Welcome to Harris BCD Maxiva ULX UHF Liquid Cooled Transmitters

Welcome to Harris BCD
Maxiva ULX
UHF Liquid Cooled
Transmitters
Presented by:
Harris Training Department
November 20, 2012
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Maxiva Overview 1-1.1
Overview
Maxiva™ ULX Series
Liquid Cooled
UHF Multimedia
Transmitter
ULX 25000 AN
Model no. prefix
Model no. suffix
U = UHF
L = Liquid Cooled
X = Transmitter
AN = analog
AT=ATSC
DV=DVB-T/H
T2= DVB-T2
IS=ISDB-T
CT= CTTB
CM=CMMB
FL=FLO
Peak visual power for analog
Average power for digital
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Maxiva Overview 1-1.2
Design Considerations
 Software defined
 Capable of current/future analog &
digital standards
 Improved efficiency
 Low operating cost
 Environmentally friendly
 Easy to maintain & service
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Maxiva Overview 1-1.3
New Technology
 50V, high power, UHF LD-MOS FET
 AC-DC power supply “block”
 M2X exciter – software definable
M2X & TCU
PA Module
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Maxiva Overview 1-1.4
Maxiva – Liquid Cooled Transmitter
•
General Overview:
– UHF Liquid-Cooled multi-standard transmitter
– Broadband design / frequency agile for all UHF
– Incorporates new PowerSmart™ technology:
• First available 50 Volt UHF LDMOS Power Devices
• Best in Class Power Density
• Higher Efficiency ~30% better than previous designs Lower Power Consumption
• Green design – RoHS compliant
– Power levels per PA cabinet:
• Analog:
• ATSC:
• COFDM:
26.2 kW pk sync
12.3 kW average
8.7 kW average
(power at cabinet output)
– Incorporates Apex M2X multimedia exciter
– TCU (transmitter control unit)
– Easy software upgradeability to new standards
as they become available (e.g. DVB-T2)
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Maxiva Overview 1-1.5
Maxiva – Liquid Cooled Transmitter
• Additional Benefits:
– RoHS compliant / CE compliant
– Modular design
– Simpler single gain stage PA modules
• Less Complexity
• Higher reliability (fewer components)
• Smaller and lighter for ease of handling
• Front load – hot-pluggable design
• Field serviceable design with sub-assembly repair
– Redundancy built into control system
– All digital Real Time Adaptive Correction
(RTAC)
– Includes Harris web-enabled remote GUI
interface
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Maxiva Overview 1-1.6
Power Levels
Output Power Level kW (before filter)
Cabinets PA Modules
ATSC
470-698
> 698 MHz
MHz
470-494
MHz
DVB-T
495-630
631-670
MHz
MHz
>670 MHz
Analog
470-860
MHz
2
2.0
1.7
1.2
1.2
1.2
1.1
3.6
3
3.0
2.6
1.8
1.9
1.8
1.7
5.2
4
4.0
3.4
2.4
2.5
2.4
2.3
7.1
6
6.0
5.2
3.6
3.8
3.6
3.4
10.5
8
8.0
6.9
4.8
5.0
4.8
4.4
13.8
10
9.6
8.3
5.7
6.1
5.7
5.5
17.0
12
11.5
10.0
6.9
7.3
6.9
6.5
20.9
16
15.4
13.3
9.2
9.7
9.2
8.7
26.2
2
18 (12+6)
16.9
14.7
10.4
9.8
10.4
9.8
31.4
2
24 (12+12)
22.2
19.3
13.3
12.6
13.3
12.6
41.4
2
32 (16+16)
29.8
25.7
17.8
16.8
17.8
16.8
51.8
3
36 (12+12+12)
33.3
29.0
20.0
18.8
20.0
18.8
62.1
3
48 (16+16+16)
44.6
38.5
26.7
25.2
26.7
25.2
77.6
1
Analog power given is peak visual power. DVB-T & ATSC power given is average power.
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Maxiva Overview 1-1.7
Power Levels
Output Power Level kW (afterfilter)
Cabinets
PA Modules
Analog*
470-860 MHz
2
3,200
3
5,000
4
6,800
6
10,000
8
13,000
10
16,500
12
20,000
16
25,000
2
18 (12+6)
30,000
2
24 (12+12)
40,000
2
32 (16+16)
50,000
3
36 (12+12+12)
60,000
3
48 (16+16+16)
75,000
1
Analog power given is peak visual power. DVB-T & ATSC power given is average
power.* Indicates power levels used in model numbers.
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Maxiva Overview 1-1.8
Apex M2X Exciter & TCU Controller
RTAC Control &
Status LED’s
Color touch screen
PC GUI
Status LED’s
Status LED’s
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(behind cover) Ethernet
RF sample port and
10MHz, 1PPS signals
Control
Buttons
Maxiva Overview 1-1.10
Maxiva ULX Front View
Apex M2X
Exciters
TCU System
Controller
B
A
Redundant
Pre-Drivers
18
PA’s
(up to 8)
Slot numbers
shown here.
11
Redundant
Driver-PA’s
10
9
Installed PA
modules vary
by model.
8
PA’s
(up to 8)
Slots are numbered. PA’s are interchangeable.
1
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Maxiva Overview 1-1.11
Maxiva ULX Front View
TM page 5-2.
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Maxiva Overview 1-1.12
Cabinet Rear View
TCU, PS1&2, exciter, preamps
Main Circuit
Breakers
Temp range for
inside equipment:
0 to 45o C.
Temp range for
outside equipment:
-33 to 45o C.
Control Circuit
Breakers
Lower PAs
Upper PAs
Coolant In/Out
Hoses
RF Output
Line
Upper 8-way
Combiner
If both fans fail transmitter
will keep operating until PA
modules overheat.
10 kW Final
Reject Load
3dB Power
Combiner
Redundant
Cabinet
Blowers (2)
Lower 8-way
Combiner
See Section 200 dwg. 801-0222161 control boards. AC fans.
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Maxiva Overview 1-1.13
Liquid
Cooled
Main Cabinet Block Diagram
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Maxiva Overview 1-1.14
Maxiva PA Module Key
Features
• Broadband, hot-pluggable design
• Blind-mate control, power, RF and liquid connectors
– No rear access required for hoses, as in Atlas and most
other competitive transmitters
• More compact PA module 22 kg (48.5 lbs)
– Easier to handle than Atlas. Easier one person
replacement
• Simpler design, single gain stage
– Less parts, less complex & more reliable
• Designed for easy serviceability
– Modular design with field replaceable RF pallets, LDMOS
devices (pallets) and Power Supplies
• 1 for 1 power supply to RF device ratio
– Provides excellent redundancy and lower cost per unit
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Maxiva Overview 1-1.15
Maxiva PA Module
AC-DC
Converters (8)
Module weight
< 22kg
Air flow keeps PS
electrolytics cool
RF Pallets (4)
Out
Coolant blind
mate connectors
In
Output RF
Connector
Power
Combiner
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Cold Plate
Maxiva Overview 1-1.16
Maxiva PA Module
User replaceable sub-assemblies shown
AC-DC Converter Module
Txer AC input ranges 208-240V or 380-415
-15 to 10% with AC warning at -15%
TEK PS single phase 90-264VAC
PN 901-0222-011G
Handle
RF Pallet
Latch
PN 901-0222-081G
LDMOS Device
with Heat
Spreader
Diagnostic
Port
Status LED’s
LDMOS FET
Copper for good heat transfer
PN 943-5601-041
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Maxiva Overview 1-1.17
Maxiva PA Module
3 Power Supply 2 LDMOS
5
VSWR
1 Power On
6
Overload
4
Temperature
7
RF Input OK
Index
LED Color
Indication
Description
1
Green
ON-OFF
2
Red
LDMOS Failure
3
Red
P.S. Failure
When one or more P.S. failed. Trips when PS <40V.
4
Red
Temp. Fault
Temp sensors in monitor board and on pallets. Trips if pallet > 90oC or
monitor board > 65oC.
5
Red
VSWR Fault
Reflected power overload (input and output). Trips if ref. > 100w avg. ATSC.
6
Red
Power Overload
Input power overdrive trips if > 55.7W peak. Output overload > 2219W trips.
7
Green
Input Power OK
OK: Green, Input Power Low: Red (<.16W)
NEW
ON: Green, OFF:None
One or more LDMOSFET failed. Trips when LDMOS current <.5A
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Maxiva Overview 1-1.18
Optional Module Test System
PA Module Test System:
9810222012
(includes PA diagnostics unit)
PA Diagnostics Unit:
971-00040-080
DP: 988-2765-001
TM :888-2765-001
DP: 988-2764-001
TM 888-2764-001
PA Diagnositic unit cable:
256-0346-000
USB/AB cable :
256-0346-000
Kit, PA Diagnostics Unit
Cables & doc. package:
971-0040-081
Diagnostics Unit
Load
Pump & Heat
Exchanger
6-10mW RF input
650W RF output COFDM
Control Panel
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Maxiva Overview 1-1.19
TCU
• TCU in main cabinet contains GUI (graphical
user interface panel PC).
• TCU cards used may vary with model.
TCU
• All TCU’s contain MCM card (board).
• MCM’s in each cabinet connected by system
buss.
• Cabinet 1 TCU is main controller in multicabinet systems. Other TCU’s are slaves.
• Battery for real time clock on PCM card. Check
for presence on site.
• Transmitter stays on air if portions of TCU
MCM or PCM card fail.
• Failed cards must remain in TCU with power
applied. Cards are not hot swappable.
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Maxiva Overview 1-2.1
TCU – Front Panel
Transmitter Control Unit
GUI screen calibration can be accessed during reboot. Tap screen
when “Touch screen to calibrate.” text appears. 5 point cal begins.
Reboot of TCU takes about 2 minutes. Transmitter will stay on air if
reset button on PCM card is used. MCM reboot takes transmitter off air
for a short period.
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Maxiva Overview 1-2.2
TCU – Hardware Buttons
Pressing Auto turns on ALC and
transmitter maintains set power
level.
Normal operation is in Auto
mode.
Switching to Manual disables ALC.
Used primarily for power calibration.
LED’s green for normal
operation, yellow for
warnings and red for
faults.
Manual button must be pressed for 5
seconds to actuate.
LED’s and switches mounted on
user interface board.
Switches PDU and IPA pair.
• Power
Control – ALC Auto/Manual
• Remote - Enable/Disable
• Power - Raise/Lower
• Exciter - A/B
• Drive - A/B
• Transmitter - On/Off
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Maxiva Overview 1-2.3
TCU - with PCM-1 card
Redundant PSs
1&2
PDU/IPA Switch
Exciter Switch
Pump Switch
Flash Card
(2GB,FAT 16 Format
use Sandisk Ultra II)
Serial
Connection
(use 612-1601-000
RS232-RJ45 adapter
)
and TeraTerm
MCM reset
TCU Front Panel
pull forward then down
PCM-1 card
Hole in each side
for handles
Panel PC shown here
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Maxiva Overview 1-2.4
TCU – with PCM-2 card
Local Ethernet
Connection
Fixed IP 192.168.2.100
Redundant
PSs 1 & 2
PDU/IPA
Switch
Exciter
Switch
Micro SD card
2GB, 971-0039-071
Flash Card
Pump
Switch
(2GB,FAT 16
Format use
Sandisk Ultra II)
Serial
Connection
(use 612-1601-000
)
RS232-RJ45
adapter and
TeraTerm
PCM reset
MCM reset
Hole in
each
side for
handles
PCM-2 card
TCU Front
Panel pull
Panel PC
forward then down
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Maxiva Overview 1-2.5
TCU - PCM-1 & PCM-2
971-0039-056T
Lithium battery, CR1025, 3V, 10mm, 660-0093-000
PCM-1 reset
On-board
computer
PCM-2
reset
• Designed for use with panel PC (not LCD)
• PCM-2 upgrade is recommended.
• Offers improved operation.
• Replacement kit 973-4512-007 contains
service bulletin, instructions and board.
• Uses micro SD card, 2GB, 971-0039-071 as
hard drive. Image stored on computer
board too.
971-0039-156T
Lithium battery, 20mm, 3V, CR2032 660-0054-000
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Maxiva Overview 1-2.6
TCU - Access
Cover removed for
access to cards
Screw removed to allow TCU
body to pivot downward
TCU – front panel lowered, unit pulled out from rack.
Caution ! Support unit when removing side screws.
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Maxiva Overview 1-2.7
TCU - Access
Depress button
on both sides
to slide unit
into rack
PCM1 card
shown
Be careful with
ribbon cables
(front and rear)
TCU – Pulled out of rack and pivoted downward
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Maxiva Overview 1-2.8
TCU - Components
Base board
PS
board
Behind front panel:
• LCD shown here (panel
PC not shown)
Keep fans
clean
• User interface board
(behind LEDs & buttons)
Redundant PS1
Main Control
Module
MCM
Redundant PS2
PA interface – 2
(if more than 8
PA’s)
PA interface – 1
PS
monitor
Exciter
Switching
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Customer
I/O
Processor control
module PCM-1
(uprocessor daughter
board)
RF detector (pump control
daughter board)
Maxiva Overview 1-2.9
TCU – PS
971-0039-008T
Fan Plug
3.3, 5, +/-15 V PS
24 V PS
Fan 952-9252-006
• Not hot pluggable – Turn off Control breaker before reinserting.
• Individual supplies soldered onto board - difficult to change in field
• Keep fan and TCU filters clean, keep spare PSs
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Maxiva Overview 1-2.10
TCU - Cards
• PS 1 & 2 - Redundant 24V power supplies. Operate flushing fan current
monitor, produce supply voltage for external RF switch, supply boards in
TCU. Turn off Control breakers before removal or replacement.
• PA Interface (Digital I/O) - Provides interface between TCU, IPA
(driver) and PA backplane boards. The interface features 40 digital
outputs/inputs and 24 analog outputs and inputs. A fully populated cabinet
will require two PA interface cards, one card per eight PA modules. The PA
interface card sends the ON/OFF commands to the PA modules and
receives fault information and status from them.
• PS Monitor - Monitors AC lines for phase imbalance and high or low
voltage, coolant inlet/outlet temperature, coolant flow, leaks, combiner
temperature and cabinet fans.
• Exciter Switch - Contains PWB relay, 2 RMS detectors with adjustable
trips (via EPOTs) for power monitoring and a control/status interface for
Exciters A and B.
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Maxiva Overview 1-2.11
TCU - Cards
• Customer I/O - Provides parallel remote control, status and meter
outputs. Connector A has all inputs and Connector B has all outputs.
• RF Detector/Pump Control/ Interlocks - Consists of a main
board and a daughter card. It features 7 RMS detectors with adjustable
trip points (via EPOTS). It has pump control and interlocks on one D25
pin connector and interfaces to an analog downcoverter board via
another D25 connector.
• Processor Control Module (PCM) - ARM based micro module
running embedded Linux OS. It provides a touch screen for enhanced
monitoring and control, exciter and multi-cabinet data collection, fault
logs and web remote connectivity.
• Standard Master Control Module (MCM) - FPGA based
controller used for all critical transmitter control functions.
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Maxiva Overview 1-2.12
TCU GUI Screens
Original Version TCU (LCD)
Control Buttons
GUI Screen
Status LED’s
Original TCU did not have capability of displaying M2X screens.
Direct connection to M2X was required to make changes to settings.
Local login using username = admin and password = harris
Remote login using username = admin and password = harris2009
Username and password fixed. Login on System Service Screen locally.
Recommend use of Mozilla Firefox. Use zoom feature to enlarge GUI display. Ctrl + or Ctrl next level solutions
Maxiva Overview 1-3.1
TCU GUI Screens
Panel PC TCU – PCM1 Card
Login using username = admin and password = harris2009
Username and password fixed. Login on System Service Screen locally.
Remote GUI screens looks just like new style TCU.
Recommend use of Mozilla Firefox, Chrome or or IE8 web browser.
Use zoom feature to enlarge GUI display. Ctrl + or Ctrl Control Buttons
GUI Screen
Status LED’s
Power Control - Auto is normal operating position.
Manual is used only for calibration purposes.
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Maxiva Overview 1-3.2
TCU GUI Screens
Panel PC TCU – PCM 2 Card
First login locally username = admin and password = admin to enter Admin screen.
Use Admin screen to set usernames and passwords. Login after setup via Login button.
Passwords can be changed remotely if Admin password is changed from admin.
Remote GUI screens looks just like new style TCU.
Recommend use of Mozilla Firefox, Chrome or or IE8 web browser.
Use zoom feature to enlarge GUI display. Ctrl + or Ctrl Login
GUI Screen
Control Buttons
Status LED’s
Power Control - Auto is normal operating position.
Manual is used only for calibration purposes.
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Maxiva Overview 1-3.3
TCU – Admin Login - PCM-2
• Initially passwords must be set locally (not
via remote web session).
• Remote login as administrator allows all
passwords to be viewed.
• If admin password has been changed then
remote setting of passwords is allowed.
Factory
defaults
Must be set up prior to
remote web use
Sets timeout of TCU
password. Navigation to
exciter screens and back to
TCU requires new TCU login.
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Maxiva Overview 1-3.4
TCU HOME GUI Screen via Web Browser
Press Exciter buttonsee next slide.
TCU Home Icon
Remote GUI screens and control panel buttons. Use
zoom (Ctrl +/_) feature to enlarge GUI display.
Power Control - Auto is normal operating position.
Manual is used only for calibration purposes.
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Maxiva Overview 1-3.5
Exciter access via TCU GUI
Exciter screens accessible from TCU GUI. Use web browser zoom feature
to enlarge GUI display. Buttons on exciter section work via software.
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Maxiva Overview 1-3.6
TCU – System Home Screen - PCM-2
Select Cab 1, 2
or 3 to go to
TCU Home
screens.
This is Home screen for multiple cabinet transmitters.
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Maxiva Overview 1-3.7
TCU – Home Screen - PCM-2
Sound in analog models.
Log in as Eng to
make changes.
Next page.
Red background
indicates a fault
Active Exciter
Sub-Menus
Follow
Active Drive Chain
Inactive Drive Chain - Yellow
Note: If exciter GUI screens are accessed locally you must log into the TCU each time you return.
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Maxiva Overview 1-3.8
TCU – Event Log – PCM-2
Save to .txt file
on computer
Print log
Clear Log
Date and time
set.
Slide down for
additional entries
(up to 1000).
Date and time
cleared.
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Maxiva Overview 1-3.9
TCU - Drive Chain - PCM-2
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Maxiva Overview 1-3.10
TCU - Power Amps - PCM-2
•
Approximate 1 amp per FET PA module idle current
•
Use scroll bars and next cabinet buttons to access additional data
•
FET current, temps and voltages available via PA diagnostics unit.
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Maxiva Overview 1-3.11
TCU – Output - PCM-2 (single cabinet)
ALC 3.2V-3.6V nominal at factory. V increases as PA
modules warm up. Saturation is 4V. V adjusted by changing
attenuator at PDU splitter input while in manual mode.
Change power here for
single cabinet systems.
RF switch selection (Ant/Load) displays
here if status is present. Transmitter will
mute while switch moves.
Power Out (kW) = Normal Power x (# of good modules/total # of modules)2
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Maxiva Overview 1-3.12
TCU – Output - PCM-2 (multiple cabinet)
ALC 3.2V-3.6V nominal at factory. V increases as PA
modules warm up. Saturation is 4V. V adjusted by changing
attenuator at PDU splitter input while in manual mode.
Change power here for
multiple cabinet
systems.
ALC Setup instructions given in Section 5
of technical manual 888-2628-300 (Rev C).
Power Out (kW) = Normal Power x (# of good modules/total # of modules)2
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Maxiva Overview 1-3.13
TCU - Power Supply - PCM-2
• AC Mains High >10% gives Warning
From PS in TCU
• AC Mains Low < -15% gives Warning
• AC Phase Imbalance & MOV Fuse # give
Warning but do not turn off Txer
• AC Phase Sequence gives RF mute,
pumps and heat exchanger off, goes
back to on when fault clears.
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Maxiva Overview 1-3.14
TCU – System - PCM-2
Temperature in TCU
Coolant Temps
Flow in liters per minute.
Varies with model and
installation.
Mutes RF when open
resumes when interlock
closed.
Faults off when open.
Needs reset to resume
operation.
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Maxiva Overview 1-3.15
TCU – System> Service - PCM-2
All user
settable
Submenus
follow
Time/dates automatically
set if NTP ON & TCU
connected to network.
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Maxiva Overview 1-3.16
TCU -System >Service>System Setup - PCM-2
Sets 100% bar.
Sets exciter
frequency
Effects
screens in
analog
0-8 used settings can be
stored. CAL & MCM settings
saved to Eprom for N+1
uses.
0-8 settings used for N+1
cases to store CAL & MCM
settings to Eprom. Current
changes stored to value
entered here.
Saves CAL & MCM settings
to compact flash card.
0-8 setups can be recalled
for N+1 cases. Frequency,
CAL and settings can all be
recalled.
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Maxiva Overview 1-3.17
TCU-System >Service>Network - PCM-2
Identifies
transmitter IP on
network by this
name.
Can be Enabled
or Disabled. If
Enabled IP
address set by
network. If
Manual IP set
set by user.
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Maxiva Overview 1-3.18
TCU – System>Service>Software Update - PCM-2
PCM version
running
PCM version
(old). Press
Activate to
load old
program.
Press View
MCM version
running
MCM version
(old). Press
Activate to
load old
program.
Press View
This page used to upload
software files for PCM & MCM.
Once uploaded they can be
activated on the PCM and MCM
Software Management screens.
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Maxiva Overview 1-3.19
TCU – System>Service>Cab Setup - PCM-2
Sets nominal cabinet
power for ALC. Max
power limit is 10%
over this value
See next slide
Set these values for
each cabinet.
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Maxiva Overview 1-3.20
TCU - System/Service/Cabinet Setup/Service Mode - PCM-2
The cabinet flow meter sends out a frequency sample based on the flow rate. The transmitter RF is
MUTED if there is insufficient flow (<50% of recommended). When flow is restored and the flow
meter frequency is above the threshold, the transmitter automatically UNMUTES.
Service Mode screen allows three faults to be disabled. These faults cause the transmitter to
MUTE: Coolant Flow, Inlet/Outlet Temperatures and Coolant Leak. If for any reason any of these
sensor devices are faulty, and there is no evidence of a real problem, customers can remain on-air.
For example if the flow meter becomes defective but in fact there is sufficient flow, then the
customer can put the transmitter in the Service Mode of operation while a replacement is sent.
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Maxiva Overview 1-3.21
TCU – System>Service>System Setup> System Threshold - PCM-2
2.8% of nominal is maximum.
Power bar turns red here.
Set to 100 mV less than detector
voltage during system reflected
power calibration.
Power bar turns yellow here.
Power bar turns red here.
Warnings and faults are logged
when levels reached.
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Maxiva Overview 1-3.22
TCU – System>Service>System Setup>System Calibrate - PCM-2
3.0-3.2 V nominal.
3.6V saturated.
Calibrations done here
control foldback
operation and VSWR
fault events.
Nominal 2V during cal.
In multi-cabinet
transmitters the reject load
calibration shows up here.
Set to approximately 3V at
100% reject power.
Enter cal value measured
on power meter in W.
Press to disable VSWR
protection for 5 minutes.
Use during reflected cal.
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Maxiva Overview 1-3.23
TCU – System>Service>Cab Setup>Cab Pwr Calibrate - PCM-2
3.0-3.2 V nominal.
3.6V saturated.
Nominal 2V during cal.
Nominal 1- 3.2V at full
power out. Enter value in
micro W.
Disables VSWR for 5 minutes.
Used during reflected cal.
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Maxiva Overview 1-3.24
Outline Drawing, 1 Cabinet 843-5601-279 Sh 1 Section 100
Drawing Title Box
Revision History
Drawing number
Revision number
1 of 2
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Maxiva System Drawings 2-1.1
Outline Drawing, 1 Cabinet 843-5601-279 Sh 1 Section 100
Drawing notes may be numbered
inside a triangle on the drawing.
1 of 2
Latest revision
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Previous revision
Maxiva System Drawings 2-1.2
Wiring Diagram, PA Cabinet 843-5601-001 Sh 1 Section 200
Wire
number
(159)
Number of
conductors
(8)
Continues on
sheet 3
section B8
Signal name
EXC B CTL
1 of 10
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Maxiva System Drawings 2-1.3
Wiring Diagram, PA Cabinet 843-5601-001 Section 200
Continues
on 1/A1 &
2/A1
Vertical ID
Signal name
EXC B CTL
Board
number
Horizontal
ID
3 of 10
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Maxiva System Drawings 2-1.4
Outline Drawing, 1 Cabinet 843-5601-279 Sh 1 Section 100
1 of 2
next level solutions
Maxiva System Drawings 2-1.5
Outline Drawing, 1 Cabinet 843-5601-279 Sh 2 Section 100
Both versions of
heat exchanger have
two fans
Internal pump
module (future)
25 kW
cooling
system
50 kW
cooling
system
2 of 2
next level solutions
Maxiva System Drawings 2-1.6
Block Diagram, 1 Cabinet 843-5601-284 Sh 1 Section 100
1 of 2
next level solutions
Maxiva System Drawings 2-1.7
Block Diagram, 1 Cabinet 843-5601-284 Sh 2 Section 100
2 of 2
next level solutions
Maxiva System Drawings 2-1.8
Wiring Interconnect, 1 Cabinet 843-5601-705 (was 282) Section 100
1 of 1
next level solutions
Maxiva System Drawings 2-1.9
AC Power Flow, 1 Cabinet 843-5601-583 Sh 1 (was 283) Section 100
1 of 2
next level solutions
Maxiva System Drawings 2-1.10
AC Power Flow, 1 Cabinet 843-5601-583 Sh 2 (was 283) Section 100
2 of 2
next level solutions
Maxiva System Drawings 2-1.11
Layout, RF System 1 Cabinet 843-5601-281 Section 100
1 of 4
next level solutions
Maxiva System Drawings 2-1.12
Layout, RF System 1 Cabinet 843-5601-281 Section 100
2 of 4
next level solutions
Maxiva System Drawings 2-1.13
Layout, RF System 1 Cabinet 843-5601-281 Section 100
3 of 4
next level solutions
Maxiva System Drawings 2-1.14
Layout, RF System 1 Cabinet 843-5601-281 Section 100
4 of 4
next level solutions
Maxiva System Drawings 2-1.15
Layout, Plumbing, 1 Cabinet 843-5601-562 Section 100
1 of 6
next level solutions
Maxiva System Drawings 2-1.16
Layout, Plumbing, 1 Cabinet 843-5601-562 Section 100
2 of 6
next level solutions
Maxiva System Drawings 2-1.17
Layout, Plumbing, 1 Cabinet 843-5601-562 Section 100
3 of 6
next level solutions
Maxiva System Drawings 2-1.18
Layout, Plumbing, 1 Cabinet 843-5601-562 Section 100
4 of 6
next level solutions
Maxiva System Drawings 2-1.19
Layout, Plumbing, 1 Cabinet 843-5601-562 Section 100
5 of 6
next level solutions
Maxiva System Drawings 2-1.20
Layout, Plumbing, 1 Cabinet 843-5601-562 Section 100
6 of 6
next level solutions
Maxiva System Drawings 2-1.21
Wiring Diagram, PA Main 843-5601-001 Section 200
Customer
I/O Panel
Exc. A
Exc. B
1 of 10
next level solutions
Amplifier Cabinet Drawings 2-2.1
Wiring Diagram, PA Main 843-5601-001 Section 200
2 of 10
next level solutions
Amplifier Cabinet Drawings 2-2.2
Wiring Diagram, PA Main 843-5601-001 Section 200
11-18
1-8
IPAs
3 of 10
next level solutions
Amplifier Cabinet Drawings 2-2.3
Wiring Diagram, PA Main 843-5601-001 Section 200
Cab Buss pin 7 used
Predriver & IPA
control lines
801-0222-131
IPA Backplane
RF Drive
Adjusts drive
to preamp
801-0222-101
843-5601-062
4 way
3 way
2way
6 way
8 way
4 of 10
next level solutions
Amplifier Cabinet Drawings 2-2.4
Wiring Diagram, PA Main 843-5601-001 Section 200
Upper splitter
RF drive from IPA switch
Upper cabinet
PA backplanes
¼ wave hybrid
Control buss
Lower cabinet
Lower splitter
5 of 10
next level solutions
Amplifier Cabinet Drawings 2-2.5
Wiring Diagram, PA Main 843-5601-001 Section 200
6 of 10
next level solutions
Amplifier Cabinet Drawings 2-2.6
Wiring Diagram, PA Main 843-5601-001 Section 200
7 of 10
next level solutions
Amplifier Cabinet Drawings 2-2.7
Wiring Diagram, PA Main 843-5601-001 Section 200
8 of 10
next level solutions
Amplifier Cabinet Drawings 2-2.8
Wiring Diagram, PA Main 843-5601-001 Section 200
9 of 10
next level solutions
Amplifier Cabinet Drawings 2-2.9
Wiring Diagram, PA Main 843-5601-001 Section 200
AT2 – forward power sample.
Change value to set detector
voltage during forward cabinet
cal.
10 of 10
AT1 – reflected power sample.
Change value to set detector
voltage during reflected cabinet
cal.
next level solutions
Amplifier Cabinet Drawings 2-2.10
SCH, 4 PA Backplane 801-0222-101 Section 200
Jumper 2&3 for
208-240
1&2 for 380-415
AC-DC Converter
AC-DC
Converter
AC-DC
Converter
1 of 5
next level solutions
Amplifier Cabinet Drawings 2-2.11
SCH, 4 PA Backplane 801-0222-101 Section 200
2 of 5
next level solutions
Amplifier Cabinet Drawings 2-2.12
SCH, 4 PA Backplane 801-0222-101 Section 200
3 of 5
next level solutions
Amplifier Cabinet Drawings 2-2.13
SCH, 4 PA Backplane 801-0222-101 Section 200
4 of 5
next level solutions
Amplifier Cabinet Drawings 2-2.14
SCH, 4 PA Backplane 801-0222-101 Section 200
5 of 5
next level solutions
Amplifier Cabinet Drawings 2-2.15
SCH, IPA Backplane 801-0222-131 Section 200
1 of 3
next level solutions
Amplifier Cabinet Drawings 2-2.16
SCH, IPA Backplane 801-0222-131 Section 200
2 of 3
next level solutions
Amplifier Cabinet Drawings 2-2.17
SCH, IPA Backplane 801-0222-131 Section 200
3 of 3
next level solutions
Amplifier Cabinet Drawings 2-2.18
ULX-25000AN
N or Stages
4
Splitter/Combin
er Loss/Gain
-0.50
Device Losses
Combiner
Unbalance Loss
-0.50
Total Gain (Loss)
-6
-3
-1.2
-1.2
-7.22
-4.21
32.0
0
19
16
4
-12.04
12.04
0.00
-1
-1.2
-0.6
0
-0.05
-0.15
1.00
-13.24
11.44
0
-0.05
-0.15
19
Peak Sync
0.082
Power (Watts)
0.073
0.014
0.0052
8.31
659.9
524.18
24.9
1879
26178
26178
25879
25000
Back Porch
0.049
Power (Watts)
0.043
0.008
0.003
4.95
393
312
15
1118
15582
15582
15404
14881
Peak Power
(Watts)
0.135
0.120
0.023
0.00086
13.71
1088.7
864.82
41.00
3257
45386
45386
44867
43344
Peak RF Voltage
(Volts)
4
3
2
1
37
330
294
64
571
2130
2130
2118
2082
Peak Power
(dBm)
21.30
20.80
13.58
9.37
41.37
60.37
59.37
46.13
65.13
76.57
76.57
76.52
76.37
Average Power
0.054
(Watts)
0.048
0.009
0.003
5.49
436.4
346.7
16.4
1306
18194
18194
17986
17375
16.83
9.61
5.40
37.40
56.40
55.40
42.16
61.16
72.60
72.60
72.55
72.40
3.97
3.97
3.97
3.97
3.97
3.97
3.97
3.97
3.97
3.97
3.97
3.97
Average Power
17.33
(dBm)
Peak/Average
3.97
Ratio (dB)
Hybrid Loss
-0.15
Block Diagram ULX-5000AN
16 Analog Modules/1 Cabinet
Power Budgets 3-1.1
ULX-12300AT
N or Stages
4
Splitter/Combi
ner Loss/Gain
-0.50
Device Losses
-6.02
-3
-1.2
-1.2
-7.22
4.2
1
16
4
-12.04
12.04
0.00
-1
-1.2
-0.6
0
-0.05
-0.15
-1.00
-13.24
11.44
0
-0.05
-0.15
Combiner
Unbalance Loss
Total Gain
(Loss)
Peak Power
(Watts)
Peak RF
Voltage (Volts)
Peak Power
(dBm)
Average Power
(Watts)
Average Power
(dBm)
Peak/Average
Ratio (dB)
Hybrid Loss
-0.50
0.289
0.258
5
5
24.61
24.11
32.0
0
19
19
0.04
9
0.019
29.389
1
2334
1854
87.92
3500
48774
48774
48215
46579
2
1
54
483
431
94
592
2208
2208
2196
2158
12.68
44.68
63.68
62.68
49.44
65.44
76.88
76.88
76.83
76.68
0.002
3
3.6999
293.9
233.4
11.1
879
12251
12251
12111
11700
16.8
9
0.00
6
0.036
0.032
15.61
15.11
7.89
3.68
35.68
54.68
53.68
40.44
59.44
70.88
70.88
70.83
70.68
9
9
9
9
9
9
9
9
6
6
6
6
6
-0.15
Block Diagram ULX-12300AT
16 ATSC Digital Modules/1 Cabinet
Power Budgets 3-1.2
ULX-8700DV
N or Stages
4
Splitter/Combi
ner Loss/Gain
-0.50
Device Losses
Combiner
Unbalance Loss
Total Gain
(Loss)
Peak Power
(Watts)
Peak RF
Voltage (Volts)
Peak Power
(dBm)
Average Power
(Watts)
Average Power
(dBm)
Peak/Average
Ratio (dB)
Hybrid Loss
-0.50
-6.02
-3
-1.2
-1.2
-7.22
-4.21
32.0
0
19
16
4
-12.04
12.04
0.00
-1
-1.2
-0.6
0
-0.05
-0.15
1.00
-13.24
11.44
0
-0.05
-0.15
18
0.843
0.752
0.143
0.05
4
85.705
2710
2153
102.07
4354
60674
60674
59980
57944
9
9
4
2
93
521
464
101
660
2463
2463
2449
2407
29.26
28.76
21.54
49.33
64.33
63.33
50.09
66.39
77.83
77.83
77.78
77.63
0.034
0.030
0.006
3.412
271.0
215.3
10.2
644
8974
8974
8872
8570
15.26
14.76
7.54
3.33
35.33
54.33
53.33
40.09
58.09
69.53
69.53
69.48
69.33
14
14
14
14
14
10
10
10
8.3
8.3
8.3
8.3
8.3
17.3
3
0.00
22
-0.15
Block Diagram ULX-8700DV
16 DVB-T Modules/1 Cabinet
Power Budgets 3-1.3
ULX-8700IS
N or Stages
4
Splitter/Combi
ner Loss/Gain
-0.50
Device Losses
Combiner
Unbalance Loss
Total Gain
(Loss)
Peak Power
(Watts)
Peak RF
Voltage (Volts)
Peak Power
(dBm)
Average Power
(Watts)
Average Power
(dBm)
Peak/Average
Ratio (dB)
Hybrid Loss
-0.50
-6.02
-3
-1.2
-1.2
-7.22
-4.21
32.0
0
19
16
4
-12.04
12.04
0.00
-1
-1.2
-0.6
0
-0.05
-0.15
1.00
-13.24
11.44
0
-0.05
-0.15
18
0.843
0.752
0.143
0.05
4
85.705
2710
2153
102.07
4354
60674
60674
59980
57944
9
9
4
2
93
521
464
101
660
2463
2463
2449
2407
29.26
28.76
21.54
49.33
64.33
63.33
50.09
66.39
77.83
77.83
77.78
77.63
0.034
0.030
0.006
3.412
271.0
215.3
10.2
644
8974
8974
8872
8570
15.26
14.76
7.54
3.33
35.33
54.33
53.33
40.09
58.09
69.53
69.53
69.48
69.33
14
14
14
14
14
10
10
10
8.3
8.3
8.3
8.3
8.3
17.3
3
0.00
22
-0.15
Block Diagram ULX-8700IS
16 ISDB-T Modules/1 Cabinet
Power Budgets 3-1.4
ULX ALC LOOP
The ALC (automatic level control) in the ULX transmitter
regulates the power output of the transmitter as
amplifier gains vary.
ALC provides the only output regulation for the ULX
transmitter system.
The PA modules do not have a automatic power control.
PA module gain drops as they warm up. ALC increases
the RF drive level to modules maintaining the desired
power output.
ALC is based on cabinet forward power. It uses the
forward cabinet power sample for regulation. System
forward power is not used for output power regulation.
next level solutions
Maxiva Overview 3-2.1
ULX ALC LOOP Components
1.
2.
3.
4.
Cabinet forward power RF detector is in the TCU RF Monitor card
The TCU MCM (main controller module) card generates the ALC voltage
Pre-Driver Unit (PDU) contains the variable attenuator that adjusts the drive level
Cabinet directional coupler provides the RF forward sample
Predriver
Chassis
Predriver A
(PDU-A)
16 PAs
IPA-A
Internal
Cabinet
Coupler
AT8
AT1
RF Drive From
Exciter
RF Splitter
IPA-B
÷
Σ
AT2
Predriver B
(PDU-B)
TCU
12-Bit
0 to 4 V
D/A
0 to 3.6 V
A/D
12-Bit
Cabinet ALC Voltage from
MCM Card
Cabinet Forward Power Sample
to TCU RF Monitor Card
next level solutions
Maxiva Overview 3-2.2
Cabinet ALC Voltage
Two voltages are key to ALC operation:
• Cabinet ALC voltage
• RF cabinet forward sample detected voltage
Cabinet ALC Voltage adjusts the electronic attenuator in each PDU (predriver unit) to raise the power up or down.
4V gives maximum power (minimum attenuation) and 0V gives the lowest
power (maximum attenuation).
The ALC voltage needs to be between 3.2 to 3.6 Volts. 3.6 is best.
As the amplifiers heat up their gain decreases and the ALC will increase the
ALC voltage to a higher level.
If ALC of 4V is reached, the loop is maxed out and there is no way to
increase the power further. The ALC voltage must be lowered.
next level solutions
Maxiva Overview 3-2.3
Cabinet ALC Voltage Adjustment
Adjust ALC voltage with power control set to Auto as long as calibration has
been performed . Turn Tx off when changing attenuators.
Change attenuator AT8 between the exciter and the PDU until ALC voltage is
3.2 to 3.6 V .
The attenuator AT8 is shown on the previous diagram.
ALC Voltage.
Must be between 3.2
to 3.6 V at nominal
power
next level solutions
Maxiva Overview 3-2.4
Cabinet Forward Sample Detected Voltage
The cabinet detected voltage, shown on the Cab Pwr Calibrate
screen (next page) is developed from the forward power sample on
the cabinet internal coupler.
The detection takes place in the RF Monitor card in the TCU.
The RF detector has a voltage range of 0 to 3.6V.
Therefore, careful attention must be paid to ensure the detector is
not saturated.
If when doing a power calibration the detected voltage reads above
3.6 volts, the detector is saturated and the ALC loop will not work.
next level solutions
Maxiva Overview 3-2.5
Cabinet Forward Sample Detected Voltage
The forward voltage needs to be between 3.0 to 3.2 V at nominal power.
When doing a power calibration, maintaining this voltage within this range
is critical for correct operation of the control loop.
The forward power detected voltage can be read from the Cab Calibration
page.
Cabinet Forward
Voltage.
Must be between 3.0
to 3.2 V at nominal
power
next level solutions
Maxiva Overview 3-2.6
Cabinet Forward Sample Detected Voltage
Adjustment
Set the transmitter POWER CONTROL to MANUAL
The only way to adjust the forward power detector voltage is to
change the attenuator connected to the internal cabinet coupler
forward sample. This is shown as AT2 in the diagram.
Since the drive chain PDU-A + IPA-A may have slightly different
combined gain than the PDU-B + IPA-B path, both drive chains
must be checked. The ALC voltage may be slightly different
between the two paths. But as long as it falls within the limits
(3.2 to 3.6 V), the performance will not suffer.
next level solutions
Maxiva Overview 3-2.7
Power Calibration
When both the ALC voltage and the cabinet forward detected voltage
are within range, a cabinet power calibration must be performed so that
the ALC routine can store all references.
Perform the cabinet forward power calibration in POWER CONTROL
MANUAL mode.
Once the calibration is done, go to the Output page and enter the
transmitter nominal power in the Cab Fwd Pwr Reference box.
Enter the transmitter
nominal power
next level solutions
Maxiva Overview 3-2.8
Power Calibration
Set the POWER CONTROL to AUTO.
The AUTO button may flash for a few seconds and then should stay
solidly lit. Try entering different Cab Fwd Pwr Reference values to make
sure the ALC loop commands the transmitter properly to the exact
power entered.
Once the calibration is done, go to the Output page and enter the
transmitter nominal power in the Cab Fwd Pwr Reference box.
Enter the transmitter nominal
power. This value will set the
transmitter output power. The
Raise/Lower buttons on the TCU
will also change this value.
next level solutions
Maxiva Overview 3-2.9
ULX PA Module – Component ID
AC
Distribution
Monitor
I/O
Connector
4-Way
Splitter
PA AC-DC
Power Supply
Signal
Distribution
Coolant
In/Out
PA Pallet
4 –Way
Combiner
RF Out
PA Module Cover Removed
next level solutions
Maxiva PA Module 4-1.1
PA/IPA Module – Simplified Block Diagram
200 to 240 VAC
2 ea.
50 Vdc via steering
diodes
Pallet
2 ea.
*
Combiner
*
Pallet
+12 V
2 ea.
*
Pallet
Splitter
2 ea.
*
*
Pallet
19-20 dB gain typ.
Indicates Pallets and PSs removed from IPAs in Txers with 8 or less PA modules.
Modified IPAs can’t be used as PAs. PAs can be used as IPAs.
next level solutions
Maxiva PA Module 4-1.2
PA/IPA Module – Board ID
Note: These ID numbers follow the GUI error messages. See TM page 5-9.
PS1
Out
P4
Coolant
PS2
*
PS3
*
PS4
P3*
PS5
PS6
*
PS7
*
PS8
*
P2
P1
In
RF Out
PS = Power Supply
P = Pallet
Indicates Pallets and PSs removed from IPAs in Txers with 8 or less PA modules.
* Modified IPAs can’t be used as PAs. PAs can be used as IPAs.
next level solutions
Maxiva PA Module 4-1.3
PA Module – Monitor Board
Monitor
Pin in modified IPA module.
next level solutions
Maxiva PA Module 4-1.4
PA Module – AC Distribution Board
PA Module Cover Removed
Signal
distribution
board (extends
under splitter
board)
AC
Distribution
Board
PS Connects
Here
next level solutions
Maxiva PA Module 4-1.5
PA Module – AC-DC Power Supply
PA Module Cover Removed
PA AC-DC
Power Supply
PA or IPA Modules (systems with more than 8 PAs) Module Part No.:
971-0040-004 without RF monitor port in front.
971-0040-003 with RF monitor port in front.
IPA Module (systems with 8 PAs or less) Part No.:
971-0040-011 without RF monitor port in front.
971-0040-006 with RF monitor port in front.
next level solutions
Maxiva PA Module 4-1.6
PA Module – AC-DC Power Supply
Interface Connector
Under Board
Fuse F1
Part no. 398-0777-001
Fuse 8A 250V Fast 5mm x20mm
Output Adjustment
Pot
Output Wire
48V
PS Module
Part no. 901-0222-011GT
Pad, Thermal
Part no. 411-0126-000
next level solutions
Maxiva PA Module 4-1.7
PA Module – AC-DC Power Supply
AC/DC CONVERTER INTERFACE BLOCK DIAGRAM
PFE500-48
5A
AC1
AC(L)
AC2
AC(N)
R
-BC
5.755V ---- 44V
Rtrim1
Vout
+S
Rext
TRIM
JP1
+BC
Vtrim Levels
4.122 V --- 46V
+V
Setting AC to DC
output voltage:
-V
-S
1. Remove JP1
Vtrim
2.49V
2.490V ---- 48V
2. Set Vout to 48V
3. Replace JP1
0.875V ---- 50V
next level solutions
Maxiva PA Module 4-1.8
Wiring Diagram, PA Module 843-5601-012 Section 600
208-240VAC
6
5
TB1
J9 pins 2 & 3 +12V from
AC distribution board
TB3
TB2
801-0222-021
56 pins, AC
and Gnd
Sync,
status,
monitoring
24 pins
1
3
2
J3 pins 6 & 8 +12V
out to test box
5
4
6
8
7
801-0222-011
RF input
Port 4
360o
Port 3
270o
801-0222-071
Port
180o
J1-21 & 22
+12V out to
test box.
J1-36 +3.3V
Port 1
90o
J1
J4
801-0222-061
J7
J6
J5
8010222051
J2
801-0222-041
4
3
2
1
J4-3 & 4
+12V out
801-0222-081
801-0222-091
Port 4
Port 3
Port 2
Port 1
J1
J2
1 of 1
next level solutions
Maxiva PA Module Drawings 4-2.1
SCH, I/O Connector 801-0222-041 Section 600
J1-A thru D, 4 rows
of 6 pins each. 24
pins.
J1-E thru H
J1-J thru L
7 rows of 8 pins
each. 56 pins.
1 of 1
TB1 thru TB3 AC
distribution board
TB1 thru TB3
respectively.
next level solutions
Maxiva PA Module Drawings 4-2.2
SCH, AC Distribution 801-0222-021 Section 600
R6-R8 allows limited operation
of AC/DC converter so they can
power +12V relays.
Feeds 3 PS.
Feeds 3 PS.
Feeds 2PS.
1 of 2
next level solutions
Maxiva PA Module Drawings 4-2.3
SCH, AC Distribution 801-0222-021 Section 600
Votage is approx. 50V
from PS1-8 via steering
diodes.
2 of 2
next level solutions
Maxiva PA Module Drawings 4-2.4
SCH, PA Pallet 801-0222-081 Section 600
Differential amp.
From
Sheet 2
Bias adjust.
Bias temp adjust.
Source Q4
Thermistor for PA
module temp.
Zener diode regulator.
1 of 2
next level solutions
Maxiva PA Module Drawings 4-2.5
SCH, PA Pallet 801-0222-081 Section 600
Bias for Q1
1a idle
current
0o
Bias for Q2
-90 o
2 of 2
To sh. 1
1a idle
current
next level solutions
Maxiva PA Module Drawings 4-2.6
SCH, 4 Way Splitter 801-0222-071 Section 600
1/4 power
1/4 power
1/4 power
1/4 power
70.7 ohm lines
-270O
-90O
-360O
-180O
-180O
Grounds
1/2 power
¼ wave hybrid
0O
Wilkinson
Splitter
-90O
Input from IPA
1/2 power
-90O
Used as phase shifter.
Zs = ZO2/ZL
Zo = SQRT(ZS x ZL)
Pout = Pnorm (# good amps/total amps)2
1 of 2
next level solutions
Maxiva PA Module Drawings 4-2.7
SCH, 4 Way Splitter 801-0222-071 Section 600
2 of 2
next level solutions
Maxiva PA Module Drawings 4-2.8
SCH, 4 Way Combiner 801-0222-091 Section 600
2X Watts
3 dB Hybrid
1:1 Combiner
-90O
X Watts
-180O
X Watts
1 of 2
4X Watts
3X Watts
4.77 dB Hybrid
2:1 Combiner
-270O
X Watts
next level solutions
6 dB Hybrid
3:1 Combiner
-360O
X Watts
Maxiva PA Module Drawings 4-2.9
SCH, 4 Way Combiner 801-0222-091 Section 600
2 of 2
next level solutions
Maxiva PA Module Drawings 4-2.10
Wiring Diagram, Pre-driver 843-5601-062 Section 500
DC to phase &
gain board.
Output amp.
RF from
exciter
switcher
1 of 1
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Pre-driver Drawings 4-3.1
SCH, Phase & Gain 801-0222-221 Section 500
1 of 5
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Pre-driver Drawings 4-3.2
SCH, Phase & Gain 801-0222-221 Section 500
2 of 5
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Pre-driver Drawings 4-3.3
SCH, Phase & Gain 801-0222-221 Section 500
Hybrid
RF in.
Mute opens or
closes this
switch.
Varying bias values
changes phase 0-90o
for each hybrid.
3 of 5
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Pre-driver Drawings 4-3.4
SCH, Phase & Gain 801-0222-221 Section 500
4 of 5
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Pre-driver Drawings 4-3.5
SCH, Phase & Gain 801-0222-221 Section 500
5 of 5
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Pre-driver Drawings 4-3.6
SCH, Pre Driver Module Interface 801-0222-261 Section 500
1 of 2
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Pre-driver Drawings 4-3.7
SCH, Pre Driver Module Interface 801-0222-261 Section 500
2 of 2
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Pre-driver Drawings 4-3.8
SCH, Pre Driver Signal Interface 801-0222-271 Section 500
1 of 1
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Pre-driver Drawings 4-3.9
SCH, Down Converter 801-0222-241 Section 400
1 of 9
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Downconverter Drawings 4-4.1
SCH, Down Converter 801-0222-241 Section 400
2 of 9
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Downconverter Drawings 4-4.2
SCH, Down Converter 801-0222-241 Section 400
3 of 9
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Downconverter Drawings 4-4.3
SCH, Down Converter 801-0222-241 Section 400
4 of 9
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Downconverter Drawings 4-4.4
SCH, Down Converter 801-0222-241 Section 400
5 of 9
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Downconverter Drawings 4-4.5
SCH, Down Converter 801-0222-241 Section 400
6 of 9
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Downconverter Drawings 4-4.6
SCH, Down Converter 801-0222-241 Section 400
7 of 9
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Downconverter Drawings 4-4.7
SCH, Down Converter 801-0222-241 Section 400
8 of 9
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Downconverter Drawings 4-4.8
SCH, Down Converter 801-0222-241 Section 400
9 of 9
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Downconverter Drawings 4-4.9
PA/IPA Module – Pallet Replacement
PA Pallet
PA Module Cover Removed
4
6 & 11
1.
2.
3.
4.
5.
6.
7.
Turn off PA module breaker.
Unscrew hold down screws and remove PA
module.
Remove PA module cover.
Remove 4 center pallet hold down screws.
Remove 5 additional pallet hold down screws
(circled).
De-solder two jumpers and the blue & gray DC
supply wires.
Remove board and cleanup heat transfer
compound.
8.
9.
10.
11.
12.
13.
14.
15.
Reapply heat transfer compound. Use a small
roller to apply even, thin coat.
Install pallet and all hold down screws.
Torque 4 allen screws to 30 in lbs.
Solder two jumpers and blue & gray wires.
Replace PA module cover.
Replace PA module in rack. Tighten module
hold down screws.
Turn on PA module breaker.
Press ON button to reset all modules.
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Maxiva Maintenance Overview 5-1.1
PA/IPA Module – Pallet Replacement
Soldered Jumper
Module Repair Kit:
Part no. 990-0160-002
Includes:
Pallet
Heat transfer Compound
Buss wire (for UAX)
Ribbon Wire (jumpers)
Circled allen screws
to be torqued
Soldered Jumper
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Maxiva Maintenance Overview 5-1.2
PA Module – PS Replacement
PA AC-DC Power Supply
PA Module Cover Removed
5 & 10
4
1. Turn off PA module breaker.
2. Unscrew hold down screws and remove
PA module.
3. Remove PA module cover.
4. Remove 4 PS hold down screws.
5. Remove supply wire from WAGO block.
6. Remove board from connector and
cleanup heat transfer compound.
7. Reapply heat transfer compound. Use a
small roller to apply thin coat evenly.
8.
9.
10.
11.
12.
Install new PS.
Install PS hold down screws.
Reconnect supply wire to WAGO.
Replace PA module cover.
Replace PA module in rack. Tighten
module hold down screws.
13. Turn on PA module breaker.
14. Press ON button to reset all modules.
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Maxiva Maintenance Overview 5-1.3
PA Module – PS Replacement
Interface Connector
under board
Fuse F1
Part no. 398-0777-001
Fuse 8A 250V Fast 5mm x20mm
Supply Wire
PS Module
Part no. 901-0222-011GT
Pad, Thermal
Part no. 411-0126-000
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Maxiva Maintenance Overview 5-1.4
PA Module – Power Supply Voltage Adjust
AC/DC CONVERTER INTERFACE BLOCK DIAGRAM
PFE500-48
5A
AC1
AC(L)
AC2
AC(N)
R
-BC
5.755V ---- 44V
Rtrim1
Vout
+S
Rext
TRIM
JP1
+BC
Vtrim Levels
4.122 V --- 46V
+V
-V
-S
Setting AC to DC
output voltage:
1. Remove JP1
Vtrim
2. Set Vout to 48V
2.490V ---- 48V
3. Replace JP1
0.875V ---- 50V
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Maxiva Maintenance Overview 5-1.5
PA Module – Board ID
Note: PS numbers are numbered in reverse order of Pallets.
PS1
PS2
PS3
PS4
PS5
PS6
PS7
PS8
Out
P4
Coolant
P3
P2
P1
In
RF Out
PS = Power Supply
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P = Pallet
Maxiva Maintenance Overview 5-1.6
PA Module – PS Troubleshooting
SCH, PA Monitor
801-0222-051 Sheet 14 of 14
1
3
………………..
..……………..
4
2
Front Connector on PA Module
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Maxiva Maintenance Overview 5-1.7
PA Module – Test Connector Pin out
Pin
Signal
Pin
1
/ON-OFF STATUS (0V -4.9V)
2
PS8 VOLTAGE (3.8V)
27
P3 FET 1 CURRENT (.3V)
28
GND
3
PS VOLT SEL-TB (44=5.15V,
4
GND
29
P3 FET 2 CURRENT (.3V)
30
CANH (3.2V)
5
AVG INPUT POWER (.012V)
6
+12V (11.9V)
31
P4 FET 1 CURRENT (.3V)
32
CANL
7
GND
8
+12V (11.9V)
33
P4 FET 2 CURRENT (.3V)
34
GND
9
OUTPUT POWER (.023V)
10
PALLET 1 TEMP (2.0V)
35
PA SUM CURRENT (.3V)
36
/SPI-CS(TMS)
(3.2V)
11
REFLECTED POWER (.022V)
12
PALLET 2 TEMP (2.0V)
37
PS1 VOLTAGE (3.8V)
38
SP1-SCK(TCK)
(3.2V)
13
FAULT STATUS 3 (4.95V)
14
PALLET 3 TEMP (2.0V)
39
PS2 VOLTAGE (3.8V)
40
SPI-MOSI(TDI) (3.2V)
15
FAULT STATUS 2 (4.95 V)
16
PALLET 4 TEMP (2.0V)
41
PS3 VOLTAGE (3.8V)
42
SPI-MISO (TDI) (3.2V)
17
FAULT STATUS 1 (0V)
18
AMBIENT TEMP (2.0V)
43
PS4 VOLTAGE (3.8V)
44
SPI-JTAG-SEL
(3.2V)
19
P1 FET 1 CURRENT (.3V)
20
ON/OFF FROM TB (0 V)
45
PS5 VOLTAGE (3.8V)
46
GND
21
P1 FET 2 CURRENT (.3V)
22
PSV TB SEL (0 V)
47
PS6 VOLTAGE (3.8V)
48
BP SYNC PRESENT
(4.9V)
23
P2 FET 1 CURRENT (.3V)
24
GND
49
PS7 VOLTAGE (3.8V)
50
GND
25
P2 FET 2 CURRENT (.3V)
26
GND
46=4.12V, 48=2.49V, 50= .87V)
Signal
Voltages taken with module enabled and no RF
applied.
Pin
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Signal
Pin
(0V)
Maxiva Maintenance Overview 5-1.8
Optional Module Test System
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Maxiva Maintenance Overview 5-1.9
Optional Module Test System
Front Connection on PA Modules
Handheld Analyzer
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Maxiva Maintenance Overview 5-1.10
Optional Module Test System
FROM TRANSMITTER
CABINET DEDICATED
PA FIXTURE HOSE AND
CABLE CONNECTIONS
PA
Cable Harness
EXTENSION HOSES
TEST FIXTURE
• The select buttons toggles through the meter
choices.
• For troubleshooting on the bench, a test
fixture is available. The PA plugs into the test
fixture.
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Multimeter
2
10.3
Pallet Current
PS Voltage
Temperature Text
Driver Current
Select
Faults
Select
PS
Overtemp
Pallet
Fwd Power
Refled Power
Other
PA ON
ON/OFF
Overdrive
Underdrive
Drive Stage
Maxiva Maintenance Overview 5-1.11
Optional Module Test System
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Maxiva Maintenance Overview 5-1.12
Transmitter Fuses – Have Spares
OPA Module Power Supply (901-0222-011G):
F1 - 3980777001 • FUSE 8A 250V FAST 5MM X 20MM
MOV / AC Sample (901-0222-361G):
F1 to F4 – 3980586000 • FUSE, FAST 600VAC/500VDC 12A
Contactor Control Board (901-0222-601G):
F1 to F8 – 3980489000 • FUSE, CART 5X20MM 2A SLOW
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Maxiva Maintenance Overview 5-1.13
Transmitter Internal Liquid Cooling System Layout
• 16 PA module 2 IPA module system shown.
• Combiners and splitters liquid cooled.
• 55o C. coolant inlet temp. warning. @ 65o C. RF
faults off. Turns on automatically when cooled.
• Typically 3 degs C difference in temperature
between inlet and outlet of Txer. Delta not limited
however.
• In Manual pump mode
- Low flow will cause an RF mute.
- No flow will switch off pump and transmitter.
• In Auto pump mode
- Low flow or no flow causes a pump switch.
- If flow is not restored after four pump
switches in a 5 minute period pumps and Txer
go off.
• Coolant leak causes fault OFF. Manual turn ON is
required to re-start.
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Maxiva Maintenance Overview 6-1.1
Low Flow Fault Levels
A pump switch (in auto mode on dual pump models) or an RF mute will occur (in manual
mode or in single pump models) when levels below these flow values are reached.
Number of PA Minimum Flow
Modules
Liters/Minute
1
11.36
2
15.14
3
18.93
4
22.71
5
26.50
6
30.28
7
34.07
8
37.85
9
41.64
10
45.42
11
49.21
12
53.00
13
56.78
14
60.57
15
64.35
16
68.14
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Maxiva Maintenance Overview 6-1.2
Cooling System Block Diagram
Hose
Hose
Bucket
Closed Loop (pressurized) Cooling System
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Maxiva Maintenance Overview 6-1.3
HE Pump Module
Outlet
Inlet
Temperature
Probe
Vent
Air
Separator
Relief Valve
Pump B
Pump A
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12 psi Pre-charged
Bladder Tank
(reservoir)
Maxiva Maintenance Overview 6-1.4
Pump Module and Control Panel
• Indoor use only
• Requires Phillips
screwdriver to open.
• Inverters control AC supply
frequency and motor speed.
• Loss of flow for 5 sec.
causes pump switch.
• Loss of flow that causes 4
pump switches in 5 minutes
turns off pumps.
Pump Module Rear View
Pump Module & Control Panel
Front View
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Maxiva Maintenance Overview 6-1.5
Cooling Control Panel
Pump B
Inverter
Fan A
Inverter
Pump A
Inverter
Fan B
Inverter
System Control
LOCALREMOTE
Pump & Fan
Breakers
Pump Switches
ON/OFF
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Maxiva Maintenance Overview 6-1.6
Inside Cooling Control Panel
AC to
Fans
Status &
Control
FAN and
Pump
Breakers
3 Phase AC Input
Inverters maintain output phases with loss of input phase.
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Maxiva Maintenance Overview 6-1.7
Inside Cooling Control Panel
Control
lines to Tx
AC to Fans
See Wiring Diagram or TM 888-2625-001 for connection details.
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Maxiva Maintenance Overview 6-1.8
Cooling Control & Interlock
Connections on Tx
Interlock Jumpers
Cabinet Safety 8-9
Control lines to
Pump Module
System RF Mute 5-6
Cab RF Mute 11-12
System Safety 2-3
AC to Fans
See Wiring Diagram for connection details.
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Maxiva Maintenance Overview 6-1.9
Inverter Controller
• Set up of Controller for pumps and fans is
described in the HE Pump Module technical
manual 888-2625-001 Section 3.
• Controllers differ for pumps (2HP) and fans
(1HP).
• Controllers differ for supply volatges 3
phase 208 to 240 VAC or 380-415 VAC
(determined at time of order)
• Specify voltage when placing order.
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Maxiva Maintenance Overview 6-1.10
Inverter Controller
• Pump potentiometers only active when pump module set to LOCAL mode.
• Pump inverter settings LL (pump lower limit Hz) = recommended flow rate)
and F202 (set to same value as LL) need to be set on site.
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Maxiva Maintenance Overview 6-1.11
Inverter Controller
• Allows operation with loss of phase.
• Voltage and frequency supplied to pumps and fans changes
with cooling requirements.
• Specify voltage when placing order.
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Maxiva Maintenance Overview 6-1.12
Heat Exchanger
• Heat exchanger designed for
outdoor use.
• 3 phase 208 to 240 VAC or 380415 VAC (determined at time of
order).
Air Flow
• Specify voltage when placing
order.
• One heat exchanger & pump
module unit is required for each
PA cabinet.
• 50 kW heat exchanger can be
mounted vertically or
horizontally.
• 25kW heat exchanger mounts
vertical only.
Closed Loop System Heat Exchanger (top)
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Maxiva Maintenance Overview 6-1.13
Heat Exchanger
Conduit and emergency cut off by Customer
Inlet
Air Flow
Heat Exchanger Exhaust (fan side)
Outlet
Heat Exchanger Intake (fin side)
50 kW vertical heat exchanger shown.
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Maxiva Maintenance Overview 6-1.14
Valve ID
Globe or ball valves
used in supply line for
filters or test loads.
Gate Valve
(use in return lines only)
Globe Valve
Ball Valves
(use in supply line)
(90o on/off)
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Maxiva Maintenance Overview 6-1.15
Cooling System Installation
• Route RF system first to minimize use
of elbows.
• Install pipe or hose so coolant can be
fully drained from all parts of system.
• Avoid sharp bends in hoses.
• Install drain valves in system low
points and vents in system high
points.
• Install heat exchanger outside &
protect from falling ice.
• Need 2 M clearance on exhaust side of vertical heat exchanger. 10 M
on horizontal units.
• Need 1 M clearance on intake side of heat exchangers.
• Some models won’t support a water cooled test load. Air cooled load
may be needed.
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Maxiva Maintenance Overview 6-1.16
Cooling System Installation
• Hoses must be supported every few
feet using padded clamps.
Padded
Clamps
Vent
• Static pressure (pumps off) of 10 psi
is required before turn on.
• Flush cooling system prior to first use
(bypass Tx cabinet).
Sight
glass
• 50/50 glycol/water mixture
• Initial PH > 8.0
• System air purger and sight glass
need to be located at the highest point
in the system.
Bypass
Manifold Assy.
Purger
See section 2 in Technical Manual for
installation instructions.
• Sight glass used to check fluid level, flow and for presence of air
bubbles.
• Low fluid level or presence of bubbles indicates that system needs to
be charged with more coolant.
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Maxiva Maintenance Overview 6-1.17
Cooling System Installation
Supply
Return
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Maxiva Maintenance Overview 6-1.18
Cooling System Maintenance
• Check coolant level monthly. Check for bubbles, level of coolant in
sight tube and static pressure of 10 psi.
• Operate valves monthly to insure continued trouble free operation.
• Check glycol/water ratio regularly (quarterly). Use a float
hydrometer or digital refractometer with ethylene glycol. Use a
digital refractometer with propylene (hydrometers not accurate with
propylene).
Note: Hydrometers only work for ethylene glycol-based
coolants/antifreeze. Propylene glycol should not be read with a
hydrometer due to the fact that up to 70 percent concentration
specific gravity increases, but above 70 percent specific gravity
decreases. A 100 percent solution reads identical to a 40
percent solution.
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Maxiva Maintenance Overview 6-1.19
Cooling System Maintenance
• Check coolant PH regularly (quarterly) PH > 8.0 is ok.
• PH < 8.0 indicates additives or coolant change needed.
• Alternate pumps monthly. Use GUI In Local. Pumps switch when
turned ON/OFF.
• Check and clean strainer regularly (quarterly at first then yearly).
Pumps must be off to clean the strainer.
• Check and clean heat exchanger fins frequently (quarterly or more
often in dirty locations).
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Maxiva Maintenance Overview 6-1.20
Pump Module Pressures
Return
(10psi)
Supply
(40-50psi)
These pressures will vary from system to system depending on no. of
elbows, hose size and length, transmitter model etc.
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Maxiva Maintenance Overview 6-1.21
Pump Module Strainer Assembly
• Pump must be off to
clean screen.
• Strainer screen is
removed with
adjustable wrench.
Strainer
Screen
• Clean after initial
system flushes.
Top of Pump Module
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Maxiva Maintenance Overview 6-1.22
Cooling System Maintenance
"Inhibitor Additions”
Over time, the corrosion inhibitors in heat transfer fluids may become depleted.
UCAR HTF Inhibitors can be added to replace those lost and restore anti-corrosion
properties. Union Carbide inhibitor packages replenish corrosion inhibitors while
adjusting the fluid’s pH and reserve alkalinity. If the analytical report suggests the
need for additional corrosion inhibitors, it will also recommend the best UCAR
Inhibitor package for your system."
Above from:
http://www.dow.com/PublishedLiterature/dh_0035/0901b80380035962.pdf
?filepath=/heattrans/pdfs/noreg/180-01442.pdf&fromPage=GetDoc
General Dow Chemical information at:
http://www.dow.com/PublishedLiterature/dh_0034/0901b80380034ba4.pdf
?filepath=/heattrans/pdfs/noreg/180-01463.pdf&fromPage=GetDoc
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Maxiva Maintenance Overview 6-1.23
Broadcast Customer Portal (eCustomer Home Page)
• Got to http://support.broadcast.harris.com/
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Customer Portal 7-1.1
Customer Portal - Login Window
Apply for User
ID and
Password
MUST use OK button to
submit User ID &
Password
• If you are a new user select “New User” and then specify
a user ID and a password.
• Log in using your new User ID and Password.
• Note: You must use the OK button to submit your Log
In/Password. Using the enter key will not work.
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Customer Portal 7-1.2
Customer Portal – Access Summary
•Go to this link and create an account (or login if you already
have an account)
http://support.broadcast.harris.com
•Logon to the site and click on “Review Documentation”
•Select “Television Transmission”
•Select “UHF Digital”
•Select “Maxiva-ULX”
•Click “Manual, Technical-Maxiva ULX TM (Dry Cooler or HE)”
•File Download page will display, select “Open” or “Save”
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Customer Portal 7-1.3
Customer Portal – Opening Page
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Customer Portal 7-1.4