules.
PB AVG V:44.2V
Displays Average DC volts for the entire power block
PB TOTAL I:192.3A
Displays Total DC current drawn from the power supplies by the entire power block
PA1A:OK
Displays PAx A side Status: OK or FAULT
PA1B:OK
Displays PAx B side Status: OK or FAULT
PA 1 VDC:44.2V
Displays PAx PAV reading
PA 1A AMPS:13.8A
Displays PAx A side current reading
PA 1B AMPS:13.1A
Displays PAx B side current reading
PA 1 TEMP:45.3C
Displays PAx heatsink temperature reading
Note
PA readings will be repeated for all Power Amplifiers (4 times FAX5 and 7 times all others) and Power
Blocks (up to 4) in the transmitter.
3.7.5
STATUS>OUTPUT Menu
The OUTPUT submenu displays information on the RF power for the system and each power block. The power block readings will be repeated for each power block in the transmitter, up to four. Reject load readings are for the Power Block and/or cabinet combiner and will only be available on the FAX20/30/40 models.
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3‐15
Table 3-5 STATUS>OUTPUT Menu Description
Menu
Field
Description
OUTPUT:OK
OK, Warning or Fault
FORWARD:9901W
Displays Transmitter Forward Power
REFLECTED:0W
Displays Transmitter Reflected Power
VSWR:OK
OK or FAULT; Trips at 1.5:1
VSWR FLDBK:OK
OK or FAULT Foldback point is user settable via GUI between 1.3:1 and 1.5:1
PWR LIMIT:OK
OK or FAULT; Power limit is 110% of calibrated power; set in hardware
REJ LEVEL:0%
Displays Reject load power in percent; 100% would be with one power block off or 1 cabinet shut off
REJ LOAD:OK
OK or FAULT; Faults are RF, Fan or Temp
PA BLOCK 1
FORWARD:9901W
Displays Power Block Forward Power
REFLECTED:0W
Displays Power Block Reflected Power
VSWR:OK
OK or FAULT; Power block Trips at slightly higher than 1.5:1 for power block
VSWR FLDBK:OK
OK or FAULT; Set in code to slightly higher than 1.5:1 for power block
PWR LIMIT:OK
OK or FAULT; Power limit is 110% of power block calibrated power
Note
PA Block readings will be repeated for each Power Block in the transmitter.
888‐2720‐001
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Section-3 Operation
October 28, 2013
3.7.6
STATUS>POWER SUPPLIES Menu
The POWER SUPPLIES submenu displays information on the power supplies in each power block. The menu displays both status and meter reading for each individual supply. The Power Supply fault has three fault outputs to the transmitter, these however are tied together on the Power Supply Interface Board and reported as a generic fault. To obtain the actual fault in the power supply, refer to the troubleshooting section of this manual. Table 3-6 STATUS>POWER SUPPLIES Menu Description
Menu
Field
Description
PA BLOCK 1
PS SUMMARY:OK
OK or Fault; Any supply is faulted this will be Fault
AC MAINS:OK
AC Mains Undervoltage Monitor: OK or Fault; below approximately 190 VAC is Fault
PB AVG V:44.2V
Average power supply DC voltage in PB x
PB AVG I:192.5A
Total DC current drawn from all 7 power supplies combined in PB x
PS METERS
PS Meters for Voltage and Current
PS1:OK
OK or Fault; generic power supply fault Rectifier, Power or Temp
PS2:OK
OK or Fault; generic power supply fault Rectifier, Power or Temp
PS3:OK
OK or Fault; generic power supply fault Rectifier, Power or Temp
PS4:OK
OK or Fault; generic power supply fault Rectifier, Power or Temp
PS5:OK
OK or Fault; generic power supply fault Rectifier, Power or Temp
PS6:OK
OK or Fault; generic power supply fault Rectifier, Power or Temp
PS7:OK
OK or Fault; generic power supply fault Rectifier, Power or Temp
Note
Power Supply readings will be repeated for each Power Block in the transmitter.
3.7.7
STATUS>SYSTEM Menu
The SYSTEM submenu displays status information on the Control and Cooling sections of the transmitter If any of the submenus are not shown as NORM or OK then the System LED will be Yellow or Red.
The following are events that can issue a System Fault or Warning:
•
•
•
•
•
•
•
•
Power Mode ‐ Normal, Low or UPS
APC ‐ On or Off
Power Limit ‐ 110% of calibrated power
VSWR Foldback ‐ 1.3: to 1.5:1 User configured
Mute ‐ asserted by controller or remote Mute
Interlock ‐ External or Equipment
Control Mode ‐ Normal, Backup or Lifesupport
Fans ‐ Fan fault on door or Reject load
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October 28, 2013
•
3‐17
Airflow ‐ Measured on PS Interface board
. Table 3-7 STATUS>SYSTEM Menu Description
Menu
Field
Description
SYS SUM:OK
System summary OK, Warning or Fault
APC STATUS:ON
APC Status ON or OFF
APC MODE:DRIVE
APC Mode DRIVE(APC to Exciters) or IPA(APC to the IPA)
CTRL MODE:NORM
Control Mode NORM or Backup (Only way this can be backup is Control switch S1 on System Interface bd is set to BACKUP)
PWR MODE:NORM
PWR Mode Norm, LOW or UPS
INTERLOCK:OK
Interlock status OK or FLT(J1‐24 User Interface)
RF MUTE:NO
RF Mute NO or MUTED
REMOTE MUTE:NO
Remote Mute NO or MUTED
EQUIP INTLK:OK
Equipment Interlock OK or FLT(J1‐9 User Interface)
SYSTEM METERS
PA BLOCK x
3.7.8
APC REF:3.50V
APC Reference set by micro during system calibration
APC OUT:3.53V
APC output voltage, changes with Raise/Lower Power
PWR LIMIT:0.00V
Power Limit 0 V until the 110% power limit is reached or VSWR Foldback occurs(1.3:1 to 1.5:1)
FRONT TEMP:41.0C
Front Temperature measured on Control&Display Board(Indication Only)
FANS:OK
Status of fans on rear door of power block OK or FAULT
AIRFLOW STAT:OK
Status of airflow sensor OK or FAULT
REAR TEMP:36.1C
Rear Temperature measured on Power Supply Interface (Hot Air through PA Modules and power supplies) controls fan speed
AIRFLOW:90%
Percent of airflow measured on Power Supply Interface Board; Typically 90% under normal operating conditions. Ramps up to 100% under fault conditions and higher exhaust temperatures
STATUS>>SW REVISIONS
Software revisions currently installed in the transmitter, includes Bootloader, GUI and Application software.
3.7.9
STATUS>>TEST
Test mode is for future software development.
888‐2720‐001
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Section-3 Operation
October 28, 2013
3.8
SET-UP Button
Pressing the SET‐UP button brings up a listing all of the features the operator can control and customize in the transmitter. This sub menu also allows for all calibrations for the entire transmitter. Figure 3‐15 and Figure 3‐16 is the SETUP Menu Tree.
Note
When making changes to the transmitter via the LCD Remote must be Disabled.
Figure 3-14 SETUP Menu
When used with a FAX exciter the some exciter configure menus are available on the transmitter lcd. If these menus are blank or do not match the setup menu fields on the exciter lcd then a communications problem exists. This communication between controllers is via RS485. Ensure the transmitter interface cable is seated properly and the RS485 baud rates match in both exciter and transmitter SETUP>>NETWORK SETUP menus.
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October 28, 2013
3‐19
SETUP
TXCONTROL_______PWRMODESET:NORM
EXCONAIR:A
IPAONAIR:A
EXCSWMODE:AUTO
IPASWMODE:AUTO
APC:ON
SYSTEMSETUP_____ ID:HARRISTRAINING
DATE:06/05/2012
TIME:9:39:27AM
TXCONFIGURATION_TXMODEL:FAX20
FREQ:98.10MHz
PWR:20000Watts
U
C
S S
DUALEXCITERS:YES
INTERNALIPA:YES
ACINPUT:3D
TXCALIBRATE______TXPOWERCAL___________MODULATION:FM
TXTPO:10000W
CALIBTRATE:NO
POWERSUPPLYSET_______MODULATION:FM
PS SET:50V
PSSET:50V
SET:NO
AIRFLOWSET____________PB1AIRFLOW>>___________________________AIRFLOW:1992mV
AIRFLOWCAL:97%
SETPB1100%:NO
PB2AIRFLOW>>_______ AIRFLOW:1992mV
AIRFLOWCAL:97%
SETPB2100%:NO
PWRBLOCKCAL__________UNITPWR:10000W
CALIBRATE:NO
PB1FWD:3.53V
PB2RFLD:1.54V
REJLOADCAL____________SYSREJECTCAL>>______REJLEVEL:0%
REJSENSE:275mV
SETSYS100%:NO
CALRESTORE____________MODULATION:FM
PWRCALGAIN:2.81V
CALRESTORE:NO
Figure 3-15 SETUP Menu Tree Page 1
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Section-3 Operation
October 28, 2013
SETUPContinued
EXCITERSETUP______EXCSELECTED:A
EXCTYPE:FLEXSTAR
EXCSLCSEL:FM
EXCPWRCAL____________MODULATION:FM
EXCPWR:1990mV
EPWRCAL:2260mW
CALIBRATE:NO
SETTHRESHOLD:NO
EXCCONFIGSubmenusareforFAXExciterONLY
SeeFAXExciterManual
EXCCONFIG>>
NETWORKSETUP____ REARMACADDRESS:
REARMODE:
REARIPADDRESS:
REARGATEWAY:
REARSUBNETMASK:
FRONTMACADDRESS:
FRONTIPADDRESS:
RS485BAUDRATE:
000000000000
STATIC
137.237.245.120
137.237.245.97
255.255.255.192
000000000000
192.168.117.88
115200
DISPLAYMODE______DISPLAYMODE:EXPERT
Figure 3-16 SETUP Menu Tree Page 2
3.9
Transmitter Setup/Configuration and Calibration
3.9.1
SETUP>TX CONTROL Menu
The TX CONTROL menu allows for control of the Exciters and IPAs within the FAX transmitter.
Table 3-8 SETUP>TX CONTROL Menu
Menu
Description
PWR MODE SET
NORM, LOW (Low Power) or UPS; Low power sets RF output at approximately 25% of Calibrated power; UPS mode asserted from User Remote J1;See Note 1
EXC ON AIR
Manually switches exciters A or B to on‐air
IPA ON AIR
Manually switches IPA A or B to on‐air
EXC SW MODE
Sets Exciter switching mode between AUTO and MANUAL; See Note 2
IPA SW MODE
Sets IPA switching mode between AUTO and MANUAL; See Note 2
APC
Sets APC mode to ON or OFF; See Note 3
NOTE 1 ‐ The PWR Mode should be left in NORM, this allow for full transmitter power out. The LOW or low power mode will set the transmitter to approximately quarter power. This can be used for antenna work or anytime the need for the transmitter to operate at this level. This setting is also available via the remote GUI. The transmitter will go to this mode automatically under certain fault conditions such as reject load fault or a cooling fault.
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3‐21
Note 2 ‐ If the Exciter and IPA switch modes are set to Auto, the transmitter will still allow the user to manually force either to the off‐air IPA or exciter. However, when the switch mode is set to Manual, the IPA and exciter cannot be automatically switched. Ensure these are set to AUTO at all times unless performing maintenance. In the case of single exciter operation the Exciter switch mode is ignored.
Note 3 ‐ The APC should always be left to ON. If this is set to OFF, the transmitter power will not be controlled by APC and TPO will not be maintained to ±0.25 dB. Under certain fault conditions the transmitter controller will shut the APC off.
3.9.2
SETUP>SYSTEM SETUP Menu
The ID must be set using the Remote GUI. See Section 3.10 for details of how to connect and navigate the Remote GUI (Station Name).The ID can be up to 20 characters long before being cutoff on the LCD screen.
The DATE and TIME menus will allow for them to be changed/updated. The date is entered in mm dd yyyy format. The Month automatically becomes the first selection. The time is entered as a 24 hour clock however, after entering the time is displayed as a 12 hour clock. For example, to enter a time of 3:00 PM, enter 15 for hours.
3.9.3
SETUP>TX CONFIGURATION
Table 3-9 SETUP>TX CONFIGURATION Menu
Menu
Description
TX MODEL
FAX5/10/20/30/40
FREQ
Sets frequency (See Note below)
PWR
Sets the calibration of the bargraph on the LCD Home Screen; once forward is set the reflected will be set to 1.5:1 VSWR based on forward power
DUAL EXCITERS
YES for 2 Exciters or NO for Single Exciter
INTERNAL IPA
Yes for Internal IPA;NO for IPA BYPASS; Always IPA
AC INPUT
1PH,3D,3Y (Display Only)
FREQ is display only unless using a FAX exciter. In case of the FAX this field is bidirectional between the the transmitter and Exciter and this setting will actually change transmitter frequency.
Setting the DUAL EXCITERS to YES will enable AUTO switch function.
3.9.4
SETUP>TX CALIBRATE
The TX CALIBRATE Menu allows for calibration of all parameters in the FAX transmitter. The calibration procedures can be found in Section 5 of this manual.
3.9.5
SETUP>TX CALIBRATE>TX POWER CAL Menu
The steps for power calibration are outlined in Section 5 of this manual. These steps should be followed in order to accurately calibrate your FAX transmitter. There is a calibration point stored for each of the Modulation modes, FM,FM+HD and HD. If the transmitter is setup to run in more than one mode a power calibration must be completed for each mode that will be used.
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Section-3 Operation
October 28, 2013
.
Table 3-10 SETUP>TX CALIBRATE>TX POWER CAL
Menu
Description
MODULATION
Transmitter mode to calibrate power in;FM,FM+HD,HD; Set by exciter
TX TPO
RF Power to calibrate the transmitter at (TPO)
CALIBRATE
Calibrate YES or NO
3.9.6
SETUP>TX CALIBRATE>POWER SUPPLY SET
There is a power supply setpoint stored for each of the Modulation modes, FM,FM+HD and HD. If the transmitter is setup to run in more than one mode the supply voltage must be set for each mode that will be used. All supplies in all of the power blocks will be set to this voltage.
Warning
THE TRANSMITTER RUNS MOST EFFICIENT AT LOWER SUPPLY VOLTAGES, HOWEVER
THE TRANSMITTER CAN FAULT UNDER CERTAIN CONDITIONS (FREQUENCY, QUALITY
OF LOAD, ETC) WHEN THE POWER SUPPLY VOLTAGE IS SET TOO LOW. TYPICAL
FAULTS WILL BE PA MODULE OVERDRIVE. IF THE TRANSMITTER IS REPORTING THIS
FAULT AND POWER SUPPLY VOLTAGE IS SET TO MINIMUM, TRY RAISING THE VOLTAGE UP 2 VOLTS TO SEE IF THE PROBLEM CLEARS.
Table 3-11 SETUP>TX CALIBRATE>POWER SUPPLY SET
Menu
Description
MODULATION
Transmitter mode to set power supply voltage;FM,FM+HD,HD Should match exciter mode.
PS SET
Voltage to set the power supply DC output between 44 and 52 VDC in 0.1 Volt steps
SET
YES or NO
3.9.7
SETUP>TX CALIBRATE>AIRFLOW SET
To set airflow the transmitter fans must be at full speed which is 100% airflow. Also prior to calibrating airflow the air filters should be checked and cleaned if necessary. See Section 5 of this manual for airflow calibration procedure. Airflow calibration must be completed for power block in the transmitter.
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3‐23
Table 3-12 SETUP>TX CALIBRATE>AIRFLOW SET
Menu
SubMenu
Description
PB1 AIRFLOW
AIRFLOW
Airflow Voltage to ADC (Display Only)
AIRFLOW CAL
% of airflow currently being measured by transmitter
SET PB1 100%
YES or NO;To set airflow the transmitter fans should be running full speed which is 100% airflow.
Note
Under normal conditions the airflow % typically will be between 75 and 90 %.
3.9.8
SETUP>TX CALIBRATE>PWR BLOCK CAL
This procedure is not in the FAX5/10 menu since there is only one power block and it is calibrated using the TX PWR CAL menu. In a FAX20/30/40 there will be multiple power blocks and voltages for each will appear in the menu. See Section 5 of this manual for detailed power block calibration procedure.
The power block power cannot be measured directly with an in‐line meter, so the power will be estimated based on transmitter power which should be calibrated prior to calibrating the power block. The power block should be calibrated at the 2 % above power block power. The following example is for FAX20@ 20 kW:
(TX TPO/# of power blocks) + 2%
(20000/2) = 10000
10000 +(10000* 2%) = 10,200 Watts The 2% is an estimate of loss in the splitting and combining systems within the FAX.
Table 3-13 SETUP>TX CALIBRATE>PWR BLOCK CAL
888‐2720‐001
Menu
Description
UNIT PWR
10200W; Power that the power block will be calibrated to. CALIBRATE
YES or NO
PB1 FWD
3.50 V; Calibration reference voltage for power block forward power
PB1 RFLD
1.73V; Calibration reference voltage for power block reflected power
PB2 FWD
3.50 V; Calibration reference voltage for power block forward power
PB2 RFLD
1.73V; Calibration reference voltage for power block reflected power
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Section-3 Operation
October 28, 2013
3.9.9
SETUP>TX CALIBRATE>REJ LOAD CAL
Reject load calibration will only be in FAX20/30/40 models. It is used to calibrate the power into the power block combiner reject load (6 kW) and the cabinet combiner reject load (12 kW). There will be multiple Reject Loads in the FAX30/40 models. See Section 5 of this manual for detailed Reject Load calibration procedure.
Table 3-14 SETUP>TX CALIBRATE>REJ LOAD CAL
Menu
Description
REJ LEVEL
0%;Power that is currently input to reject load (Display Only)
REJ SENSE
275 mV; Voltage from reject load detector that is on Fan Control Board (Display Only)
SET SYS 100%
YES or NO
3.9.10
SETUP>TX CALIBRATE>CAL RESTORE
Used to restore last calibration stored in memory. Only one is stored. If a calibration is completed, ie forward or reflected power, and it is not correct restore will not correct the problem. Calibration will be required again. Table 3-15 SETUP>TX CALIBRATE>CAL RESTORE
Menu
Description
MODULATION
Mode transmitter is in, FM, FM+HD or HD
POWERCAL GAIN
Calibration Gain setting for transmitter (Display only)
CAL RESTORE
YES or NO
3.9.11
SETUP>EXCITER SETUP
Allows for setup and power calibration for each exciter. Also to set the Threshold where the exciter switches to the backup.
Table 3-16 SETUP>EXCITER SETUP
Menu
Submenu
Description
EXC SELECTED
A or B; Set to on‐air exciter; See Note 1
EXC TYPE
Set to Exciter type; DIGIT,FLEXSTAR,FAX, MICROMAX,SUPERCITER, CUST DRV,CUST IPA; See Note 2
EXC SLC SEL
NA,FM or HD; See Note 3
EXC PWR CAL
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MODULATION
FM,FM+HD or HD Display Only of current exciter mode EXC PWR
1990mV; See Note 4
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3‐25
Table 3-16 SETUP>EXCITER SETUP
Menu
Submenu
Description
EPWR CAL
2260mW: Power to cal at, should match EXC PWR above
CALIBRATE
YES OF NO; See Note 5
SET THRESHOLD
YES or NO; See note 6
Note 1 ‐ Selecting Exciter A or B in this menu does not change the on‐air exciter. This allows for setup up of the exciter that is currently on‐air, not for calibrating the off‐air exciter. Ensure that the correct exciter is selected in this menu.
Note 2 ‐ Exciter type must match the exciter model for the exciter selected. For Harris Broadcast products, the list is filled with models currently available. For non‐Harris Broadcast exciters, select either CUST DRV or CUST IPA. CUST DRV is for non‐Harris Broadcast exciters that have an external APC input that can accept 0‐4.75 VDC. The exciter must have a fast enough APC response time to allow the exciter to vary its output power with respect to this voltage. The transmitter will increase this APC voltage when it requires more drive and decrease this voltage when it requires less drive. When using CUST DRV, the IPA within the FAX is set for maximum gain. If trying to run in the FM+HD or HD modes, this setting is required.
CUST IPA is for non‐Harris Broadcast exciters that do not have an external APC input. In this mode, the exciter will put out a fixed drive using its internal APC and the APC from the transmitter will drive the FAX IPA. This mode cannot be used for any HD modes. If using CUST IPA dipswitch S1‐5 on PA Backplane board 1(top board) where the IPA plugs in must be set to ON. This passes the APC voltage to the IPA.
Note 3 ‐ EXC SLC SEL is used only for Split Level Combined systems. This setting will depend on the mode of the FAX in SLC operation, NA for non‐SLC applications.
Note 4 ‐ The exciter voltage will be set bu the scaling in the exciter. In Harris Broadcast exciters it is typically set to 4 VDC=x Watts. This voltage should be set as close as possible to 2000 mV at TPO when dual exciters are used. Note 5 ‐ Exciter calibration must be completed for each mode of operation that will be used by the transmitter. Note that the exciter calibration is in milliwatts not watts. Most Harris Broadcast exciters display in Watts.
Note 6 ‐ The threshold setup is for dual exciter systems only and sets the point were changeover occurs. The actual switchover is based on the voltage from the exciter and the threshold can be set in the range of 100 mV to 2000 mV. If outside that range the default is 40 % of the calibrated voltage. 3.9.12
SETUP>NETWORK SETUP
The network setup page refers only to the rear Ethernet port of the FAX transmitter.
The following ports are used in the FAX transmitter. Webserver ‐ Port 80 TCP/UDP
Telnet ‐ Port 23 TCP/UDP
SNMP ‐ Port 161 TCP/UDP (User configurable 161, 162, 49152 to 65535)
SNMP Traps ‐ Port 162 TCP/UDP
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Section-3 Operation
October 28, 2013
Table 3-17 SETUP>NETWORK SETUP
Menu
Description
REAR MAC ADDRESS
00‐00‐00‐00‐00‐00; Display only
REAR MODE
STATIC or DHCP
REAR IP ADDRESS
192.168.1.10
REAR GATEWAY
255.255.255.0
REAR SUBNET MASK
192.168.1.1
FRONT MAC ADDRESS
00‐00‐00‐00‐00‐00; Display only;See Note 1
FRONT IP ADDRESS
192.168.117.88; Display only
RS485 BAUD RATE
115200 or 312500; when used with FAX Exciter ONLY, must match exciter
Note 1 ‐ The front panel Ethernet port is setup as a DHCP server and a LAN should NOT be connected to this port. This port is setup for local test and monitoring and the default IP address is factory set to 192.168.117.88. It will automatically assign the computer an IP address on its subnet. To make any changes to the setup via the front Ethernet port, REMOTE must be disabled.
If a remote control connection is to be made via IP, the rear Ethernet port should be used for this purpose. Using the SETUP>NETWORK SETUP menu, the rear Ethernet port parameters can be changed. These parameters include IP address, Subnet Mask, Default Gateway and Mode.
To access the GUI a simple web browser can be used. To login and navigate the Remote GUI see 3.10 Remote Graphical User Interface (GUI) of this manual.
3.9.13
SETUP>DISPLAY MODE
Display mode can be either EXPERT or NOVICE. Setting Display Mode to Novice locks out the ability to change the transmitter setup and controls within the Setup menu. This screen is not password protected and accessible by anyone.
3.9.14
SETUP>RESTORE DEFAULTS
Restore defaults allows the user to restore the factory setup, which is the way the transmitter shipped after final test.
3.10
Remote Graphical User Interface (GUI)
The Remote GUI can be accessed from either the front or rear Ethernet port on the FAX transmitter. It requires a login on both ports. This login screen is shown in Figure 3‐17.
The Front Ethernet port is a DHCP Server, it should not be connected to the LAN/WAN or IP addressing problems will occur. The front Ethernet port IP address is 192.168.117.88 and is coded into the software so the user cannot change it. See Section 3.7.12 for setting up the rear Ethernet port.
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WARNING: Disconnect primary power prior to servicing.
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October 28, 2013
3‐27
Figure 3-17 Remote GUI Login Screen
Note
Depending on the version of software the factory default LOGIN’s and PASSWORD’s may be different.
Beginning in August 2013 these were changed. See below for more details. Old passwords will be
retained when upgrading.
Beginning August 2013:
From the login screen there are three logins that are set at the factory. The passwords are case sensitive and max 9 characters.
Engineer Login 1 ‐ Username: harris; Password: harris
Engineer Login 2 ‐ Username: user2; Password: pass2
Engineer Login 3 ‐ Username: user3; Password: pass3
Engineer Login 4 ‐ Username: user4; Password: pass4
Administration Login ‐ Username:admin; Password: admin
The Engineer logins allow full control and monitoring of the transmitter. To make changes via the Front Ethernet port, REMOTE must be set to Disable. If connecting to the rear Ethernet port REMOTE must be set to Enable.
The Administration login, Figure 3‐18, allows for the user to setup the passwords for the Engineer logins, set the password for the netadmin login, and the set the timeout for the GUI. The netadmin username and password can be changed.
Prior to August 2013:
From the login screen there are three logins that are set at the factory. The passwords are case sensitive and max 9 characters.
Engineer Login 1 ‐ Username: admin; Password: admin
Engineer Login 2 ‐ Username: user2; Password: pass2
Administration Login ‐ Username:netadmin; Password: harris
The Engineer logins allow full control and monitoring of the transmitter. To make changes on either Front Ethernet port, REMOTE must be set to Disable.
The Administration login, allows for the user to setup the passwords for the Engineer logins, set the password for the netadmin login, and the set the timeout for the GUI. 888‐2720‐001
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Section-3 Operation
October 28, 2013
Figure 3-18 Administration login Screen
3.10.1
GUI HOME SCREEN
After the user has correctly entered one of the two Engineer login/password combinations the GUI will open at the FAX Home screen shown in Figure 3‐19. All of the configuration settings available are under the SYSTEM button on the home screen. Each of these menus will be described in the following sections. The other buttons are for control and monitoring, these are the same parameters that were discussed in the LCD menu tree Sections above. It is best for the users to navigate through these to get familiar where to find information about each section of the transmitter.
Figure 3-19 GUI Home Screen
The buttons on the right side of the home screen are for monitoring, setup and control. Each button will take the user to a submenu (s). No changes can be made and no control is available unless a valid Engineer login is used. If using the rear Ethernet port Remote must be enabled and if using the front Ethernet port Remote must be disabled.
Transmitter ID ‐ The middle of the top bar shows the ID, this can be changed in the SYSTEM>SERVICE> menu. The Station ID can be up to 20 characters long.
Transmitter Model ‐ Top bar on the right side shows the model of FAX 5/10/20/30/40.
EVENT LOG ‐ Displays the Event Log
FWD 100% Mark ‐ The vertical bar in the power bargraph reflected power display is 100% power based on the “Nominal Power (w) in the SYSTEM>SETUP Menu. This can also be changed in the SETUP menu on the LCD. This is not necessarily the power the transmitter was calibrated at.
RFLD 100% Mark ‐ The vertical bar in the power bargraph display for reflected power is 100% power based 1.5:1 VSWR of the calibrated power.
Mode ‐ shows the current operating mode of the transmitter, FM, FM+HD,HD or SLC. Display Only.
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3‐29
Frequency ‐ Shows current operating frequency of the transmitter entered into the FAX. For FAX exciters this changes the exciter frequency via RS485. For all other exciters it is display only and to see current frequency the operator must refer to the exciter frequency.
The icons in the middle of the screen are analogous to the buttons on the right side of the display. If one or more of the icons are red, that icon can be clicked on and the user can drill into the submenus to find a particular fault. The fault log can also be viewed under the SYSTEM menu by clicking the SYSTEM button and navigating to the fault log. The Primary Faults will turn Red when any of the events shown changes state.
AC Mains ‐ Faults when the AC line voltage to the main power supplies drops below 190 VAC on any phase.
External Interlock ‐ Turns red when the External Interlock on the Remote connector J1‐24 and J1‐25 are not closed.
VSWR ‐ Faults at VSWR of 1.5:1
Exciter Trip ‐ Displays the status of the internal Exciter switchover relay.
IPA Trip ‐ Displays the status of the internal IPA switchover relay.
Foldback ‐ Warning at 1.3:1 VSWR (factory Default). This setting can be changed in the GUI SYSTEM>SERVICE Menu. The range is 1.3 to 1.5.
3.10.2
Event Log Menu
Figure 3-20 GUI Fault/Event Log Screen
The Fault/Event log in software revisions prior to Application code 24 was strictly a Fault log. The log is shown in Figure 3‐20. Faults are shown as active, in red, and cleared with date and time. To reset the log click on the Reset Log button. To display only Active Faults click on the Active Faults button.
The first fault in Figure 3‐20 shows that PA4 was out in power block 1 (PB1). The fault occurred at 15:41:41 on 10/
02/12. It was cleared at 14:41:42 on 10/02/12.
The events can be filter by clicking on any of the letters in the [AC / FWIA].
A = Active Faults
C = Cleared Faults
F = Faults
W = Warnings
I = Information
A = Action
Clicking the floppy disk icon will open a new tab in the web browser, this can then be saved as a text file, html file or copy and pasted into excel.
Clicking on the printer icon will allow the event log to be printed to an installed printer.
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Section-3 Operation
October 28, 2013
3.10.3
System>System Setup Menu
Figure 3-21 System Setup Screen
Frequency ‐ Set in the LCD SETUP menu. Sets the exciter frequency when used with FAX exciter. All other exciters this is display only.
Nominal Power ‐ Sets the 100% mark on Bargraph for forward power
Number of Exciters ‐ Must be set to 2 for dual exciter mode. This will enable auto switching function
Internal IPA ‐ Always set to YES (Future Need)
AC Mains ‐ Display only, has no effect on transmitter operation
VSWR Foldback ‐ Sets the foldback point between 1.3 and 1.5. Factory default setting is 1.3. This setting affects only the transmitter VSWR not each individual power block VSWR. The power blocks are set to foldback at 1.5:1 in FAX20/30/40.
Fwd Pwr Warn Thresh (dB) ‐ If RF power out drops below this threshold a Warning will be generated and Bargraph will turn Yellow. This is based on calibrated power.
Fwd Pwr Fault Thresh (dB) ‐ If RF power out drops below this threshold a Fault will be generated and Bargraph will turn Red. This is based on calibrated power.
3.10.4
System>System Setup>System Service Menu
Figure 3-22 TIME Screen
Station Name ‐ Up to 20 characters
Model Number ‐ Set at factory
Serial Number ‐ Set at the factory
Feature Key ‐ Sets up the options that are installed in the exciter. Contact Harris Broadcast Service for details
Date/Time ‐ Sets the clock in the transmitter. Disabled when NTP is enabled. See Section 3.10.8 for NTP Config.
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3.10.5
3‐31
System>System Setup>System Config Menu
Figure 3-23 System Config Screen
Programmable Output 1‐4 ‐ Allows for 4 Remote I/O outputs on J1 User Remote to be user configured. Drop down box shows available settings.
Exciter Configuration ‐ Allows for selecting the exciter type for each exciter in service. Drop down box shows available settings.
3.10.6
System>System Setup>Network Menu
The Network screen allows configuration of the rear Ethernet port.
Note
Be sure to click Save before exiting screen or changes will be lost. Save will appear once changes are
made.
Figure 3-24 Network Setup Screen
Front Ethernet Port IP Address is hard coded in software and cannot be changed.
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Section-3 Operation
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3.10.7
System>System Setup>Network>SNMP Menu
The Harris Broadcast transmitter family supports monitoring and alarming functionality via SNMP (Simple Network Management Protocol). Basic control of the equipment is possible after activation in the equipment. SNMP versions V1 and V2c are implemented.
Figure 3-25 SNMP Screen
MIBs ‐ Base MIB is Standard Harris Broadcast Transmitter MIB. IRT MIB is extended MIB, with functions for Dual Exciters. Check box to enable MIB.Un‐checked disables MIB.
Port ‐ Default is 161 (range is 161,162,49152‐65535)
RD Community ‐ Read Community Private or Public; Default set to Public
RW Community ‐ Write Community Private or Public; Default set to Private
SNMP Version ‐ FAX allows for version 1 or 2c only
Trap 1‐3 ‐ IP address of SNMP trap receiver. Port 162 is default trap port, not changeable. Community Public or Private.
The Harris Broadcast MIB’s are usable in all NMS (Network Management Systems) and is provided in text‐format. The advantage of this monitoring system is, that there is no difference between the monitoring of various Harris Broadcast equipment. Once the MIB is integrated into the NMS, all different devices can be monitored via the central station.
The Harris Broadcast MIB files, Base and IRT, for use with SNMP connectivity are available on the Harris Broadcast Customer Portal at www.ecustomer.broadcast.harris.com (registration required)
3.10.8
System>System Setup>Network>NTP Menu
Note
For NTP to work a connection to the Internet is required.
Allows for time and date setup in the FAX transmitter via NTP, this is used for accurate time/date in the Event Log only. The time reference can be changed to UTC (Requires Server address). To change Reference go to the System>Network>NTP menu.
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3‐33
.
Figure 3-26 UTC Time Setup
If using the UTC setting for more accurate time and date, an IP address of a UTC time server must be entered. A list of time server IP addresses can be obtained from NIST.
NTP ‐ Enabled or Disabled
NTP Server ‐ IP Address of one of the NTP Time servers throughout the world.
Update Interval ‐ Transmitter will update Time via NTP per this setting. Range 2 ‐ 1000 minutes.
UTC OFFSET Hrs ‐ Enter an offset in hours that your location is from Greenwich Mean Time. User must take into consideration daylight savings time if applicable.
UTC OFFSET Min ‐ Enter an offset in Minutes that your location is from Greenwich Mean Time. User must take into consideration daylight savings time if applicable.
3.10.9
SYSTEM>System Setup>Network>ISP Menu
Figure 3-27 ISP Screen
The ISP menu is used for uploading software the FAX and also to save a configuration file from the transmitter. This configuration file contains all of the user settings as well as calibration data. It is a good practice to save a configuration file when installation of the transmitter is complete as well as when any configuration or calibration changes have been made. See Section 5 of the manual for uploading software and saving configuration procedures.
Note
The preferred method of uploading software to the FAX is using the ISP external to the GUI. The external
ISP menu can be obtained by typing in the IP address as shown (front panel): 192.168.117.88/isp.
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Section-3 Operation
October 28, 2013
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4‐1
FAX 5/10/20/30/40KW
October 28, 2013
Section-4 Theory
4
4.1
FAX Transmitter Configurations
The following theory of operation is intended to provide a general overall knowledge of how the FAX high power series (5 kW through 40 kW) of transmitters work. The FAX series of transmitters can be operated in any one of three modes, which are:
•
•
•
The analog FM mode, with the PA modules operated class C mode to maximize efficiency.
The multiplex mode where analog FM and digital (HD) RF signals are both amplified in the same power ampli‐
fiers. For this mode, the PA modules are operated class AB, because digital HD requires linear amplifiers.
Digital HD mode only. For this mode, the PA modules are operated class AB, because digital HD requires linear amplifiers.
The 10 kW FAX transmitter is the basic building block for all other high power FAX transmitters. The FAX10 does not contain an integrated exciter at this time and requires an exciter external to the transmitter chassis. All FAX transmitters have provisions for dual exciters with internal RF switching. All of the current Harris Broadcast FM exciters can be used or the FAX is setup to allow another manufacturers exciter to be used. The 5 kW FAX transmitter has the identical hardware of the FAX10, except there are four less PA Modules and three less PS Modules. The 5 kW exciter setup is slightly different than the 10 kW and will be explained in the 5 kW section.
A 20 kW FAX transmitter consists of a 10 kW transmitter and a 10kW Power Block combined. The 10kW transmitter is referred to as the primary power block or power block 1 because it contains the front panel LCD Display and Multi‐unit Interface that controls the overall transmitter. The FAX20 is housed in a single cabinet.
A 30 kW FAX transmitter consists of a 10 kW transmitter and two 10 kW Power Blocks combined. The FAX30 is housed in two cabinets with a cabinet combiner that combines them.
A 40 kW FAX transmitter consists of a 10 kW transmitter and three 10kW Power Blocks combined. The FAX40 is housed in 2 cabinets like the FAX30
4.1.1
10kW RF Block Diagram Description
Figure 4‐1 shows the RF block diagram portion of a FAX 10 kW transmitter. It has seven PA modules and one IPA module that have identical hardware and are interchangeable in the event of failure.
The two main differences between the PA Module slot and the IPA module slot is the IPA uses only one of its FET’s and the other as a backup IPA. The other difference is the IPA can accept the APC is case the exciter has no external APC input.
FAX PA Modules consists of a pair of RF pallets driven and combined externally. A module control board provides simple control functions including turning the amplifier on and off, set the mode of operation between class C operation for FM service, and class A/B for digital service and fault monitoring and reporting. 888‐2720‐001
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Referring to Figure 4‐1, the output of the RF Switch board feeds a 2‐way Wilkinson splitter. The outputs of the 2‐
way splitter in turn feed two 7‐way Wilkinson splitters. This divides the IPA output by 14 equal signals to feed each of the 14 FETs on 7 PA modules. The RF output from each of the 14 FETs is then fed to the 14‐way Wilkinson combiner. The 14‐way combiner also houses a low pass filter to remove any harmonics from the amplifiers.
Wilkinson splitters were used to provide better isolation, lower loss and 0 degrees phase shift. This phase becomes important when we discuss the combining of the power blocks in the FAX20/30/40.
The output of the LPF then goes through a 6‐port directional coupler to a 1‐5/8" EIA Unflanged output on the rear of the transmitter.The ports on the directional coupler feed the controller RF sample for APC and VSWR detection. There are also ports for modulation monitoring and the RTAC signals for the Flexstar Exciter Pre‐Correction when the transmitter is running in Class AB mode.
IPA RF Switch Module
Exciter A RF Input
IPA Module
Exciter B RF Input
Exciter Switch
Relay, on System
Interface Board,
PA Backplane
IPA RF Output to
PA System 2-Way
Splitter
PA Module
PA Module
7-Way
Splitter
PA Backplane
PA Module
RF Input From IPA
High Level RF Switch
2-Way
Splitter
PA Module
14-Way
Combiner/
LPF
RF Output
through a
multi-loop
Directional
Coupler
PA Backplane
PA Module
7-Way
Splitter
PA Module
PA Backplane
PA Module
Figure 4-1 FAX 10 kW Power Block
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PA BackPlane
IPA RF Level
To Sys Inf
Rear
Panel
J4
J12
RF Switch Bd
Exc A
J2
J4
J5
4‐3
A
J5
J3
J7
J4
To 14-Way
Splitter
J6
B
J13
Exc B
RF Switch Bd
System Interface
Board
Exciter power displayed
on FAX is a DC Voltage
from Exciter. There is
no RF detector for
Exciter Power
IPA
Module
IPA RF Level Detected on
RF Switch board, it is DC
voltage used for IPA RF
Fault and switching
RF Switch Bd relays switch in
tandem. For FAX20/30/40 All IPA’s
will be on A or B
3 dB Pad provides isolation between
Exciters and IPA and helps prevent
overload of IPA
Figure 4-2 FAX10/20/30/40 Drive Chain
The block diagram in Figure 4‐2 shows the FAX10/20/30/40 RF flow from the exciters to the output of the IPA switch that drives the power block splitter. The dual exciters are shown feeding an exciter selector switch. The exciter selector switch relay is located on the System Interface Control Module located to the right of the Power Supply Modules. In a dual Exciter system, the system controller will automatically switch when the on‐air exciters RF power drops below a preset level. This level can be set by the user.
The output of the Exciter switch relay goes to the IPA Switch Board input. The input of the RF Switch board has a 3 dB pad for isolation between the exciter and the IPA. The IPA switch has 2 relays one on the input to the IPA and one on the output of the IPA, these switch in tandem. For protection, the transmitter will be muted while switching occurs.
The RF Switch board also contains the IPA RF output level detector. The IPA switches when the detector output drops below 0.5 VDC.
4.1.2
FAX5 RF Block Diagram
The FAX5 utilizes the same chassis and hardware as the FAX10. However, it uses fewer PA modules and Power supplies and also has a slightly different RF Chain. In the 10 kW transmitter there are 14 FET’s to achieve 10 kW, so in a FAX5 seven FET’s are required. In this case there are 3 PA modules and one IPA/PA module.
Refer to Figure 4‐3, the exciters now have two different paths and only 1 IPA. The other FET in the IPA slot runs continuously as a PA. Exciter A is a high power exciter and bypasses the IPA and drives the 7‐way splitter directly. This requires the exciter to output approximately 60 Watts which is the normal IPA power. If Exciter A power out drops below the preset level (0.5 VDC on the detector) and the transmitter switches, Exciter B then drives the IPA and runs at approximately 3 Watts. The RF Switch that was used for IPA’s now is the exciter switcher in the FAX5. The Exciter switch that resides on the System Interface board is not used.
All other circuits in the FAX5 work identical to the FAX10.
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Section-4 Theory
October 28, 2013
PA BackPlane
High Power Exciter
Rear
Panel
IPA RF Level
To Sys Inf
J4
RF Switch Bd
Exc A
J2
A
J5
J3
To 7-Way
Splitter
J6
B
J7
J5
J4
Exc B
RF Switch Bd
Low Power
Exciter
IPA/PA0
Module
Exciter power displayed
on FAX is a DC Voltage
from Exciter. There is
no RF detector for
Exciter Power
RF Switch Bd relays switch in
tandem. For FAX20/30/40 All IPA’s
will be on A or B
3 dB Pad provides isolation between
Exciters and IPA and helps prevent
overload of IPA
IPA/PA0 Module
uses one FET as
a IPA and one as
PA.
IPA RF Level Detected on
RF Switch board, it is DC
voltage used for IPA RF
Fault and switching
Figure 4-3 FAX5 Drive Chain
4.1.3
FAX20 RF Block Diagram
The FAX20 contains two 10 kW power blocks in one cabinet. One power block contains the Micro Module controller, the other power block has only a LED Status board. Figure 4‐4 is a block diagram of the RF of the FAX20.
3 dB Hybrid combiner
requires 90° Phase to
combine at the RF Output
10 kW -90°
-3 dB @ -90°
20 kW
PB1
Exciter
Drive
Ʃ
÷
10 kW 0°
-3 dB @0°
Splitter on Multi-Unit
Interface Panel
3 dB Hybrid type
PB2
6 kW
RJ
LD
0° Phase shift through
power blocks, all splitters
and combiners are
Wilkinson type
Reject load
sized to ½
power of 1
power block
To calibrate
shut off 1
power block
for 100 %
Figure 4-4 FAX 20 RF Block Diagram
The output of the Exciter switcher drives a 2‐way splitter. This splitter is a 3 dB Hybrid type and one output port has a 90° phase shift. The power blocks each have a 0° phase shift which allows for the correct phasing at the power block combiner. The 6 kW power block combiner reject load is sized to accept half the total RF in the case where one power block is off. Copyright ©2013, Harris Broadcast
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4.1.4
4‐5
FAX30 RF Block Diagram
The FAX30 contains three 10 kW power blocks in 2 cabinets. One power block contains the Micro Module controller, the other power blocks have only a LED Status board. Figure 4‐5 is a block diagram of the RF of the FAX30.
3 dB
3 dB
-4.77 dB
-90°
10 kW -90°
20 kW -90°
PB1
-1.6 dB 0°
÷
Exciter
Drive
Ʃ
10 kW 0°
÷
4.77 dB
PB2
-4.77 dB
0°
30 kW
4.77 dB
6 kW
RJ
LD
Ʃ
3 dB
10 kW -180°
PB3
-4.77 dB -90°
÷
-4.77 dB -180°
12 kW
RJ
LD
All splitters and combiners external to
the power blocks are Hybrid type
Reject load
sized to 1
cabinet
Figure 4-5 FAX30 RF Block Diagram
The output of the Exciter switcher drives a 2‐way splitter. This splitter is a 4.77 dB Hybrid type and one output port has a 90° phase shift. In cabinet 1 (‐1.6 dB/0° port) drives a second 3 dB hybrid. The output provides the correct phase shift to combine the 2 power blocks in cabinet 1 and the RF signal now has a ‐90° phase shift compared to the input signal. To get this signal to combine with cabinet 2 an additional phase shift of ‐90° is required in cabinet 2 so that the inputs to the 4.77 dB cabinet combiner are ‐90° from each other.
The system now requires 2 reject loads, a 6 kW power block combiner reject load and a 12 kW cabinet combiner reject load. The cabinet combiner load is sized to accept half the total RF in the case where one cabinet is off. 888‐2720‐001
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Section-4 Theory
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4.1.5
FAX40 RF Block Diagram
The FAX40 contains four 10 kW power blocks in 2 cabinets. One power block contains the Micro Module controller, the other power blocks have only a LED Status board. Figure 4‐6 is a block diagram of the RF of the FAX40.
3 dB
20 kW -90°
10 kW 0°
-6 dB 0°
3 dB
PB1
-3 dB 0°
÷
10 kW -90°
3 dB
PB2
-6 dB -90°
3 dB
Exciter
Drive
40 kW
6 kW
RJ
LD
÷
3 dB
3 dB
10 kW -90°
-6 dB -90°
PB1
20 kW -180°
-3 dB -90°
÷
12 kW
RJ
LD
10 kW -180°
Reject load
sized to 1
cabinet
PB2
-6 dB -180°
6 kW
RJ
LD
All splitters and combiners external to
the power blocks are Hybrid type
Figure 4-6 FAX40 RF Block Diagram
The FAX40 is basically two FAX20’s combined. There is an extra 2‐way splitter on the input and a 3 dB Hybrid combiner on the output with the associated reject load.
4.1.6
System APC
The FAX APC (Automatic Power Control) operates in two modes, Exciter or IPA. With the exception of the Micromax, all Harris Broadcast exciters will have an external APC input. In this case the APC would feed the exciter. If the exciter does not haven external APC input that is able to accept the level from the FAX transmitter then the APC would feed the IPA inside the transmitter. The APC from the FAX10/20/30/40 is in the range of 0 to 3.5 VDC, 0 V being 0 watts out of the exciter. For a FAX5 the APC is 0 to 4.75 VDC.
Figure 4‐7 shows a simplified block diagram of the FAX APC which is located on the System Interface/Multi‐Unit Interface board depending on the FAX model. The Power Control Reference is actually derived from the Micro and Control and Display board. This reference shown on the block diagram as pwr_ctrl_ref, is set during the calibration process at 3.5 VDC at the calibrated power. The pwr_ctrl_ref voltage stays constant, the only thing that changes this in Normal control mode is the user raising or lowering power.
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4‐7
Figure 4-7 APC Simplified Block Diagram
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Section-4 Theory
October 28, 2013
In the event of a failure and the transmitter goes to Backup control, the Backup Control Ref pot would become the power reference. The raise/lower power buttons will not function, however the APC still functions and the power can be adjusted using the pot.
The APC is affected by several control lines in the system, forward power, reflected power foldback, forward power limit and mute. When the forward power changes the APC changes in the opposite direction, ie if forward power increases the APC voltage decreases thus lowering the exciter power which in turn lowers the transmitter power back to its setting.
If the transmitter has an elevated reflected power that is above a user set threshold of 1.3 to 1.5:1, the voltage on the VSWR Foldback line increases, this causes APC to lower the exciter power. If the forward power limit, which 10% above calibrated power is hit, the Forward Power Limit voltage is increased which decreases the exciter power. If the instantaneous reflected power exceeds 1.5:1, the VSWR Fault circuit will send a Fault OFF the controller as well as a Mute to the APC. The controller will make three attempts to bring the transmitter back to power. After the third attempt the transmitter will stay off and will require user intervention to turn it back on. In Backup control the three‐strike is no longer available and the transmitter will remain OFF in the event of a VSWR fault.
The APC is shown driving the exciter, if a product such as the Harris Broadcast Micromax is used, the APC switch to the exciter is opened and the APC switch to the IPA is closed. The APC still functions the same but the extra Op‐Amp sets the correct level for the FAX IPA input.
4.1.7
PA Module Description
Each PA Module contains 2 RF Power Amplifiers referred to as "A" and "B." A FAX 10 kW Transmitter and Power Block uses 8 of these modules. One of the eight modules is used as an IPA module. Figure 4-8 PA Module
Figure 4‐8 above right side shows the PA Module with the cover off. There are 2 PWAs. On the left is the PA pallet which contains amplifiers A and B. On the right is an additional circuit card that contains the module control logic and interface functions. The PA circuit board is mounted on a thick solid copper substrate. The RF Power transistors are soldered down directly to the copper substrate. Copper is used because it is the best conductor of heat and will dissipate the heat away from the RF power transistors quickly and evenly. The copper substrate then mounts to the aluminum heatsink assembly to dissipate the heat away from the copper. There is a thin film between the copper spreader and the aluminum heatsink for optimum heat transfer.
The RF signal is amplified in the PA modules by specially designed LDMOS Power FETs with a nominal gain of 14 – 22 dB, depending on frequency and operating mode. Both sides are identical so only one path will be described. RF drive power enters Amplifier via J1. RF passes through a forward power coupler for overdrive detection, then to an input matching network to the FET Q1. The FET operates in push‐pull to produce approximately 800W FM power into a 50 ohm load. Their low impedance outputs are transformed via the output network to 50 ohms and passed to a reflected power coupler for VSWR protection. RF Output exits the board via edge connector pins on J1. Copyright ©2013, Harris Broadcast
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4‐9
To make the module safe to hot plug it the traces for the RF output, RF input and +VDD are a different length, See Figure 4‐9. The RF output traces are longest so when inserting a module the load is the first to be connected. When removing a module the load will be the last to be disconnected. Next in length is the +VDD and finally the last to be connected inserting and the first to be disconnected removing a module is the RF input drive.
RF Output
+VDD
RF Input
Figure 4-9 PA Module Edge Connector
The +VDD PA voltage has a range from +44 VDC to +52 VDC. The actual voltage varies depending on which mode the transmitter is in: FM only, FM + HD, or HD only mode. The reason to have different voltages for different modes is to maximize transmitter PA efficiency and spectrum performance. The gate bias circuit performs 3 functions: PA ON/OFF, Class C Bias for FM Mode of operation, and Class AB Bias for HD Modes. A control voltage of ‐5V at J2‐4 turns Q5 off which allows the RF Amplifier to operate. The Bias Mode voltage alters the PA bias voltage to cause the PA amplifier to operate at Class AB or Class C. The control voltages come from the module Control board. Thermistors RT1 and RT2 are used to stabilize the bias as the temperature of the module varies. Pots R102 and R103 are set at the factory to precisely set the Class AB bias. Pots R101 and R104 are adjusted for Class C operation. These pots should not be adjusted. Thermistor RT3 monitors the heatsink temperature. If the heatsink temperature gets too high (90° ‐ 100°C), the Module Control board will shut off the full PA Module. 4.1.8
Power Supply System Description
The Power Supply Interface Board performs several functions as follows:
•
•
•
•
•
Interfaces power supplies DC output with the PA modules
Busses dc from supplies for IPA and fans
Monitors AC line for under voltage
Monitors airflow and exhaust air temperature
Provides distribution of the +5 VDC to the rest of the system
Figure 4-10 Power Supply Interface Board
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The AC Mains connect to the board which feeds the AC into each power supply module. The power supplies are single phase input and operate from 190 to 300 VAC, 50 or 60 Hz. The AC service connected to the FAX must have a Line to Line voltage or Line to Neutral voltage that falls within this range. The AC service into the transmitter or AC distribution panel in the rack can be single phase, 3‐Phase Delta or 3‐Phase Wye. There is an AC Mains Monitor circuit that monitors for low voltage only. The approximate trip point is just below 190 VAC which produces a fault but no action is taken, the transmitter will stay on the air. The transmitter will continue operate when 1 or 2 phases are lost but at a much reduced power. In the power block the supplies are distributed across the phases.
Control signal PA ON/OFF from the System Interface Controller, named PS_ON on PS Interface board, feed each power supply to turn its DC output ON or OFF. The DC output can be in the range from +44 VDC to +52 VDC to accommodate different modes of transmitter operation. There is a +VDC output from each of the 7 supplies to feed 7 PA Modules. Each PA has a dedicated Power Supply Module. If a Power Supply Module fails, the associated PA Module will shut off. This configuration allows for multiple failures while the remaining supplies keep the transmitter on the air at a reduced power level. The +VDC for the IPA comes from a diode controlled sharing circuit that connects to each of the PS +VDC lines. Because of the power supply module sharing, multiple supply failures will not affect the IPA +VDC. The IPA has an in‐line fuse F10 (15 Amp) on board. In the Normal Control mode +VDC output is controlled via RS485, if in Backup Control the power supply voltage will change by approximately 2 V when switched between Class C and Class AB. There must be at least two functioning power supplies for the transmitter to remain operating.
There is an auxiliary +5 VDC output from each supply. This supply is the main 5 Volts that feeds the control circuitry. There are no other power supplies in the system. Any other voltages on any of the boards in the transmitter are regulated from the 5 Volts. In the case of FAX models with multiple power blocks, the +5 VDC from each is diode gated back to the main power block. If the AC fails to the main power block which houses the Multi‐Unit controller the transmitter will remain on the air using 5 Volts control voltage from the other power blocks.
The Airflow is measured by comparing two LM50B temperature sensors, one a heated reference sensor the other in direct path of airflow. When the airflow in the transmitter drops the sensor in the airflow path will increase in temperature and its output will trip U2‐7 causing the transmitter to shut off. Once airflow returns the transmitter will automatically turn back on.
Dipswitch S1 serves 2 functions, sections 1 and 2 are used to set the AIRFLOW fault trip level. Switches 4, 5, 6, and 7 are used to disable Power Supply Modules 4, 5, 6, and 7 in the FAX 5 transmitter as it only uses 4 Power Supply Modules. In the 10kW Power Blocks, the are set in the OPEN (OFF) position.
Power for the Fans also is provided by the Power Supply Module’s sharing circuit. The shared PA Volts feed fuse F9 (15 Amp) then to the Fan Control Board.
4.1.9
Fan Control Board Description
The Figure 4‐11 shows the Fan Monitor board. The Fan Control board monitors each fans tach, controls the speed of the fans and also has a RF power detector when used on a reject load.
The cooling fans in the system are variable speed and run at a reduced speed under normal operating conditions. When certain faults occur, such as a PA fault, the controller ramps all fans in the system to full speed. This would include the reject load in the FAX20/30/40 transmitters. If a fans tach drops below a preset hardware limit, the board reports a fault back to the FAX main controller. The fault also lights a corresponding LED that can be seen on board at the rear door of the transmitter.
The RF detector and temperature sensor are used when the board is mounted on a reject load. The RF sample from the reject load is detected and a DC voltage sent back to the controller. This sample is calibrated to 100% when an entire power block is off or an entire cabinet depending on the system. The temperature sample detects the reject load temp and is sent back to the controller. If either temp or RF exceed a preset limit, a reject load fault is generated and the transmitter will increase fan speed to 100% and reduce the transmitter power to 25% to protect itself.
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Figure 4-11 Fan Control Board
4.1.10
Front Panel Control/Display Board Description
The Control and Display board performs the following functions in the FAX transmitter:
•
•
•
•
•
•
Interface to the Micro Module
Interface to the Front Panel User Interface
Contains Ethernet Ports
Has Backup Hardware control
Generates the APC Reference in Normal Control Mode
Stores Configuration in memory
The Control & Display Module consists of a control/display board and micromodule. The control/display board has the simple hardware control circuits to take care of primary functions such as ON/OFF, Module restrike, Remote enable, Drive chain select and Power reference generation. All hardware on the board is associated with interfacing to the micromodule for enhanced control operation. The micromodule board attaches to the Control/display board and provides the key microprocessor control functions as well as the Web interface. It also provides the user interface to the LCD and front panel buttons and status indicators.
The FAX transmitter has three control modes of operation, Normal, Basic hardware control and Life support control.
Normal Mode: In this mode of operation, the transmitter has full functionality with the primary control functions being done in Hardware (HW) but the hardware can be controlled by the microprocessor. The key states such as ON/OFF, Remote ENABLE/DISABLE, etc are stored in non volatile hardware ICs that will remember the last state even if there is not microprocessor control and a loss of AC power. Web interface is fully functional and the microprocessor can perform more advanced control of the transmitter to optimize operation and performance.
HW Control‐ In this mode the micro is assumed to be disabled or failed. It is disconnected from the Hardware control system so undefined states of operation do not disrupt basic operation. At this point additional hardware required for transmitter operation is enabled on the System interface board. The transmitter has all required functionality for parallel remote control and protection. Some automatic modes of operation like Auto exciter and IPA switching are not available.
Lifesupport Control‐ In this mode the entire Control and Display board can be non operational and the transmitter will still be able to be operated via life support hardware on the System Interface board. The System interface hardware used in the HW control mode is still active. The primary loss of functionality compared to the HW control mode is that there is no front panel control of Remote mode and power Raise lower. Transmitter ON/OFF functionality is still available from parallel Remote control
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The transmitter configuration is stored in memory on this board. This configuration contains the user setup, ie dual exciter, frequency,exciter type, etc, as well as all calibrations. This file is a downloadable file that can be stored on a computer and uploaded in the event the Control and Display board needs to be replaced. It is a good idea to store this when the transmitter is first installed and any time a change to setup or calibration is completed.
The board also provides the power control reference to the System Interface board APC hardware. This reference is 3.5 VDC and remains constant under normal conditions. If the raise or lower power button is pressed this voltage changes, lower power will lower the reference voltage. See APC and System Interface for further details.
4.1.11
System Interface Control Board Description
The FAX 10kW transmitter contains a System Interface control Module that mounts directly to the right of the Power Supply Modules. This board provides several functions for the transmitter system.
•
•
•
•
•
•
•
•
•
Operates as a transmitter interface or a power block interface (FAX20/30/40)
Hardware control in lifesupport mode
Exciter interface and exciter RF switching
The APC hardware is located on board
OptoCouplers for Remote control via Parallel I/O
Forward and reflected power detection and metering samples
Hardware for VSWR protection and power limit functions
System status LED’s
Multiplexing bus for meter readings
The exciter interface can be setup to accept any exciter, Harris Broadcast or another manufacturer. If a non‐Harris Broadcast exciter is used the dipswitch settings will need to be properly set and a custom interface cable made. If dual exciters are used the RF switching is done on board. To achieve automatic switching a DC voltage proportional to RF power must come from the exciter, this voltage is monitored and when a user set limit is reached the exciter automatically switches.
If using one of the iboc modes there are status lines that come from the exciter to tell the controller if the transmitter should be in class C or class AB. When the exciter switches to one of the three modes, FM, FM+HD or HD Only, the controller sets the proper power supply voltage, sets the PA modules to the correct class of operation and loads the calibration points for forward and reflected power in the system and power blocks (FAX20/30/40). Keep in mind if using multiple modes of operation that each mode requires calibration.
The transmitter sends a mute, APC and Exciter active line back to the on‐air exciter. The mute line can be set to active hi or low depending on dipswitch settings. The APC voltage is on the range of 0 to 4 VDC, if using a non‐Harris Broadcast exciter the exciter input must be compatible. See the APC description in Section 4.1.6, System APC
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Remote control functions are located on board. The User Interface J1 on the rear panel interfaces to the opto‐
couplers. This is the only remote control available in backup mode. RF Mute and TX OFF inputs can be defeated by setting dipswitches. There are also four programmable Status outputs that are user definable, a computer must connected via Ethernet to set this up.
There are two interlocks available External and Equipment. The External Interlock must be closed or the transmitter will not operate. If the External Interlock is opened during operation the transmitter shuts down and requires a TX ON command to resume. Equipment Interlock when pulled low will shut the transmitter off, when switched hi the transmitter will resume normal operation.
There are remote analog voltage outputs for System Forward Power, System Reflected Power, PA Voltage and Total PA Current (DC).
The forward and reflected power detectors are identical circuits. These are fed from the same port on the System directional coupler. Using the same port and having identical detectors and control of the gain in the detector path allows for automatic calibration of reflected power without adding a mismatch or swapping cables on the coupler. When calibrating the system power the the user inputs the TPO to calibrate to and the AGC is turned off, this allows the power to be adjusted without fighting the power control. The gain through the detector path is set to minimum at this point. Phase 1 is complete. Next step is to set the exciter RF power so the transmitter forward power as read on a external meter is same as the user TPO entered. When the calibration routine is started the controller will set the gain to get 3.5 VDC for a forward power sample. THe controller then turn calibrate to ON (Same as setting S2‐8 to ON) and this puts a 2 VDC reference on each gain stage input. The micro reads the voltage at the output of the forward power stage, then adjusts the reflected stage gain until it matches the forward stage voltage output. Calibration is turned off and the TPO is set to equal the 3.5 VDC. Reflected is then calculated based on the 3.5 VDC being 1.5:1 relative to the TPO set.
VSWR Fault and foldback as well as Forward Power limit are implemented in hardware. The Forward Power limit is set to 10% above the TPO calibrated. This is done off the 3.5 VDC reference that was established during the calibration routine. The 3.5 VDC from the forward power detector stage is sent to a comparator circuit, when the forward power exceeds 110% of TPO the comparator output increases. The forward power limit is fed to the APC which limits the it from increasing system power.
VSWR has two thresholds, foldback and fault. The foldback threshold is user settable in the GUI in the range of 1.3 to 1.5:1. Based on the 3.5 VDC sample that is equal to 1.5:1 relative to the TPO calibrated, the hardware setpoint is 1.3:1 for foldback. If the user sets this to a higher value the micro increases the comparator reference voltage to set the trip point higher. In backup control mode this defaults back to 1.3:1. The VSWR Fault is set to 1.5:1 in hardware. When the VSWR exceeds 1.5:1 a resettable latch is set which sends a System Fault OFF command to the micro. The micro will shut the transmitter off and attempt to bring the transmitter back on, or Restrike. The micro module will attempt to restrike the transmitter three times before is stays off. The advance 3‐strike is only available in Normal Control mode.
The faults, powers, voltages and currents are all multiplexed back to the micro module. The control and switching circuitry are located on the System Interface board. In the case of multiple power blocks and cabinets these lines would be sent to the Multi‐Unit Interface board.
Figure 4-12 System Interface Control Board
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Section-5 Maintenance
5
5.1
Introduction
This section provides maintenance, calibration and board replacement procedures for qualified technical personnel. This section assumes that the Engineer performing the maintenance has a working knowledge of the transmitter and Section 3 of this manual in particular.
Routine maintenance of the FAX series transmitter consists of regular cleaning and the monitoring of power, VSWR, voltages, and current readings to detect any deviations that might indicate a developing problem.To maximize equipment reliability and longevity, it is important to develop and stick to a well designed maintenance routine. A transmitter’s performance and longevity will be maximized if it is properly maintained by a well‐trained, technically skilled individual. To this end, Harris Broadcast offers a variety of training classes specific to Flexiva FAX series transmitters. Contact your Harris Broadcast representative or visit the Harris Broadcast website at www.harrisbroadcast.com for more information on training offerings.
5.1.1
Safety Precautions
The amplifier chassis is composed of two general zones: the front half, as accessed by the front door and the rear half, as accessed by the rear door.
The front door is hinged and can be opened while the transmitter is running for access to the PA, IPA, and PS modules. The PA, IPA, and PS modules may be replaced while the transmitter is operating. The rear door requires a tool to gain access and should never be opened while the transmitter is operating. It is very dangerous to attempt to make measurements or to replace components in the rear chamber with the mains power applied. If door is opened while transmitter is operating, the transmitter will trip the airflow sensor and shut the transmitter down until it is closed. Shut off all power before servicing the transmitter, other than replacement of PA, IPA, and PS modules.
Warning
NEVER PERFORM TRANSMITTER MAINTENANCE WHILE ALONE AND/OR NOT FULLY
ALERT. SERIOUS BODILY INJURY OR DEATH COULD RESULT FROM FAILURE TO
OBSERVE PROPER SAFETY PRECAUTIONS.
5.2
Dipswitch Settings
See the below tables for various switch settings for each printed circuit board in the transmitter. Care should be taken when replacing boards as revision levels change and this may effect the switch settings. If setting does not state "USER" then the switch should not be changed from its factory default unless Factory Service is consulted. If Setting column states "Model" the switch setting is model dependant.
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Table 5-1 Control & Display Board Switch S15
Switch
Name
Schematic Sheet
Default/
User Setting
Description
S15‐1
SW Control Disable
7
OFF
Disables all Software Control of Hardware
S15‐2
FP Enable
5
ON/User
Disables front panel ON/OFF and Raise/Lower Buttons when Remote is Enabled
S15‐3
Remote Enable LED
6
ON/User
Sets Remote Enable LED to Green
S15‐4
Remote Enable LED
6
OFF/User
Sets Remote Enable LED to Red
S15‐5
SW APC Enable
4
OFF
Enables Software control of APC (Future)
S15‐6
N/A
N/A
N/A
NOT USED
S15‐7
RS485 TERM
15
OFF
Terminates RS485 Bus
S15‐8
CAN TERM
15
OFF
Terminates CAN Bus
Table 5-2 System Interface Board S2 (Rev H hardware and later)
Switch
Name
Schematic Sheet
Default/
User Setting
Description
S2‐1
APC Volt Limit
5
OFF
OFF ‐ has a lower APC limit voltage; ON ‐ Bypasses diodes to allow APC voltage to limit higher, ≈4.75 VDC; ON when higher APC Voltage is required, ie FAX5 with Flexstar driving the high level input
S2‐2
Remote TX OFF Enable
10
OFF/USER
ON enables transmitter Remote TX OFF even when Remote is Disabled on front panel
S2‐3
RF Mute Defeat
3
Model
ON‐When Board is TX or System Controller; OFF‐ When board is Power Block Controller
S2‐4
LS Remote Enable
4
ON/USER
ON ‐ Allows User to Enable User Remote J1 in Lifesupport Mode; OFF User Remote is disabled in Lifesupport mode
S2‐5
EXT Mute Defeat
10
OFF/USER
Allows User to Defeat External RF Mute J1‐7;ON=Disabled
S2‐6
APC Fault OFF
6
ON
ON=APC Disabled with PA or PS Summary Fault
S2‐7
APC OFF
6
OFF
OFF=APC Enabled; ON=APC Disabled
S2‐8
PWR CAL
6
OFF
Used in Power Block Calibration Routine ONLY
Note
The functionality of S2-1 of System Interface Board 901-0234-051 changed on Hardware Revision H. For
Revision G and earlier use Table 5-3. All other switches functionality remained the same. This switch
should be set according to the voltage range required by the APC input of the exciter in use.
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Table 5-3 System Interface Board S2 (Rev G hardware and earlier)
Switch
Name
Schematic Sheet
Default/
User Setting
Description
S2‐1
APC Hardware Control
4
ON
ON ‐ for hardware control of APC; OFF for software control of APC; Software control of APC not implemented at this time. If switch is set to OFF the APC will not function.
Table 5-4 System Interface Board S3
Switch
Name
Schematic Sheet
Default/
User Setting
Description
S3‐1
MUX Unit 1
12
Model
For FAX5/10,and Power Block 1 in FAX20/30/40 ON; All others OFF
S3‐2
MUX Unit 2
12
Model
ON=Power Block 2 FAX20/30/40; All other OFF
S3‐3
MUX Unit 3
12
Model
ON=Power Block 3 FAX30/40; All other OFF
S3‐4
MUX Unit 4
12
Model
ON=Power Block 4 FAX40; All other OFF
S3‐5
System Control
12
Model
ON=TX/System Controller; OFF=Power Block Controller
S3‐6
Config
4
Model
ON=Power Block Controller; OFF=TX/System Controller
S3‐7
Default Mode
5
OFF
Used on TX/System controller only; ON=TX primary mode defaults to either HD mode
S3‐8
Default Mode
5
ON
Used on TX/System controller only; ON=TX primary mode defaults to FM
Table 5-5 System Interface Board S5 (Exciter A) and S6 (Exciter B)
Switch
Name
Schematic Sheet
Default/
User Setting
Description
S5‐1
RS485 Enable
8
Model
Used for FAX Exciter
S5‐2
FM_ON Status
8
Model
Used when Exciter has FM ON Status outputs
S5‐3
HD_ON Status
8
Model
Used when Exciter has HD ON Status outputs
S5‐4
Exciter Ready
8
Model
ON‐When Exciter has a Ready Status Line
S5‐5
RF Mute Polarity
8
Model
ON=Mute to Exciter Low;OFF=Mute to Exciter Hi
S5‐6
RF Mute Polarity
8
Model
ON=Mute to Exciter Hi;OFF=Mute to Exciter Low
S5‐7
APC Out
8
Model
ON=Exciter has External APC Input; OFF requires the APC to drive the IPA and S5‐8 (S6‐8) should must be ON.
S5‐8
Drive Control
8
Model
ON=IPA Drive Control (Exciter has no External APC input):OFF=Exciter APC Control
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Note
S5 is used for Exciter A and S6 for Exciter B and have same definitions. If exciter A and B are different
models ensure the switch settings are correct for proper operation of transmitter.
Table 5-6 Harris Broadcast Exciters Setup Table S5 & S6 System Interface
Position S5 or S6
FAX
FLEXSTAR
DIGIT/IPA Control
MICROMAX
Other Ext APC
1
ON
OFF
OFF
OFF
OFF
2
ON
ON
OFF
OFF
OFF
3
ON
ON
OFF
OFF
OFF
4
ON
ON
OFF
OFF
OFF
5
ON
ON
ON
OFF
ON
6
OFF
OFF
OFF
ON
OFF
7
ON
ON
OFF
OFF
ON
8
OFF
OFF
ON
ON
OFF
Table 5-7 System Interface S14
Switch
Name
Schematic Sheet
Default/
User Setting
Description
S14‐1
Class C
5
Mode
ON ‐ Class C (FM ONLY) Operation; OFF ‐ Class A/B (HD Mode) operation S14‐2
Class A/B
5
Mode
ON ‐ Class A/B (HD Mode) operation; OFF‐ Class C (FM ONLY) Operation
S14‐3
Equip Intlk
10
User
ON‐Equipment Interlock J1‐9 Active Hi;OFF ‐ Active Low
S14‐4
Equip Intlk
10
User
ON‐Equipment Interlock J1‐9 Active Low;OFF ‐ Active Hi
Table 5-8 Power Supply Interface Board S1
Switch
Name
Schematic Sheet
Default/
User Setting
Description
S1‐1
Air Fault Level
6
OFF
Sets Airflow Fault Trip Point, default 3.1 V; See Note 1
S1‐2
Air Fault Level
6
ON
Sets Airflow Fault Trip Point 3.1 V; See Note 1
S1‐3
PS 3 Disable
8
OFF
Disables PS3 Fault in FAX5 Only
S1‐4
PS 4 Disable
8
OFF
Disables PS4 Fault in FAX5 Only
S1‐5
PS 5 Disable
8
OFF
Disables PS5 Fault in FAX5 Only
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Table 5-8 Power Supply Interface Board S1
Switch
Name
Schematic Sheet
Default/
User Setting
Description
S1‐6
PS 6 Disable
8
OFF
Disables PS6 Fault in FAX5 Only
S1‐7
PS 7 Disable
8
OFF
Disables PS7 Fault in FAX5 Only
S1‐8
N/A
N/A
N/A
Not Used
Note 1 ‐ Only change the airflow trip point when instructed to do so by Harris Broadcast Service Engineer.
Table 5-9 Fan Control Board Switch S1 (Power Block Backdoor)
Switch
Name
Schematic Sheet
Default/
User Setting
Description
S1‐1
Fan 4 Enable
2
ON
ON ‐ When 4 fans are used: OFF‐for 6 kW Reject Load(only2 fans)
S1‐2
Fan 3 Enable
2
ON
OFF‐for FAX5 and 6 kW Reject Load
S1‐3
Speed 1
3
ON
ON=Lo Gain (Low Speed)
S1‐4
Speed 2
3
OFF
ON=Mid Gain (Mid Speed)
S1‐5
Speed 3
3
OFF
ON=Hi Gain (Hi Speed)
S1‐6
FULL OFF
3
OFF
Must be set to OFF on Power Block
S1‐7
RF 1
4
OFF
Sets Gain of RF Detector for Reject Load use only
S1‐8
RF 2
4
OFF
Sets Gain of RF Detector for Reject Load use only Note
When replacing a fan board on the reject load calibration is required. See Calibration Procedures in this
section of the manual.
Table 5-10 Fan Control Board Switch S1 (Reject loads)
Switch
Name
Schematic Sheet
Default/
User Setting
Description
S1‐1
Fan 4 Enable
2
ON
ON ‐ When 4 fans are used: OFF‐for 6 kW Reject Load(only2 fans)
S1‐2
Fan 3 Enable
2
ON
OFF‐for FAX5 and 6 kW Reject Load
S1‐3
Speed 1
3
ON
ON=Lo Gain (Low Speed)
S1‐4
Speed 2
3
OFF
ON=Mid Gain (Mid Speed)
S1‐5
Speed 3
3
OFF
ON=Hi Gain (Hi Speed)
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Table 5-10 Fan Control Board Switch S1 (Reject loads)
Switch
Name
Schematic Sheet
Default/
User Setting
Description
S1‐6
FULL OFF
3
ON
Sets the fans to run at slow speed under normal operating temps (Minimal reject load power)
S1‐7
RF 1
4
ON
Sets Gain of RF Detector for Reject Load use only; See Note 1
S1‐8
RF 2
4
OFF
Sets Gain of RF Detector for Reject Load use only; See Note 1
Note 1 ‐ S1‐7,8 set the RF detector gain. These switch settings vary for each reject load. See reject load calibration procedure in Section 5 of this manual.
Table 5-11 Cabinet Interface Board S1 (FAX20/30/40 Only)
Switch
Name
Schematic Sheet
Default/
User Setting
Description
S1‐1
N/A
N/A
N/A
Not Used
S1‐2
N/A
N/A
N/A
Not Used
S1‐3
N/A
N/A
N/A
Not Used
S1‐4
N/A
N/A
N/A
Not Used
S1‐5
Pri Rej Load Dis
3
ON=Disables the Primary reject load (12 kW)
S1‐6
Sec Rej Load Dis
3
ON=Disables the Secondary reject load (6 kW)
S1‐7
N/A
N/A
N/A
Not Used
S1‐8
N/A
N/A
N/A
Not Used
Table 5-12 PA Backplane Board Switch S1
Switch
Name
Schematic Sheet
Default/
User Setting
Description
S1‐1
MUX Row 1
2
Row Dependan
t
ON for Backplane 1; all others OFF
S1‐2
MUX Row 2
2
Row Dependan
t
ON for Backplane 2; all others OFF
S1‐3
MUX Row 3
2
Row Dependan
t
ON for Backplane 3; all others OFF
S1‐4
MUX Row 4
2
Row Dependan
t
ON for Backplane 4; all others OFF
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Table 5-12 PA Backplane Board Switch S1
Switch
Name
Schematic Sheet
Default/
User Setting
Description
S1‐5
Analog Bias Control
2
OFF/User
ON Enables the APC voltage to control the IPA; OFF disables APC voltage to IPA (Exciter Control) S1‐6
IPA Current Reference
2
OFF
Sets the Overcurrent trip point of the IPA. Always OFF.
S1‐7
PA Fault
2
Slot Dependan
t
ON for Backplane 2 ‐4(PA Slots), OFF for Backplane 1
S1‐8
IPA Fault
2
Slot Dependan
t
ON for Backplane 1(IPA Slot); OFF for Backplane 2‐4
Note ‐ Backplane 1 is at the top (Row with IPA) and Backplane 4 is bottom row.
Table 5-13 RF Switch Board S1
Switch
Name
Schematic Sheet
Default/
User Setting
Description
S1‐1
NC
1
N/A
Not Used
S1‐2
400 W
1
OFF
Future
S1‐3
250 W
1
OFF
Future
S1‐4
200 W
1
ON
ON for all FAX units, used for calibration of IPA and Fault threshold
S1‐5
100 W
1
OFF
Future
S1‐6
60 W
1
OFF
Future
S1‐7
40 W
1
OFF
Future
S1‐8
15 W
1
OFF
Future
5.3
Transmitter Cleaning
Table 5-14 Suggested Maintenance Routine
Periodicity
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Task
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Section-5 Maintenance
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Table 5-14 Suggested Maintenance Routine
Review readings and compare with baseline readings and/or factory test data report to detect any deviations.
Weekly
Monthly to semi‐annually Periodic inspection and cleaning (see procedure)
Verify power meter calibrations (see procedure)
Verify reserve exciter and IPA switchover functionality
Verify external interlocks (station load temp sensor, patch panel position switch, coax switch interlock, etc.)
Annually
5.3.1
Inspect / replace air internal filter(s) (see procedure) Inspect / clean PA module heatsink fins (see procedure)
Air Filter Replacement Procedure
The front door air filter requires periodic replacement. How often depends on the air quality at the site. When the filter is filled with dust/dirt, it will reduce the air flow to the point where the modules will overheat, then shut down. All FAX transmitters are supplied with a spare piece of filter media, so that a new piece may be rotated into service while the original piece is being washed and allowed to dry. Warning
DO NOT UNDER ANY CIRCUMSTANCE INSTALL A WET OR MOIST FILTER IN THE
TRANSMITTER. CONTACT HARRIS BROADCAST SERVICE TO PURCHASE ADDITIONAL
FILTER MEDIA, AS NECESSARY.
STEP 1
STEP 2
STEP 3
STEP 4
STEP 5
STEP 6
Open front door by loosening thumbscrews on reverse side of front door.
On the inside of the door, remove the metal frame holding the filter in Remove filter media from filter retainer frame. With a clean cloth wipe excess dirt from the door frame where media was.
Install replacement media in retainer frame and screw the metal frame back on.
Close the front door and tighten thumbscrews. Gently wash the dirty filter media in lukewarm water with a mild soap detergent until all dust and debris is removed. Rinse thoroughly to remove all soap.
Allow filter media to dry and save for use as replacement media next time procedure is performed.
5.3.2
PA Module Cleaning Procedure
The PA and IPA module heatsinks do not have large openings for airflow. As a result, it is common for the heatsinks to collect dirt over time especially if the air filters have not been maintained properly. The modules should be cleaned with compressed air on a schedule to be determined on site, depending on the air system, filtering, humidity etc. At least once a year is highly recommended. Warning
THE PA MODULES ARE DESIGNED TO HANDLE VERY HIGH TEMPERATURES AND MAY
BE EXTREMELY HOT. DO NOT TOUCH THE MODULE SIDES WITH BARE HANDS AFTER
THE TRANSMITTER HAS BEEN RUNNING, ESPECIALLY IN HIGH AMBIENT TEMPERATURE ENVIRONMENTS.
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STEP 1
5‐9
Remove PA module from transmitter. Caution
DO NOT ATTEMPT TO CLEAN THE PA MODULES WITH COMPRESSED AIR
WHILE THEY ARE STILL INSTALLED IN THE TRANSMITTER. THIS WILL
FORCE DUST DEEPER INTO THE TRANSMITTER.
STEP 2
STEP 3
Blow compressed air into heatsink fins to remove dust buildup. If compressed air is not available, use a vacuum cleaner to suction dust from heatsink.
Use a dry longhair paintbrush to dislodge stubborn dust.
Note
If dirt has built up in the heatsink fins where a paint brush can’t reach, take a piece of cotton cloth and
wedge down between the fins by pulling tight on each end of the cloth. Slide cloth back and forth to
remove dust and dirt. Remove and shake dirt from cloth and repeat in each slot.
STEP 4
Replace PA module in transmitter and repeat for each module.
Warning
REMOVING IPA WHILE TRANSMITTER IS OPERATING WILL CAUSE THE TRANSMITTER
TO SHUTDOWN AND BE OFF AIR.
5.3.3
Periodic Cleaning and Inspection
The FAX 10kW power block should be periodically opened, inspected for dust buildup, and cleaned. This inspection should also check for signs of progressive damage, such as cracking cables or evidence of heat stress/burning. In the case of a single power block transmitter (FAX5kW /FAX10kW), the transmitter must be switched off and mains power removed to safely perform the steps given below. In the case of larger model transmitters (FAX20kW ‐ FAX40kW), one power block may be shut down and serviced while the other(s) continue transmitting. Please consult section 5 for a procedure to follow to safely service one PA chassis at a time.
STEP 1
While transmitter is still operating at full power, inspect all external transmission line sections for localized discolorations or “hot spots” that are warm/hot to the touch.
a.If localized heating is found, switch off transmitter, open transmission line, and inspect for loose bullets (anchor connectors), split bullets, contaminations, or other irregularities. Press front panel OFF button to switch transmitter off.
STEP 3 Remove all AC mains power to transmitter, including exciter(s).
STEP 4 Take steps to ensure AC mains connection is securely locked out and inadvertent mains re‐application is not possible while maintenance is being performed.
STEP 5 Open all mains access panels and inspect all mains connections for tightness, corrosion, or signs of localized burning.
STEP 6 Use hex key to open amplifier chassis rear door.
STEP 7 Verify no loose hardware has fallen to bottom of amplifier chassis over time. STEP 8 Vacuum any dust accumulations from rear chamber of amplifier chassis.
STEP 9 Vacuum any dust accumulations from output assembly. Use long vacuum cleaner attachment as necessary to gain access to hard to access spots.
STEP 10 Vacuum any dust accumulations from chassis fan blades and PS module fan blades.
STEP 11 Illuminate inside of transmitter rear chamber and inspect all cables for signs of cracking, abrasions, or heat discoloration.
STEP 2
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STEP 12
STEP 13
STEP 14
STEP 15
STEP 16
STEP 17
STEP 18
STEP 19
STEP 20
STEP 21
STEP 22
STEP 23
STEP 24
STEP 25
STEP 26
5.4
Inspect all exposed PC boards for signs of heat discoloration or rings of dried solder flux, an indication of partial solder melting.
Shine light through combiner cover (but do not remove) to inspect output assembly combiner coils for any corrosion that is crusty or pasty. It is normal for the coils to change color over time. This does not negatively impact their performance, provided it is simple oxidation and not a more aggressive corrosion due to harsh air pollution components.
Verify all push‐on (faston) connections are fully seated on PA backplanes, PS interface board, AC mains inputs, etc.
Shine light through combiner support frame to deck of output assembly and inspect ballast loads for burning or cracking.
Close amplifier chassis rear door.
Return hex key to storage position.
If transmitter is FAX20kW, visually inspect the 6kW RF reject load on rack cabinet upper rear for signs of cracked resistors or other debris.
Remove AC mains lockout precautions and apply AC mains power.
Press front panel ON button to turn transmitter on. Verify transmitter returns to full power and no alarms are reported.
As desired, use off‐air opportunity to verify integrity of all safety interlock circuits such as station load temp sensor, patch panel position switches, coaxial switch position switches, etc.
As desired, use off‐air opportunity to operate transmitter into station test load and verify test load integrity.
As desired, use off‐air opportunity to verify reserve exciter and exciter switchover functionality (where applicable).
As desired, use off‐air opportunity to verify reserve IPA and IPA switchover functionality.
Note any findings and resolutions in station maintenance log.
Date and Time Battery
The date/time battery (20mm, 3V, lithium coin battery CR2032) is normally installed at the factory. Check and verify battery is installed. The battery mounts on the front panel Display/Control board. Perform the following steps to install or replace the battery.
STEP 1
STEP 2
STEP 3
Open front panel by turning the upper and lower thumb screws counterclockwise. Swing the panel door open to access the Display/Control board located along the top inside of the door. Note, the battery holder is located on the upper left hand corner of the board.
Remove battery from package (Pt. No. 660‐0054‐000) and slide battery into holder, with positive side up against clip, until it is fully seated.
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5‐11
Figure 5-1 Date and Time Battery Location
5.5
PA/PS Replacement
5.5.1
Changing PA, IPA, & Power Supply Modules
The PA modules are hot‐pluggable and may be swapped at any time while the transmitter is operating. Any PA module may be swapped with a PA module in another position, including the PA module in the IPA position.
Figure 5-2 Module Locations
Note
The IPA and PA modules are heavy for their size. Be prepared to support the weight when module is
removed. Pa modules are designed to handle very high temperatures and may be extremely hot. Do not
touch module sides with bare hands after transmitter has been running, especially in high ambient temperature environments.
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Section-5 Maintenance
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Note
The IPA module contains two IPA amplifiers with a green “ON” status LED for each module half visible
from the front of the IPA module. If the 10kW Transmitter is operating with power out and the IPA is
removed, the transmitter will stop producing RF and therefore will be off-the-air. In the 20/30/40kW
Transmitters, only the affected Power Block will stop producing RF causing a decrease in total system
power out.
STEP 1
STEP 2
STEP 3
STEP 4
STEP 5
STEP 6
Verify which module is faulted. Use same procedure for the IPA module. In the 10kW Transmitter, removing the IPA while the transmitter is operating will cause the transmitter to stop producing RF and become off‐the‐air. In the 20/30/40kW Transmitters, only the affected Power Block will stop producing RF causing a reduction in total output power.
Open amplifier front door by loosening the 2 thumbscrews.
Remove faulted PA module from transmitter by pulling module forward and out of the slot. There are not latches holding the module in place.
Insert replacement PA module. Normally, the PA module will turn on automatically. Pressing the front panel ON button will also create an ON command for all modules without any interruption of system operation.
If desired, use the front panel LCD Display, or use a pc connected to the front panel Ethernet port, to check all PA module currents to verify new PA module has a current draw similar to all other modules. Close amplifier front door. 5.5.2
Power Supply Module Replacement Procedure
The PS modules are hot‐pluggable and may be swapped at any time while the transmitter is operating. Any PS module may be swapped with a PS module in another position.
STEP 1
STEP 2
STEP 3
STEP 4
STEP 5
Verify which module is faulted.
Open amplifier front door. Grab the top lip of the PS module and push the metal clip up to release the handle and pull supply straight out. Allow the power supply to sit removed from its slot for about 5 minutes. Re‐insert the module back in to the slot and check to see of the faults return. If the faults do not return let the supply run for 30 minutes, if no faults leave the supply in the slot.
If faults return remove the power supply from the slot.
Figure 5-3 PS module Handle Release.
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STEP 6
STEP 7
STEP 8
5.6
5‐13
Insert replacement PS module. The two right‐most LEDs should light Green automatically once PS module is fully engaged. Be sure PS module is firmly in place and the metal clip in the upper left corner secures the PS front piece. It may be necessary to press the ON button to clear the faults to allow the module to turn on.
Close amplifier front door. Configuration File, Fault Logs and Software Upload
5.6.1
Config File Save/Upload
Once your transmitter has been installed and configured properly it is a good idea to save the configuration file in case the need to upload it in the future comes up. The information is stored on the Control and Display Board, in case of failure of that card you will need to upload a saved configuration. This file should be saved each time there is a change made to configuration, calibration or new software is uploaded. Use a file naming scheme that allows for easy access to the correct file and date it.
5.6.2
STEP 1
STEP 2
STEP 3
Save Config File
Connect the PC to the transmitter using a Ethernet cable to either the front or rear Ethernet port. See Section 3.8 for Network setup information.
Open a web browser and establish a connection, once there is a connection navigate to the System>> System Setup>>Network>> ISP menu.
Click on the Configuration Tab and the DOWNLOAD button will appear. See Figure 5‐4.
Figure 5-4 FAX ISP Screen
STEP 4
STEP 5
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Click the DOWNLOAD button. A dialog box will open, click on Save File and OK.
A new dialog box will open, browse to the disk location to save the file. Rename the file using a naming convention so it is know what this file is. For example, FAX10‐install‐
09102013 for FAX 10 saved on install with the date of installation.
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5.6.3
STEP 1
STEP 2
STEP 3
STEP 4
STEP 5
Upload Config File
Establish a connection to the transmitter with a PC.
System>> System Setup>>Network>> ISP menu. See Figure 5‐5
Click Browse and locate the correct file for the upload. The default name given by the FAX is eeprom. This name may vary if the name was changed when saved from transmitter. Also note that it is best to have this file located on your hard disk drive not on a removable stick.
Click on the file, then Open and the box should populate with the file location and name. Click Submit button and the file should upload. Once the upload is complete a PROGRAM button will appear.
Figure 5-5 FAX ISP Program Screen
STEP 6
Click on the PROGRAM button, a box should pop up and state that the transmitter will loose communication and loss of RF output. Click OK, when programming is complete the transmitter will reboot. 5.6.4
Software Update Procedure
The following steps detail the procedure to update the FAX series transmitter software. You will need a PC to the Ethernet port to perform this procedure. Once the software has been uploaded and programmed the transmitter will reboot and the station will be off the air for a brief period.
FAX Software part numbers (The filename will contain the revision level of the code):
Complete ‐ 861‐1154‐082
WEB GUI(Only) ‐ 861‐1154‐032 Application code(Only) ‐ 861‐1154‐022
These files can be obtained on the Harris Broadcast Customer Portal. All customers should register at the website to obtain any updated software, manual and documentation packages.
STEP 1
STEP 2
STEP 3
Connect the PC to the transmitter using a Ethernet cable to either the front or rear Ethernet port. See Section 3.8 for Network setup information.
Open a web browser (Firefox preferred) and establish a connection to the transmitter.
Once the connection is made go back to the address bar and type in /isp after the IP Address. For example if using the front panel Ethernet port type 192.168.117.88/isp. Screen should appear as in Figure 5‐6.
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5‐15
Figure 5-6 FAX isp Home Screen
STEP 4
STEP 5
Click Browse and locate the correct file for the upload. This file should be named something like FAX_CONTROLLER_APP_REVG_0018.s19. This name may vary some. Also note that it is best to have this file located on your hard disk drive not on a removable stick.
Click on the file and the box should populate with its location on the disk. Press SUBMIT. The file will begin to upload, do not press any keys until the screen appears like Figure 5‐
7. The file size will vary depending on Rev.
Figure 5-7 isp Program Screen
STEP 6
STEP 7
STEP 8
5.6.5
The code is now in memory inside the transmitter but has not been programmed. Click on the PROGRAM button, the message "Programming Flash..." and "Rebooting..." should appear.
Transmitter should reboot.
Go back to the IP address of the transmitter and Login, verify the code took by navigating to the System>>Service>>Version screen. Verify the software revisions.
Retrieving/Printing Fault Logs
This procedure details the steps to retrieve the fault log from a FAX Series transmitter. The logs can be saved as a text file or pasted in to Excel.
STEP 1
STEP 2
STEP 3
STEP 4
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Connect the PC to the transmitter using a Ethernet cable to either the front or rear Ethernet port. See Section 3.8 for Network setup information.
Open a web browser and establish a connection and login.
Click on the Event Log tab.
Click the DISK icon. A new window will open with the log shown, see Figure 5‐8 below.
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Section-5 Maintenance
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Figure 5-8 FAX Fault Log
STEP 5
STEP 6
STEP 7
STEP 8
5.7
Click on File, Save As and save as a text or htm file.
To save into excel, highlight the all boxes, and copy on to clipboard.
Open excel and right click, select "Paste Special. When the box appears click on "Text", fault log should appear in the boxes.
To Print the file click on the Printer icon and send to a printer connected to the PC.
System Calibration Procedures
5.7.1
System Forward/Reflected Power Calibration
The output power of the transmitter system is accurately calibrated at the factory using a precision Calorimeter and load. There is no separate calibration for reflected power, once the forward is calibrated the computer auto‐
matically calibrates the reflected power in the same calibration routine. There are separate calibrations for each type of modulation, FM, FM+HD and HD. If the transmitter is used for more than one mode, each modulation type used must be calibrated. The calibration is stored in the transmitter memory and can also be downloaded to a con‐
fig file and stored for use in the case of a failed Control and Display Board. If the transmitter system needs calibra‐
tion, a calibrated power meter is required, either in‐line or a stand‐alone meter such as an Agilent 4418 or equivalent. If the transmitter is running one of the iboc modes, ensure that the power meter is capable of measur‐
ing digital modulation.
Note
If calibrating in the power in HD Only mode of operation, the power calibrated to should be 5 % higher
than the TPO the transmitter will run at. ie a TPO of 10 kW should be calibrated at 10.5 kW. Once calibration is complete use the lower button to set the transmitter at TPO.
Power Calibration Check (Start at Step 2 for External Meter):
STEP 1
STEP 2
STEP 3
STEP 4
If using an in‐line meter it should read the same as the transmitter front panel meter. If readings do not match (Typically within 5%) system power calibration may be required. To calibrate skip to the perform calibration routine below. If using an external meter please refer to the factory test data that was shipped with the transmitter, it has the calibration factors that can be entered into the wattmeter. These readings take the loss of the cables and splitter into account. On the page that has the "Transmitter Power Readings", there are the Front and Rear Sample Port Coupling Factors.
On a FAX5/10 the Front reading is the SMA connector on the front door of the transmitter. On FAX20/30/40 the Front is the SMA connector inside the front door on power block one that is next to the Multi‐Unit Control Board.
On a FAX5/10 the rear is the Mod Monitor BNC on the back panel. On a FAX20/30/40 the Rear is the J5 that is located directly on the output directional coupler.
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5‐17
Use the correct coupling factor based on which location that the wattmeter will be connected. Enter this coupling factor into the wattmeter. Please refer to the wattmeter’s instruction manual on how to enter it.
To perform calibration perform the following steps.
STEP 5
STEP 1
STEP 2
STEP 3
STEP 4
STEP 5
STEP 6
STEP 7
STEP 8
STEP 9
Turn transmitter system on and operate at rated power for a minimum of 30 minutes
Be sure transmitter remote is in DISABLE. If not, press the DISABLE button.
In the SETUP>TX CALIBIBRATE>TX POWER CAL menu verify that the correct modulation type is shown. There are 3 possible types, FM, FM+HD and HD. If the correct modulation is not shown, refer to the exciter to correct it.
Once the modulation type is correct, set the TX TPO to the correct power for the transmitter. In HD ONLY mode this power should be set to 5 % more than TPO for calibration. Press the enter button and the highlight should go away. At the bottom of the screen the message "PHASE 1 Done" should appear after a few seconds.
Go to the exciter and set it’s forward power until the in‐line or external wattmeter reads the same as the TX TPO setting in Step 4. Refer to the exciter instruction manual to adjust the forward power.
Once the meters match allow the power to settle for a few seconds to ensure the transmitter is stable.
Go to the Calibrate line and change it to "YES" and press the enter button. The transmitter will begin calibration, and the message "IN PROGRESS" will appear. This will take several seconds, do not press any keys at this time.
The message "DONE" should appear on the LCD. Calibration is now complete for both forward and reflected power and the meter readings should be the same.
For HD Only mode, use the Lower power button to set the transmitter to TPO.
If the transmitter is to be used in more than one modulation mode, repeat this procedure for each mode.
5.7.2
Power Block Power Calibration FAX20/30/40 Only
The following procedure details how to calibrate forward and reflected power each of the power blocks in a 20kW or larger system. Each power block makes up a portion of the total power in the transmitter system. For example in a FAX30 each power block outputs 10 kW or 1/3 the total power. However, the power block has to overcome some losses in the splitting and combining inside each block. For calibration we will assume this to be approximately 2%, this factor will be included in the calibration. So in the case of a FAX30 running a full 30 kW each power block will be calibrated at 10 kW + 2%(200 Watts) or 10.2 kW. For HD Mode this will be 7 %.This formula should be used to deter‐
mine the approximate power to calibrate each power block in your transmitter. The power blocks should only need calibration when the power block System Interface Board is replaced or the TPO of the transmitter is increased above where the factory calibrated it. The power block only requires one calibration regardless of how many modes of operation the transmitter may run. The power calibration should be completed for the mode that runs the high‐
est power out, typically FM+HD. For example if running FM+HD and FM only as backup the power blocks only require calibration in the FM+HD mode.
Note
If running in the HD Only mode as the main mode or the only mode the transmitter is used in, the calibration should be done by adding 7 % to the power block power. ie 10 kW +7 % or 10.7 kW.
STEP 1
STEP 2
STEP 3
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Ensure the System forward power is calibrated and the transmitter is running at that power for a minimum of 30 minutes.
Go to SETUP>TX CALIBRATE>PWR BLOCK CAL
Verify the correct Modulation Type, FM, FM+HD or HD. If the correct modulation is not shown, refer to the exciter to correct it. WARNING: Disconnect primary power prior to servicing.
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STEP 4
STEP 5
STEP 6
STEP 7
Set the UNIT POWER to the value calculated using the formula described above.
To set the gain correctly, access to the System Interface Board in each power block will be required. This is the board located to the right of the power supplies behind the Unit Controller panel.
Notice on the LCD a voltage reading for each power blocks forward and reflected power. Using S9 (raise) and S11 (lower) on each System Interface Board, set each power block so the forward reading is 3.49 V. See Figure 5‐9 for switch location.
Set Dipswitch S2 (top of the board on the left) section 8 (far right section of S2) to ON. This puts the board in the calibration mode.
Figure 5-9 Power Block System Interface Control Board.
Now adjust reflected S12 (lower) ad S13 (raise) so the Reflected voltage value for forward and reflected (using forward and reflected for same power block) match. Repeat for each power block.
STEP 9 Set Dispswitch S2‐8 on all power blocks to OFF. STEP 10 Go to Calibrate, change to YES and press Enter. Once the message DONE appears, STEP 11 Calibration is complete.
STEP 8
.
Transmitter Air Flow Calibration
5.7.3
The following procedure is used to calibrate the Airflow in each power block to insure proper cooling of the transmitter system. This is done at the factory prior to shipping and should not have to be done unless the Power Supply Interface board is replaced. The transmitter has variable speed fans and is calibrated at 100% which is full speed. Under normal conditions the fans will run at about 70 ‐ 90%, under fault conditions the fans will ramp up to full speed. On some older model units, the fans were single speed and do not require calibration.
STEP 1
STEP 1
STEP 2
STEP 3
STEP 4
STEP 5
Be sure there are no obstructions on the top or back areas of the transmitter cabinet. Periodically check the air filters for dirt buildup. It is very important to keep the filters clean at all times.
Go to SETUP>TX CALIBRATE>AIRFLOW SET
To get fans to run at full speed a fault must be created. The easiest way is to pull one PA module from its slot in the power block that is being calibrated. Be sure not to pull the IPA or the transmitter will be off‐air. The fans should ramp up to full speed.
For the power block that is being calibrated only, go to PBx AIRFLOW menu.
SET PBx 100%, change to YES and press enter. AIRFLOW CAL should read 100%.
Reinstall the PA module and fans should ramp down in speed.
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STEP 6
5‐19
Repeat this procedure for each power block in the transmitter.
5.7.4
Exciter Power Calibration/Switchover Threshold
The FAX transmitter does not measure exciter power internally, it uses a dc voltage that is proportional to the Exciters RF output. This voltage is in the Exciter interface cable and comes in for each exciter in the system. If using dual exciters each exciter will require calibration. No wattmeter is required, the FAX is calibrated by matching it to the exciters front panel power reading. If the exciter switchover threshold needs to be set or adjusted, first verify the both exciters power meters match the power meter displayed on the FAX and the EXC PWR voltage is in range. If necessary do the Exciter Power Calibration steps before proceeding on to setting the switchover threshold.
Exciter Power Calibration
STEP 1
STEP 2
STEP 3
STEP 4
STEP 5
STEP 6
STEP 7
STEP 8
Go to SETUP>EXCITER SETUP. The exciter selected should be the one that is presently on‐
air.
Go to EXC PWR CAL menu.
Ensure Modulation type is correct.
EXC PWR reading should be in the range of 1000 to 2000 mV. If not go to the exciter and set the scaling for forward power so the voltage is in range. Although the minimum voltage for setup is 100 mV for reliable operation of this feature keep the voltage in the range stated.
Set the EPWR CAL value to match the exciter power reading. Notice that this reading is in milliwatts. Some exciters such as the Flexstar read in Watts, so 2 watts will be 2000 milliwatts
Change CALIBRATE to Yes and press Enter button. Repeat for Exciter B if required.
Exciter Calibration Complete
Exciter Switchover Threshold Setup (Dual Exciters ONLY)
STEP 1
•
•
•
With the transmitter running at TPO, navigate to SETUP>>TX CONTROL and set the following:
APC to OFF
EXC SW MODE to MAN
EXC ON AIR to the exciter that the threshold is being set for A or B
STEP 2
STEP 3
STEP 4
STEP 5
Navigate to SETUP>>EXCITER SETUP and set the exciter to A or B to match Step 1
Navigate to SETUP>>EXCITER SETUP>>EXC PWR CAL
Lower the exciter power out until the transmitter has reached a point where the exciter switchover should occur, ie 75 % of TPO.
Verify the EXC PWR voltage is in the range of 100 to 2000 mV.
Note
If the threshold is set when the voltage is outside this range the switchover will default to 40 % of exciter
power which will be near 0 Watts out of the the transmitter.
STEP 6
STEP 7
STEP 8
STEP 9
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Change the SET THRESHOLD to YES and press ENTER.
Change to the other exciter and repeat these steps for switching in the other direction.
Reset the APC to ON and EXC SW Mode back to Auto.
End of procedure.
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5.7.5
Power Supply Voltage Set
The FAX transmitter allows the user to se the DC voltage output of the power supplies to obtain either best overall efficiency in the Class C (FM) mode or for best spectral performance in Class AB(HD modes). The FAX allows the power supplies to be set in the range of 44 VDC to 52 VDC. In Class C the lower the voltage typically the better the efficiency. In Class AB care should be taken not to lower the voltage to a point that the RF output spectrum exceeds the mask. If changing this setting in HD modes turn RTAC off and verify the spectrum performance has not significantly degraded when changing the voltage. The power supply voltage setting is stored for each mode (FM, FM+HD and HD), if using more than one mode the voltage must be set for each.
STEP 1
STEP 2
STEP 3
STEP 4
Go to SETUP>TX CALIBRATE>POWER SUPPLY SET
Ensure Modulation type is correct.
Change the PS VOLTS to the desired voltage. It is not necessary to turn transmitter off to change the voltage.
Change SET to Yes and press enter button.
5.7.6
Reject Load Calibration (Power/Fan Speed) FAX20/30/40 Only
Reject loads are only used in the FAX20/30/40 to combine multiple power blocks and cabinets. In a FAX20 there is only one Reject load, in a FAX30 and FAX40 there are three. Each load must be calibrated separately. Typically reject load calibration is only required if replacing the entire reject load or the fan control board mounted to the reject load. The fan control board provides the RF detector for the reject load calibration.
Power Block Combiner (6 kW) Load Calibration Procedure:
STEP 1
STEP 2
STEP 3
STEP 4
STEP 5
STEP 6
Go to SETUP>TX CALIBRATE>REJ LOAD CAL>SYSTEM REJ CAL
Remove the IPA in one power block only.
Verify the REJ SENSE voltage reading is between 3.2 and 3.8 V. If this voltage is off it may be necessary to set the gain on the Fan Control board that is mounted on the Reject Load being calibrated. The gain can be set by changing S1 sections 7 and 8.
Verify that the fans are running at full speed by checking TP5 on fan board for reject load being calibrated for greater than 4 VDC. On Rev C or later boards Yellow DS7 will turn on indicating full speed. If this is not on change the setting of S1 sections 3,4,5 until TP5 is greater than 4 VDC or DS7 lights. One of the sections should be ON.
Change SYS SET 100% to YES and press Enter button.
For FAX30/40 repeat for other cabinet power block combiner load
Cabinet Combiner (12 kW) Load Calibration Procedure:
STEP 1
STEP 2
STEP 3
STEP 4
STEP 5
Go to SETUP>TX CALIBRATE>REJ LOAD CAL>SYSTEM REJ CAL
To get 100% power into the cabinet combiner reject load pull both IPA in one cabinet or turn the AC mains off to one cabinet.
Verify the REJ SENSE voltage reading is between 3.2 and 3.8 V. If this voltage is off it may be necessary to set the gain on the Fan Control board that is mounted on the Reject Load being calibrated. The gain can be set by changing S1 sections 7 and 8.
Verify that the fans are running at full speed by checking TP5 on fan board for reject load being calibrated for greater than 4 VDC. On Rev C or later boards Yellow DS7 will turn on indicating full speed. If this is not on change the setting of S1 sections 3,4,5 until TP5 is greater than 4 VDC or DS7 lights. One of the sections should be ON.
Once voltage is in range, change SYS SET 100% to YES and press Enter button.
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FAX 5/10/20/30/40KW
October 28, 2013
5.7.7
5‐21
Backup Control Mode Power Setting
In the event that the Micro Module would fail the transmitter will revert to backup control. In backup control the power control reference from the mirco is lost and the potentiometer on the System Interface Board or Multi‐Unit Interface in FAX20/30/40, becomes the power reference. This pot can be set to the full range of the transmitter RF power capability. This pot is set at the factory to the customer TPO on the sales order. If adjustment is required it is not necessary to take the transmitter off air.
STEP 1
STEP 2
STEP 3
5.7.8
On the System Interface board or the Multi‐Unit Interface on the FAX20/30/40, set the Normal/Backup switch to Backup. Red Backup Mode LED should be on
Adjust the PWR SET located on System Interface board or the Multi‐Unit Interface pot to desired power
Set the switch back to Normal. Red Backup Mode LED should be off
UPS Mode Power Setup
User Remote J1 Pin 8 on the rear of the transmitter, Power Block 1 in FAX20/30/40, sets the FAX into the UPS mode. This line would typically come from a UPS or a AC Mains generator to set the transmitter to a power out at a point that the generator was capable of supplying enough power without being overdissapated. It also can be used in the event the transmitter needed to be turned down in power to do maintenance on the system or antenna.
STEP 1
STEP 2
STEP 3
STEP 4
5.7.9
With the transmitter ON, ground pin 8 of User Remote J1. This must be a continuous ground
If this has not be filed set the transmitter should drop to about 25 % power and System LED should be yellow.
Using the Raise/Lower buttons on the front panel, set the power to desired level. If this point is below the RF Output Warning/Fault Threshold settings you will get an alarm.
Remove ground from J1‐8 and transmitter should return to normal power out
IPA Bypass FAX 5/10 Only
If a situation ever arises where the IPA system must be bypassed, there is a convenient way to feed the Exciter RF output directly to the input of the 2‐way divider that feeds the PAs. This bypasses not only the IPA but also the RF Switch board. Depending on the exciter it may not be able t o output enough power to reach the TPO, however the transmitter will be on the air.
STEP 1
STEP 2
STEP 3
STEP 4
888‐2720‐001
Depress front panel "OFF " button and open front door.
Before connecting the exciter to J4, ensure its RF level is set to about 5 watts. Remove the coax on J4 BNC and connect the exciter RF output to J4.
Un mute the transmitter and exciter. Raise the exciter power until the transmitter is back to its TPO or 60 Watts which maximum safe power into the splitter.
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5‐22
Section-5 Maintenance
October 28, 2013
Figure 5-10 PA Bypass J4
5.8
Board and Assembly Replacement Procedures
5.8.1
Backplane Board Replacement
There are 4 Backplane boards in each 10kW Power Block. The function of the Backplane Board is to interface the Controller, Power Supply, and RF signals to each PA Module. When installing a new Backplane Board, it is important to set all 8 of the switches on Dipswitch S1 to the same settings as the switches on the board being replaced. STEP 1
STEP 2
STEP 3
STEP 4
STEP 5
STEP 6
Remove all power from the transmitter
Remove the 2 PA modules that plug into the backplane being removed.
Open the back door of the transmitter block to gain access to the boards.
The make access to the backplane easier, unbolt the Splitter/Reject load assembly. This is the large assembly with the two heatsinks mounted to the right wall in the rear of the cabinet. It is not necessary to completely remove the assembly but it helps to move it away to gain access to the right side.
To remove the Splitter assembly, first remove the 14 coaxes off the 14‐way combiner. There are four nuts that hold the assembly in place two at the top and two on the bottom. Remove all four.
Note
During re-assembly, the Black power supply wires attach to the aluminum cover panel.
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5‐23
Figure 5-11 PA Backplane Boards
STEP 7
STEP 8
STEP 9
Note where all the wires are located, ensure that they go back to the same location when re‐assembling the unit.
Remove the ribbon cable, DC Power cables and RF connectors from the backplane being replaced.
Using a small phillips screwdriver, remove the nine silver screws from the backplane. Lift the backplane from the cabinet. Note
Do not remove any brass screws.
STEP 10
STEP 11
STEP 12
STEP 13
STEP 14
STEP 15
5.8.2
Set the dipswitch on the new board to match the board just removed.
Install the new backplane into the transmitter and secure with the nine screws.
Replace the RF cables, DC power Cables and the ribbon cable to the same location they were removed from.
Re‐install the Splitter/Reject load assembly to the right side wall on the transmitter.
Re‐connect the coaxes to the 14‐way combiner.
Re‐install PA modules and turn transmitter ON.
System Interface Control Board Replacement
The following instructions explain how to replace a System Interface Control PWA including the correct setting of all PWA switches. The high power Flexiva FAX series of transmitters all use the same System Interface Control PWA. In the 10kW Transmitter and 10kW Power Block, the System Interface Module is located on the right end of the Power Supply Modules. In the 20kW/30kW/40kW Transmitters, a second Interface Module is utilized in the Primary Power Block and it is called the Multi Unit System Interface Module. The Multi Unit Module interfaces with all of the other System Interface Modules in each Power Block. The hardware for each is identical, the difference is the switch settings that determine of the board is a power block controller or a system controller.
The replacement Rev “E” or higher PWA is universal which means it can be used in either location and will replace older versions of the same PWA, however do not set the dipswiches to match earlier version boards as some new parameters have been added. Dipswitch settings are used to designate which Power Block and position the PWA will be used. Dipswitch settings are also used to identify which Harris Broadcast Exciter is being utilized in the system. Please see section 5.4.4 for guidance on proper settings for your model FAX transmitter. Figure 5‐17 above 888‐2720‐001
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Section-5 Maintenance
October 28, 2013
illustrates the location of the Multi Unit System Interface PWA and the System Interface Controller PWA within the 10 kW Power Block. To remove the System Interface Unit Control PWA, begin by removing 2 Phillips screws from the front of the System Interface Module. See Figure 5‐12.
Figure 5-12 System Interface Control Module Mounting Screws
Carefully pull the module straight out. The right side of the metal housing sits in a guide mounted on the chassis shelf.
.
Figure 5-13 System Interface Control PWA
Carefully remove the ribbon cable connectors, 5 SMA connectors and the power supply connector. All of the cables are labelled to make re‐connection easier.
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5‐25
Figure 5-14 System Interface Control Cables Removed
After the Module is removed, use a Phillips screw driver to remove the PWA from the metal housing it attached to by
removing 6 Phillips screws. Attach the replacement PWA to the metal housing. Set the dipswitches to match the
removed boards on Rev E and higher PWA’s. If replacing a PWA Rev D or earlier refer to Section 5.4.4 for a
description of each switch. The board will come in the factory default positions.
Verify system and power block calibrations are still correct.
5.8.3
Multi Unit System Interface Board Replacement
To replace the PWA in the Multi Unit System Interface Module, begin by removing the 2 front Phillip
screws securing the sheet metal tray the module is mounted on. Carefully slide the module out then remove
the 4 Phillips screws that attach the cover to the module.
Figure 5-15 Removing Multi Unit System Interface Control Module and Cover
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Section-5 Maintenance
October 28, 2013
Figure 5-16 Remove Multi Unit System Interface Control Module Cables
After the Module is removed, use a Phillips screw driver to remove the PWA from the metal housing it attached to by
removing 6 Phillips screws. Attach the replacement PWA to the metal housing. Set the dipswitches to match the
removed boards on Rev E and higher PWA’s. If replacing a PWA Rev D or earlier refer to Section 5.4.4 for a
description of each switch. The board will come in the factory default positions.
Verify that the system power calibration is still correct.
5.8.4
Control and Display Board Replacement
The following steps explain how to change the Control and Display Board. The transmitter configuration is stored on this board, if this file was not downloaded from the transmitter and stored, a copy can be obtained from Harris Broadcast. However, this file will not have nay changes that have been made since it left the Harris Broadcast factory. If Ethernet connectivity is still available, got to 5.5.1 in this section of the manual and download the file prior to removal of the board.
STEP 1
STEP 2
STEP 3
STEP 4
STEP 5
STEP 6
STEP 7
STEP 8
STEP 9
Remove all AC power to the transmitter.
The Ethernet cable catch is located between the board and the connector, it may easiest to wait until the board is removed from the door and then carefully use a small screw driver to press the catch and remove the cable. Remove all cables from the board.
Remove the board from the front door. Remove the Ethernet cable if not already done.
If the replacement board does not have a Micro Module attached, the existing one can be reused.
If required install existing Micro to new board and install the board back on the front door.
Replace all cables
Turn on the AC power and connect computer to one of the Ethernet ports.
Upload a configuration file to the transmitter. See Section 5.5.1 in this section of the manual for procedure.
Turn transmitter on and verify correct operation.
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5‐27
Figure 5-17 Control and Display Board with Micro Module
5.8.5
14-Way Power Splitter Assembly Replacement
The following instructions explain how to replace the Splitter Assembly in the rear of a 10 kW power block. These instructions can also be followed to remove the splitter for easier access to the Power Supply Interface PWA that is mounted behind it.
Caution
THE SPLITTER ASSEMBLY ALSO CONTAINS THE REJECT LOAD RESISTORS FOR
THE 14-WAY COMBINER AND IS DESIGNED TO HANDLE HIGH TEMPERATURES.
IF THERE IS AN IMBALANCE IN THE POWER BLOCK DUE TO FAILURE OF PA
MODULES THE HEATSINK COULD BE HOT. VERIFY ASSEMBLY IS COOL TO
PRIOR TO TOUCHING.
STEP 1
STEP 2
STEP 3
STEP 4
888‐2720‐001
Remove all power to the transmitter.
Open the back door to the power block that the splitter is to be replaced in.
Remove the 14 coaxes that are attached from the splitter to the 14‐Way combiner. These connections are not critical and can be reconnected in any location.
Remove the 4 nuts and hardware holding the assembly in place. There are 2 on the bottom and 2 on the right side wall at the top of the assembly. See the following Figure for nut locations.
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Section-5 Maintenance
October 28, 2013
Figure 5-18 Splitter Nut Locations
STEP 5
STEP 6
The splitter still has the coaxes to the PA Backplane boards attached. The splitter can be lifted but not removed. With a 5/16" wrench loosen each of the SMA coaxes and remove them from the backplane boards. Also remove the IPA input coax located on the side of the Splitter near the middle of the assembly.
Carefully remove the splitter. Reverse these steps to replace the new assembly.
5.8.6
14-Way Combiner Assembly Replacement
The following instructions explain how to replace the 14‐Way Combiner Assembly in the rear of a 10 kW power block. These instructions can also be followed to remove the combiner for easier access to the Power Supply Interface PWA that is mounted behind it. Prior to removal the transmission line connected to the RF output will need to be removed. In higher power FAX transmitters, 20 kW and above, the combiners will need to be removed as well. See the procedures in this section of the manual on how to remove them.
STEP 1
STEP 2
STEP 3
Remove all power to the transmitter.
Open the back door to the power block that the splitter is to be replaced in. Remove the 14 coaxes that are attached from the splitter to the 14‐Way combiner. These are the reject load connections which are not critical and can be reconnected in any location.
Remove the hose clamp from the RF output connector. Then remove all of the hardware at the arrows shown in Figure 5‐24 below. This will allow the panel to be tilted up and out of the way.
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5‐29
Figure 5-19 Remove Hardware at these locations
STEP 4
STEP 5
Remove the SMA coaxes on the directional coupler assembly. A 5/16" wrench may be required to loosen them.
Remove the 4 nuts and hardware holding the combiner assembly in place. There are 2 on each side of the combiner assembly. See Figure 5‐24 below for nut locations.
Figure 5-20 14-Way Combiner Nut Locations
STEP 6
STEP 7
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The combiner still has the coaxes to the PA Backplane boards attached. The combiner can be leaned forward but not removed. After tilting the assembly forward, carefully remove each of the coaxes that are attached to the backplane boards.
The combiner assembly can now be removed from the power block. Reverse these steps to replace with the new assembly.
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5‐30
Section-5 Maintenance
October 28, 2013
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6‐1
FAX 5/10/20/30/40KW
October 28, 2013
Section-6 Diagnostics
6
6.1
Introduction
This section contains diagnostic and troubleshooting information for the Flexiva FAX FM/HD Series of Transmitters. Should difficulties arise with your FAX transmitter, use the information in this section to help locate and correct the problem. 6.2
Troubleshooting Tables
This section provides troubleshooting tables for FAX series transmitters covered in this manual. The reader is encouraged to carefully study the table in its entirety even if the transmitter is operating without any problems at the present time. Becoming familiar with the following information will be helpful to diagnose and repair problems should any arise in the future.
6.2.1
LED Indicator Explanation
GREEN: Means OK. Does not need any attention
AMBER: Means WARNING. Transmitter is operating but there’s a problem. Should be investigated ASAP.
RED: Means FAULT. Something in the transmitter system has faulted and requires immediate attention. Transmitter could be off‐air.
6.2.2
Transmitter Front Panel Controller LED Indicators
Figure 6‐1 shows the FAX transmitter front panel operating with no Faults and the Remote Control Disabled. Table 1 provides an explanation of Status LEDs based on its illuminated color and troubleshooting tips to resolve warnings and Faults when they occur.
Figure 6-1 FAX Front Panel Status LED’s
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Section-6 Diagnostics
October 28, 2013
Also available on the front panel is an RF sample port, this is a convenient way to sample the RF output of the transmitter. This is a sample of Total RF Out from the Directional Coupler built into the Transmitter Power Block that internally connects to the 1 5/8" connector. On 20/30/40kW Transmitter Systems, this front panel port samples the RF output of weach power block. To get the RF sample of the transmitter taken from the transmitter system Directional Coupler, open the front door and locate the SMA connector on the Multi‐Unit Interface panel. This is the sample that comes from the 3 1/8" output connector on top of the transmitter cabinet. Table 1: Front Panel LED Troubleshooting Table
Symptom
Cause and Solution
EXCITER LED is Green
Exciter that is on‐air is operating with no alarms or faults. Note: In dual exciter systems the transmitter will not display the fault status of the off ‐air exciter.
EXCITER LED is Yellow
Exciter relay has tripped. Check the off‐air exciter RF output. The relay trips on RF power from exciter being too low.
EXCITER LED is Red
On‐Air exciter has a fault. Refer to the exciter LED’s and manual for further information.
DRIVE CHAIN LED is Green
All IPA’s in all power blocks are operating normally with no faults.
DRIVE CHAIN LED is Yellow
IPA Relay has tripped due to low power on either A or B side. Check IPA Module LED’s and fault log for further information. DRIVE CHAIN LED is Red
IPA is faulted. Check IPA module LED’s in each power block if both A and B sides are green check RF Switch Board in each power block. IPA faults are VSWR, Over Current,Under Voltage,Overdrive or OverTemp
POWER AMP LED is Green
All PA modules in all power blocks are operating with no faults.
POWER AMP LED is Red
One or more PA Modules are faulted or removed from the transmitter. Check fault log for further details. PA faults are VSWR, OverCurrent,Under Voltage,Overdrive or OverTemp
POWER SUPPLY LED is Green
All Power Supply modules in all power blocks are operating with no faults.
POWER SUPPLY LED is Red
One or more Power Supply modules are faulted or removed from the transmitter. AC Mains has dropped below 190 VAC or has lost a phase (3‐Phases systems only). Check fault log and individual power supply LED’s for further details.
OUTPUT LED is Green
Transmitter is ON, above warning threshold, below power limit threshold and reflected power is ok.
OUTPUT LED is Yellow
Transmitter RF power has increased to 110%(Limit) or more of calibrated power, VSWR Foldback has occurred or transmitter power has dropped below Warning threshold or reject load is fault. Check exciter and IPA power and reflected power readings. Also check reject load power and temperature.
OUTPUT LED is Red
Transmitter power has dropped below Fault threshold set in System Service menu or VSWR fault has occurred.
SYSTEM LED is Green
Transmitter and Exciter are switched ON and operating normally with no faults or alarms being reported.
SYSTEM LED is Yellow
Transmitter is reporting alarms, these are not severe enough to fault system off. Check the fault log. System alarms are due to control or cooling faults. APC is off, transmitter has switched to Low Power Mode(possible reject load fault), fan fault, airflow fault, power limit, VSWR, mute and backup control.
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Symptom
Cause and Solution
SYSTEM LED is Red
Transmitter has a serious fault and Transmitter may be OFF or Software Control has been disabled either by user or a failed control board. An Interlock open, Cooling fault or RF Mute has occurred. Check other Status LED’s and fault log for further information. MUTE LED is Green
Transmitter is ON and unmuted. Mute LED will be green when transmitter is OFF.
MUTE LED is Red
Transmitter is ON and Muted. Check Equipment Interlock J1‐9 of USER REMOTE connector on rear of power block 1. Check MUTE line J1‐7 of USER REMOTE connector on rear of power block 1. Transmitter also will flash MUTE LED red when switching to backup exciter or IPA, it should go back green once switching is complete. Restrike command will briefly turn MUTE LED red.
6.2.3
6‐3
System Interface Control Module LED Indicators
Figure 6‐2 shows the FAX transmitter System Interface Control Module Status LEDs. Following Figure 6‐2 is an explanation of status LEDs based on its illuminated color and troubleshooting tips to resolve warnings and faults when they occur.
Note
Each 10kW power Block contains an System Interface Control Module that is located at the right end of
the Power Supply Modules. This card interfaces with all the main subassemblies in the 10kW Power Block
including the front panel LCD Controller. The System Interface Control Module contains Life-Support
(Backup Mode) circuits to enable transmitter operation if the front panel LCD Controller should ever fail.
The Interface Controller contains user buttons to facilitate most transmitter operational functions. In
20kW/30kW/40kW systems, the main Power Block contains an additional identical Interface Control
Module that is referred to as the Multi Unit System Control Module. It is located directly above the Power
Supply Modules in the Main Power Block Cabinet. The Multi Unit System Controller Module interfaces
with each Power Block Cabinet’s Interface Control Module. Both Interface cards are identical. Onboard
Dipswitches determine the configuration (function) of each card.
The following picture shows the front edge of a System Interface Control Module illustrating the front panel LEDs. There are also 2 columns of surface mount LEDS down the middle. In a FAX20/30/40 the LED’s that are available depends on if the card is acting as a Multi‐Unit Interface or System Interface. If acting as System Interface in each power block, faults that are Transmitter faults will not appear on this card. Only the faults that pertain to that power block will appear. However, all faults will show up in the fault log. 888‐2720‐001
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Section-6 Diagnostics
October 28, 2013
Figure 6-2 Interface Control Module Front LEDs
Refer to the drawing 801‐0234‐051 sheet 9 of 13. DS1: +5V: Illuminates Green when the +5 Volt supply for the controller is on. 5 V typically runs 4.6 VDC
DS2: FWD PWR: Normally OFF. Illuminates Yellow when the Forward Power Limit (<110% of calibrated power) is reached
DS3: VSWR FB: VSWR Foldback: Normally OFF. Illuminates Yellow when the VSWR threshold (1.3:1 to 1.5:1depending on user setting) is exceeded and the transmitter goes into Power Foldback mode.
DS5: EXT INTLK: External Interlock: OFF when Interlock circuit is complete. Illuminates Red when Interlock circuit is open User Remote J1‐24 to J1‐25. Transmitter will fault off and require user to turn transmitter back on.
DS7: FLT OFF: System Fault OFF: Normally OFF. Illuminates Red when the transmitter Faults OFF. Check other status LED’s and the fault log for further information. VSWR Fault greater than 1.5:1 (not Foldback)will cause a System Fault Off, also an airflow fault will cause the system to fault off.
DS9: VSWR FLT: VSWR Fault: Normally OFF. Illuminates Red when the VSWR threshold (1.5:1) is exceeded. This will also cause a FLT OFF led to light.
DS11: EQUIP: Equipment Interlock: Normally OFF. Illuminates Red when the transmitter Equipment Interlock circuit J1‐9 is grounded. Transmitter will mute until the interlock J1‐9 of USER REMOTE is open, then transmitter will return to TPO. DS28 System LED should illuminate as well.
DS13: AC FLT:AC Mains Fault: Normally OFF. Illuminates Red when the AC Mains input voltage drops below the operating range of the power supply. This fault will trip when the AC voltage at the input to the Power Supply Interface board drops below 190 VAC on any phase. Verify the AC Mains to the transmitter is within the range for Copyright ©2013, Harris Broadcast
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6‐5
the service being used (single or 3‐phase). Check fuses for low voltage detector on each phase on the Power Supply Interface board in rear of power blocks. Verify cabinet or wall circuit breaker has not tripped.
DS15: LOAD FLT: Reject load Fault: Normally OFF. Illuminates Red when a fault in the combiner reject load occurs. This fault is either a fan has failed, the temperature in the reject load has exceeded fault level, or the reject load input power is high. If a reject load fault has occurred the transmitter will automatically switch to Low Power Mode, approximately quarter power. Power Reference voltage will drop to 2.7 VDC.
DS17: RF MUTE: Normally OFF, lights when the RF is muted by a TX OFF command.
DS19: Exciter Not Ready; Normally OFF. Illuminates Yellow when the Exciter is muted. Check Exciter manual for further information.
DS20: DRV CHN: Drive Chain: Normally OFF. Illuminates Yellow when the IPA is muted. This will occur when switching to the backup IPA.
DS21: REMOTE: Remote Mute: Normally OFF. Illuminates Yellow whenever a RF mute occurs. Check J1‐7 of USER REMOTE for ground which mutes the transmitter.
DS4: FM: Illuminates Green when the transmitter is in FM Mode.
DS6: FM+HD: Illuminates Green when the transmitter is in FM + HD Mode.
DS8: HD: Illuminates Green when the transmitter is in HD Mode.
DS10: MUX: Flashes with MUX activity. This should flash all the time.
DS12: APC OFF: Normally OFF. Illuminates Yellow when the APC is turned OFF. APC will be disabled when there are faults in the system such as failed PA module or PS module. Check other LED’s and the fault log for further information. This can also be turned off manually in the LCD Menu tree.
DS14: EXC B: Normally OFF. Illuminates Yellow when the backup Exciter is switched into the Drive Chain. DS16: LOW PWR: Normally OFF. Illuminates Yellow when the transmitter is switched to the Low Power/UPS mode via J1‐8 or USER REMOTE. This will also occur when the Reject Load has a fault (Fan, RF or Temp).
DS18: RESTRIKE: Normally OFF. Momentarily illuminates Yellow when the transmitter experiences an ON command pulse. This could be from an AC power failure, a High VSWR, etc. If the transmitter does not come ON and stay ON, another Restrike occurs. If the transmitter does not stay ON after the 3rd Restrike, it stays OFF.
DS34: IPA CTRL: APC to IPA: Illuminates when the transmitter is setup for APC to drive the IPA
DS31: EXC: Exciter: Normally OFF. Illuminates Red when an on‐air Exciter fault occurs. Check Exciter manual for further information.
DS30: DRV: Drive Chain Summary Fault: Normally OFF. Illuminates Red when an IPA fault occurs. Check fault Log for further information.
DS32: PA: Power Amplifier Summary Fault: Illuminates Red when any type of PA fault occurs. Check fault Log for further information.
DS29: PS: Power Supply Summary Fault: Normally OFF. Illuminates Red when any type of PS fault occurs. Check fault Log for further information.
DS33: OUT: Output Summary Fault: Normally OFF: Illuminates Red when any type of RF output fault occurs. Check fault Log for further information.
DS28: SYS:System Summary Fault: Normally OFF. Illuminates Red when any fault in the transmitter system occurs. Check fault Log for further information.
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Section-6 Diagnostics
October 28, 2013
6.3
Telnet Session
Telnet is another way of helping diagnose a problem with the transmitter. Customers should only use telnet to view readings and not use telnet to control the transmitter unless asked to do so by a Harris Broadcast Service Engineer. To open a telnet session the Windows command prompt can be used. If using Windows 7, a terminal emulator program must be used.
Figure 6-3 Telnet Login Screen
To open a session ensure the computer is either connected directly to the transmitter Ethernet port or connected to the same network as the transmitter. If connecting direct to the front panel Ethernet, ensure the computer network properties is set to DHCP. Once the computer is connected go to the command prompt and type telnet plus the IP address, ie "telnet 192.168.117.88". The screen should appear as in Figure 6‐6 asking for a password. Prior to August 2013 shipments, the telnet password is "admin".
August 2013 and later shipments password is "harrismfg"
Note: The number of telnet pages will vary depending or the revision of code installed in your transmitter.
Figure 6-4 Telnet Page 1/7
Page 1 of the telnet shows basic information about your transmitter including serial number, MAC and IP addresses, software and hardware revs. Any item shown in parenthesis () are commands, pressing the corresponding number in that page to set.
Copyright ©2013, Harris Broadcast
WARNING: Disconnect primary power prior to servicing.
888‐2720‐001
FAX 5/10/20/30/40KW
October 28, 2013
1.
Temp ‐ Rear temperature of the transmitter that is measured on the Power Supply Interface Board. This temperature is the hot air exhausted from the PA modules and power supplies. 2.
+5.0 VDC ‐ 5 volt line form the aux output of the the main power supplies. This is bussed together on the Power Supply Interface board and distributed throughout the control system. 3.
+3.3 VDC ‐ Regulated 3.3 VDC on the Control/Display Board to run the Micro Module. Schematic sheet 7.
4.
+1.8 VDC ‐ Regulated 1.8 VDC on the Control/Display Board for the Ethernet Ports. Schematic sheet.
6‐7
These items require a password which is "harris_fax"
(1) MAC Address of the front panel Ethernet port. Cannot be changed.
(2) Mode of front panel Ethernet port. Static or DHCP user setting.
(3) IP Address of front panel Ethernet port. Default shown, user setting only in telnet.
(4) MAC Address of the rear panel Ethernet port. Cannot be changed.
(5) Mode of rear panel Ethernet port. Static or DHCP user setting.
(6) IP Address of rear panel Ethernet port. User setting.
(7) Netmask of rear panel Ethernet Port. User setting.
(8) Gateway of rear Ethernet port. User setting.
(S) Save Settings. Required before changes take place.
(r) Restore Setup ‐ Restores last saved setup.
(h) Set TX S.N. ‐ Not used
(u) Set User ‐ Should be done via remote GUI (t) Set Date /Time ‐ sets transmitter date and time
(f) Store Factory ‐ stores the setup in the transmitter and can be recalled using (r) above.
(z) Debug Mode ‐ should not be used unless instructed by Harris Broadcast Service Engineer. OFF should be normal mode. (h) Set TX S.N. ‐ Sets transmitter Serial Number. Factory use only.
(l) Restore Login ‐ restores all Logins to factory default. This requires password of "harrismfg", this password is set in code and cannot be changed. (b) Bit Mode ‐ should not be used unless instructed by Harris Broadcast Service Engineer. OFF should be normal mode. 888‐2720‐001
WARNING: Disconnect primary power prior to servicing.
Copyright ©2013, Harris Broadcast
6‐8
Section-6 Diagnostics
October 28, 2013
Figure 6-5 Telnet Page 2/7 System Control/Status
Display shows status of each item that is part of the Transmitter System. Under "Control/Status" 1 ‐ 13 and A ‐ M will correspond to the Multi‐Unit Interface Board LED’s defined in Section 6.3.3 of this manual. Under "System Analog" values are shown as displayed on LCD as well as their corresponding DAC/ADC values. (1) TX ON/OFF ‐ Turns transmitter ON or OFF
(2) RF Mute Ctrl ‐ Mutes or unmutes the transmitter
(3) Pwr Raise ‐ Raises RF power of transmitter
(4) Pwr Lower ‐ Lower RF power of transmitter
(5) IPA SW Mode ‐ changes the IPA switching mode between Auto and Manual
(6) EXC SW Mode ‐ Changes the exciter switching mode between Auto and Manual
(7) IPA Switch ‐ Switches the IPA between A and B side
(8) EXC Switch ‐ Switches exciter between A and B
(a) FB THD ‐ Adjusts VSWR foldback threshold. DO NOT USE unless instructed by Harris Broadcast Service Engineer
(b) PS Ref ‐ Power supply reference DAC value. DO NOT USE Can cause power supply to exceed acceptable voltage levels
(t) Test ‐ Not used
(c) UPS Ref ‐ Reference power setting of Low Power/UPS Mode. This is mode that is set by grounding J1‐8 of the USER REMOTE. Telnet is only place where this can be changed. Default is 2700 which is approximately 1/4 power To set the UPS Low Power Mode:
•
•
•
Provide a continuous Ground on J1‐8. Press the letter c on the computer connected to the FAX. Adjust the value until the proper power has been set.
Copyright ©2013, Harris Broadcast
WARNING: Disconnect primary power prior to servicing.
888‐2720‐001
FAX 5/10/20/30/40KW
October 28, 2013
6‐9
Figure 6-6 Telnet Page 3/7 Power Block Control/Status
Display shows status of each item that is part of each Power Block. In a FAX30/40 pressing (2) will display status and values for power blocks 3 and 4, pressing (1) will switch display back to power blocks 1 and 2. The Status 1 ‐ 6 in the top sections of the screen will correspond to the LED’s on the System Interface Board in each power block.
Figure 6-7 Telnet Page 4/7 PA Modules Status/Meters
Displays IPA and PA Module Fault status, Current, PA Volts and PA Temp. In a FAX30/40 pressing (2) will display status and values for power blocks 3 and 4, pressing (1) will switch display back to power blocks 1 and 2.
Fault status bits are displayed as shown:
b0/b1/b2/b3/b4/b5
b0 = PA Overdrive ‐ greater than 25 Watts into module
b1 = VSWR Fault ‐ greater than 100 W reflected into module. Depends on frequency, load and phase angle.
b2 = Under Voltage Fault ‐ b3 = Overcurrent Fault ‐ Greater than 30 Amps current draw on pallet
b4 = Overtemp Fault ‐ faults at 95 C
b5 = Module not Present Fault
888‐2720‐001
WARNING: Disconnect primary power prior to servicing.
Copyright ©2013, Harris Broadcast
6‐10
Section-6 Diagnostics
October 28, 2013
Figure 6-8 Telnet Page 5/7 Fault Log
Page 5 displays the contents of the fault log. Each fault will show time and date of occurrence and time and date fault was cleared. (R) Clears the fault log, Up/Down arrows pages through multiple pages.
Figure 6-9 Telnet Page 6/7 Calibration Data
Page 6 displays stored calibration data for the transmitter. There are no commands available on the page. Figure 6-10 Telnet Page 7/7 Debug Information
Page 7 displays debug information for the transmitter. There are no commands available on the page. Copyright ©2013, Harris Broadcast
WARNING: Disconnect primary power prior to servicing.
888‐2720‐001
7‐1
FAX 5/10/20/30/40KW
October 28, 2013
7
7.1
Section-7 Parts List
Exploded View 10 kW Power Block
Figure 7‐1 and Figure 7‐2 are the Exploded view of the 10 kW power block. The parts given are not an exhaustive parts list but are the field replaceable parts for each assembly and sub‐assembly in the unit. If the need comes up that requires a part not listed, the numbers for that assembly can be given to a Harris Broadcast Representative who can assist in finding the correct part.
Table 7-1 FAX High Level Part Numbers
888‐2720‐001
Part Number
Description
995‐0091‐001G
FAX10K Configurable
981‐0136‐002
FAX 10 Basic Transmitter, Primary Power Block
981‐0136‐003
FAX10 Basic Power Block, Secondary 10K for FAX20/30/40
995‐0091‐002G
FAX20 Configurable
995‐0091‐003G
FAX30 Configurable
995‐0091‐004G
FAX40 Configurable
WARNING: Disconnect primary power prior to servicing.
Copyright ©2013, Harris Broadcast
7‐2
Section-7 Parts List
October 28, 2013
ASSEMBLY, FORMAT XMTR, FAX 10K FM
995 0091 001G
ASSEMBLY SYSTEM INTERFACE
901 0234 051G - SYS INTERFACE (PWA)
943 5614 100 - SYS INTERFACE BRACKET (SHEET METAL)
ASSEMBLY, BASIC, PRIMARY 10KW FAX
981 0136 002
ASSEMBLY, COMMON COMPONENTS 10KW FAX
981 0136 001
POWER SUPPLY MODULES PS1-PS7
736 0583 000 - (7) PSU, SW, 48VDC 2715W 240VAC
971 0054 035 - ASSEMBLY 10K AC DIST, 3-P DELTA
971 0054 036 - ASSEMBLY 10K AC DIST, 3-P WYE
971 0054 037 - ASSEMBLY 10K AC DIST, 1-P
RF SWITCH MODULE 971 0054 008 A13
901 0234 121G - PWA, RF SWITCH A1
943 5614 115 - RF SWITCH BRACKET (SHEET METAL)
943 5614 131 - RF SWITCH COVER (POLYCARBONATE)
UNLESS NOTED ALL QUANTITIES ARE (1) EACH
LOCATION OF
DUAL IPA MODULE
OTHER (7) SLOTS
ARE PA MODULES
POWER AMPLIFIERS MODULES IPA1 & PA1-PA7
971 0054 001 - (8) ASSEMBLY PA MODULE
901 0234 001G - PWA, FM MODULE
901 0234 041G - PWA, MODULE CONTROLLER
441 0011 000 - FILM THERMAL INTERFACE
FRONT DOOR ASSEMBLY 971-0054-005 A7
943 5614 044 - PANEL, FRONT DOOR (SHEET METAL)
943 5610 078 - SHIELD, FRONT DOOR (SHEET METAL)
943 5610 084 - COVER, FILTER (SHEET METAL)
943 5610 080 - FILTER REPLACEABLE
901 0234 071G - PWA, CONTROL & DISPLAY (A1)
971 0054 025 - ASSY, MCF5484 UC MODULE, FAX, TESTED
(901 0213 011G - PWA, MCF5484 UC MODULE A2)
943 5614 384 - FAX PANEL GASKET
660 0054 000 - BATTERY, 3V LITHIUM COIN CR2032
952 9266 001 - JUMPERS, FAX 10KW
952 9266 003 - CABLE DC
952 9266 005 - CABLE AC
952 9266 006 - CABLE RF SWITCH
952 9266 010 - CABLE SYSTEM INTERFACE POWER
952 9266 015 - SINGLE EXCITER KIT CABLES (ALL MODELS)
Figure 7-1 10 kW Power Block Front View
Copyright ©2013, Harris Broadcast
WARNING: Disconnect primary power prior to servicing.
888‐2720‐001
FAX 5/10/20/30/40KW
October 28, 2013
ASSEMBLY, I/O REAR ACCESS 971 0054 010 A9
943 5614 112 - PLATE, REAR I/O ACCESS
952 9266 007 - CABLE I/O
PLATE, COMBINER ACCESS 943 5614 087
ASSEMBLY, PWA, PS INTER 901 0234 061G A5
FUSES ON BOARD398 0488 000 - (4) 1A 250V (F1 F2 F3 F6)
398 0642 000 - (2) 5A 32VDC (F4 F5)
398 0762 001 - (2) 15A 250V (F9 F10)
7‐3
AC MAINS INPUT TERMINALS BEHIND AC ACCESS PLATE 943 5614 082
(CURRENT VERSIONS)
614 0977 000 - (6) INSULATOR
943 5614 350 - TAP WYE 3Ø
943 5614 362 - (2) TAP 1Ø
943 5614 441 - (3) TAP 3Ø DELTA
(EARLY VERSIONS)
354 0852 000 - (5) LUG 6-14AWG
410 0152 000 - (4) CERAMIC INSULATOR
410 0156 000 - (4) CERAMIC INSULATOR
344 0253 000 - (4) STUD M5x63.5 2-1/2"
971 0054 015 ASSEMBLY 16RU REAR DOOR A6 (CURRENT VERSION)
CURRENT VERSIONS DO NOT USE THE CENTER FAN
430 0358 000 - (4) FAN, 48VDC 410CFM 172MM B1-B4
430 0292 000 - (4) FAN GUARD, 6.14" DIA
448 1128 000 - LATCH COMRESSION
901 0234 151G - PWA FAN CONTROL BD A1
943 5614 268 - CLOSEOUT REAR DOOR FAN (SHEET METAL)
971 0054 006 ASSEMBLY 16RU REAR DOOR A6 (EARLY VERSIONS)
430 0356 000 - (5) FAN, 48VDC 350CFM 172MM
430 0292 000 - (5) FAN GUARD, 6.14" DIA
448 1128 000 - LATCH COMRESSION
901 0203 441 - PWA 5X FAN MONITOR A1
ASSEMBLY, BACKPLANE 971 0054 020 (4) A1-A4
901 0234 031G - (4) PWA BACKPLANE
943 5614 235 - (4) SPACER, BACKPLANE, FAX (SHEET METAL)
943 5614 239 - (4) COVER, BACKPLANE, FAX (SHEET METAL)
943 5614 240 -(16) SPACER, N CONNECTOR (SHEET METAL)
14-WAY PA COMBINER 971 0054 002 A14 -LOW PASS FILTER
971 0054 007 - ASSEMBLY DIRECTION COUPLER A2
801 0234 083G - PWB, 14-WAY COMBINER A1
801 0234 113G - (2) PWB, COMBINER JUNCTION A2 A3
943 5614 064 - HOUSING, COMBINER (SHEET METAL)
943 5614 065 - OUTER HOUSING, COMBINER (SHEET METAL)
943 5614 138 - COVER, COMBINER (SHEET METAL)
952 9266 011 - 14-WAY COMBINER, CABLES
14-WAY COMBINER LOAD 971 0054 003 A15
14-WAY SPLITTER 971 0054 004 A12
901 0234 011G - PWA, 2-WAY SPLITTER A1
901 0234 021G - (2) PWA, 7-WAY SPLITTER A2 A3
943 5614 096 - BRACKET, SPLITTER TOP (SHEET METAL)
943 5614 097 - BRACKET, SPLITTER BOT (SHEET METAL)
943 5614 496 - HEATSNIK, SPLITTER LOAD
952 9266 008 - JUMPERS, SPLITTER
544 1654 000 - REJECT LOAD RES 100 OHM 250W
544 1661 000 - (14) REJECT LOAD RES 100 OHM 10W
055 0100 005 - THERMAL COMPOND 802
801 0234 093G - (2) PWB, ISO INPUT A1, A2
801 0234 103G - PWB ISO GROUND A3
943 5614 060 - SHEILD, REJECT LOAD (SHEET METAL)
943 5614 061 - CHASSIS, REJECT LOAD (SHEET METAL)
943 5614 063 - HEATSNIK, REJECT LOAD
952 9266 009 - COMBINER LOAD CABLES
544 1681 000 - (28) REJECT LOAD RES 25 OHM 800W
055 0100 005 - THERMAL COMPOND 802
Figure 7-2 10 kW Power Block Rear View
888‐2720‐001
WARNING: Disconnect primary power prior to servicing.
Copyright ©2013, Harris Broadcast
7‐4
Section-7 Parts List
October 28, 2013
7.2
AC Distribution Panel Parts (All Models)
The following tables contain the parts that are not common on all FAX models. A FAX20/30/40 are built from multiple 10 kW Power Blocks and all the components that make those blocks are common.
Circuit Breakers for AC Distribution Panels
1‐Phase (Exciter/Auxiliary Section):
606‐1136‐160 2‐Pole,16 Amp, 480 VAC 1 Per Panel (Common to all Panels)
3‐Phase Delta Circuit Breakers:
606‐1180‐000 3‐Pole, 63 Amp, 480 VAC 1 Per Power Block
3‐Phase Wye Circuit Breakers:
606‐1180‐000 4‐Pole, 40 Amp, 400 VAC 1 Per Power Block
1‐Phase Circuit Breakers(FAX5/10/20 Only):
606‐1180‐000 2‐Pole, 50 Amp, 400 VAC 1 Per Power Block
Outlet Strips (Common to all Panels):
253‐0253‐000 230 VAC, 10 Amp, 4xC13
253‐0254‐000 120 VAC, 10 Amp, 4x5‐15R
7.3
FAX20/30/40 Specific Parts
The cabinet interface board is part of the Multi‐Unit COntrol panel located in the primary power block.
Cabinet Interface Board ‐ 901‐0234‐271G (Part of the Multi‐Unit Control Panel in primary power block)
The directional coupler is the same unit for all the FAX20/30/40 transmitters. This coupler provides the samples for the system power detection, RTAC samples and the modulation monitor sample.
971‐0023‐198 3‐1/8" EIA Un‐Flanged 3‐port 54 dB coupling factor
Copyright ©2013, Harris Broadcast
WARNING: Disconnect primary power prior to servicing.
888‐2720‐001
FAX 5/10/20/30/40KW
October 28, 2013
7.3.1
7‐5
Reject Load Parts
There are two sizes of reject load used in he FAX series transmitters, 6 kW and 12 kW. The external fan control board, fans and internal resistors are all common. Quantities are load size dependant.
Table 7-2 Reject Load Common Replaceable Parts
Part Number
Description
Qty
430‐0358‐000
Fan, 48 VDC, 410 CFM, PWM Control, 172 mm
2 or 4
546‐0338‐000
Resistor, 500 ohm, 10%, 300 Watt, Non‐Inductive
10 or 20
901‐0234‐151G
Fan Control Board
1 per Load
7.3.2
Splitters/Combiners
Table 7-3 FAX20/30/40 Combiners
Part Number
Description
971‐0054‐012
2‐way Power Combiner 20 kW output, 3 dB Hybrid
971‐0054‐019
2‐way Power Combiner 30 kW output, 4.77 dB Hybrid
971‐0054‐047
2‐way Power Combiner 40 kW output, 3 dB Hybrid
Table 7-4 FAX20/30/40 Splitters (Multi-Unit Controller Only)
888‐2720‐001
Part Number
Description
9010234281G
2‐way FAX20 Cabinet Power Splitter
9010234311G
3‐way FAX30 Cabinet Power Splitter
9010234321G
4‐way FAX40 Cabinet Power Splitter
WARNING: Disconnect primary power prior to servicing.
Copyright ©2013, Harris Broadcast
7‐6
Section-7 Parts List
October 28, 2013
Copyright ©2013, Harris Broadcast
WARNING: Disconnect primary power prior to servicing.
888‐2720‐001
Cabinet Unification Instructions
October 23, 2013
a-1
Appendix a
Rev B
a.1 Scope and Purpose
If FAX transmitter cabinets are required to be bolted together, the following instructions are to be followed. Refer to wiring
diagrams in Section 100 of the drawing package that accompanied the transmitter if needed.
a.2 Procedure
Set racks side by side with the driver transmitter (cabinet 1) on the left.
•
Must have a space of 1-3/4” between racks in both the front and back sides
Cabinet 1
Cabinet 2
Top PAB
Top PAB
Bottom PAB
888-2720-001
Cabinet 2
Cabinet 1
Bottom PAB
WARNING: Disconnect primary power prior to Servicing.
Copyright © 2013 Harris Broadcast
Cabinet Unification Instructions
a-2
October 23, 2013
1-3/4”
•
•
•
•
Loosen the pre-installed hardware between cabinet 1 & 2
Assemble filler channels to the front and rear of cabinets (3 per side).
From the top maneuver each channel onto hardware.
Tighten hardware until secure.
Filler Channel
943-5614-508
Installed Filler Channel
(3) Places (Both Sides)
Copyright © 2013 Harris Broadcast
WARNING: Disconnect primary power prior to Servicing.
888-2720-001
September 30, 2013
•
•
•
•
Cabinet Unification Instructions
a-3
Install the covers over the filler channels between the two cabinets in the front and rear.
Remove preinstalled hardware from top of racks.
Install top bracket and secure with hardware that was just removed.
Fasten the top ends of the channel covers to top bracket with finish screws.
(2)
(1)
(4)
(4)
(4)
(2)
Channel Cover ...... 943-5614-507
Top Bracket .......... 943-5614-509
Screw .................... 303-4112-025
Flat........................ 310-0026-000
Split....................... 314-0015-000
Finish Screw
Pre-installed
Hardware
Channel Cover
943-5614-507
(2) Places Front & Rear
Top Bracket
943-5614-509
Finish Screw
2 Places
Front & Rear
888-2720-001
WARNING: Disconnect primary power prior to Servicing.
Copyright © 2013 Harris Broadcast
Cabinet Unification Instructions
a-4
•
October 23, 2013
Bend back grounding strap in cabinet 2 and fasten to the grounding bar cabinet 1.
Grounding Bar
Bend Back the
Grounding Strap
•
Position the final horizontal combiner as shown and maneuver into cabinets.
Copyright © 2013 Harris Broadcast
WARNING: Disconnect primary power prior to Servicing.
888-2720-001
Cabinet Unification Instructions
September 30, 2013
a-5
•
•
Connect the final horizontal combiner to both vertical combiners.
Secure combiner with hose clamps at each inlet.
•
•
Install RF conductor assembly that shipped loose with unit.
Insert RF conductor assembly thru cabinet 2 and maneuver around combiner and connect to reject load in front of
cabinet 1.
Cabinet 1
888-2720-001
Cabinet 2
WARNING: Disconnect primary power prior to Servicing.
Copyright © 2013 Harris Broadcast
Cabinet Unification Instructions
a-6
•
•
Connect the RF conductor previously installed to the top of the horizontal combiner.
Secure hose clamp at connection.
•
•
Install directional coupler onto the horizontal combiner.
Install RF output line going from the coupler to the top of rack.
October 23, 2013
Coupler
RF Line
Even Numbers
on This Side
Coupler
Copyright © 2013 Harris Broadcast
WARNING: Disconnect primary power prior to Servicing.
888-2720-001
September 30, 2013
Cabinet Unification Instructions
a-7
•
Fasten the RF connector/bullet to top of rack and connect to the RF output line coming from coupler.
•
•
Locate the bag with 10 AC power cables in cabinet 1.
Remove cables from bag and route over to cabinet 2.
888-2720-001
WARNING: Disconnect primary power prior to Servicing.
Copyright © 2013 Harris Broadcast
Cabinet Unification Instructions
a-8
•
•
•
•
October 23, 2013
Route the 10 power cables thru the white clamps on the air duct.
Route cables 9, 11, 13, & 15 into the corner of the top power block.
Connect cables to the AC inlet connectors as shown below.
Route the black cables #203 & #204 with receptacles into air duct above transmitter.
#203 204
Air Duct
White Clamps
#9 11 13 15
#11
Brown
Copyright © 2013 Harris Broadcast
#13
Black
#15
Grey
WARNING: Disconnect primary power prior to Servicing.
#9 Green
888-2720-001
September 30, 2013
•
•
Cabinet Unification Instructions
a-9
Route cables 10, 12, 14, & 16 from side of cabinet to bottom power block.
Connect cables to bottom power block’s AC Inlet connectors as shown below.
#12
Brown
888-2720-001
#16
Grey
#14
Black
WARNING: Disconnect primary power prior to Servicing.
#9 Green
Copyright © 2013 Harris Broadcast
Cabinet Unification Instructions
a-10
•
•
•
October 23, 2013
Route the black cables w/ receptacles up to both exciters.
Plug in cable #203 to Exciter A
Plug in cable #204 to Exciter B.
Exciter B
Cable #204
Exciter A
Cable #203
Copyright © 2013 Harris Broadcast
WARNING: Disconnect primary power prior to Servicing.
888-2720-001
September 30, 2013
Cabinet Unification Instructions
•
•
Locate bag with coax cables & pink wires in rear of cabinet 2.
Remove cables from bag.
•
Route coax cables up to the directional coupler.
Connect cable #103 to J1
Connect cable #104 to J2
Connect cable #105 to J3
a-11
#104 to J2
#105 to J3
888-2720-001
#103 to J1
WARNING: Disconnect primary power prior to Servicing.
Copyright © 2013 Harris Broadcast
Cabinet Unification Instructions
a-12
•
October 23, 2013
Connect Wago connectors with pink wires #217 & #218 together in cabinet 2 as shown.
Copyright © 2013 Harris Broadcast
WARNING: Disconnect primary power prior to Servicing.
888-2720-001
September 30, 2013
Cabinet Unification Instructions
a-13
•
•
Locate the bag with a ribbon cable in the front of cabinet 1.
Remove cables from bag and route over to cabinet 2.
•
Connect Wago connectors with pink wires #210 thru #216 together in cabinet 2. Clamp Cables as shown.
W208
W209
W201
W201
#208 209
•
Connect W208,W209(FAX40 Only) and W201 as shown above. Ensure coaxes are tight but do not over-tighten.
888-2720-001
WARNING: Disconnect primary power prior to Servicing.
Copyright © 2013 Harris Broadcast
Cabinet Unification Instructions
a-14
•
•
October 23, 2013
Install blank panel onto front of cabinet 2.
Assemble rear doors on both cabinets.
Blank Panel
End of cabinet unification instructions.
Copyright © 2013 Harris Broadcast
WARNING: Disconnect primary power prior to Servicing.
888-2720-001
Support Contacts: http://harrisbroadcast.com/support
eCustomer Portal: http://support.harrisbroadcast.com
Trademarks and tradenames are the property of their respective companies.
9800 S Meridian Blvd | Ste 300 | Englewood, CO 80112 U.S.A.
©2013 Harris Broadcast
Harris Broadcast is an independent company not affiliated with Harris Corporation
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