HARRIS Mini-HD M1HD, M2HD, M3HD, M4HD Mini-HD Transmitter System Technical Manual

TECHNICAL MANUAL

888-2534-001

Mini-HD™

Transmitter System

Mini-HD

™

Transmitter System

T.M. No. 888-2534-001

© Copyright Harris Corporation 2004, 2006

All rights reserved

Printed: 1/31/2006

Rev: A

Returns And Exchanges

Damaged or undamaged equipment should not be returned unless written approval and a Return Authorization is received from HARRIS Broadcast Communications

Division. 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 Communications

Division, specify the HARRIS Order Number or Invoice Number.

Unpacking

Carefully unpack the equipment and preform a visual inspection to determine that no apparent damage was incurred during shipment. Retain the shipping materials until it has been determined that all received equipment is not damaged. 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.

Technical Assistance

HARRIS Technical and Troubleshooting assistance is available from HARRIS

Field Service during normal business hours (8:00 AM - 5:00 PM Central Time).

Emergency service is available 24 hours a day. Telephone 217/222-8200 to contact the Field Service Department or address correspondence to Field Service

Department, HARRIS Broadcast Communications Division, P.O. Box 4290,

Quincy, Illinois 62305-4290, USA. Technical Support by e-mail:

[email protected]m. The HARRIS factory may also be contacted through a FAX facility (217/221-7096).

Replaceable Parts Service

Replacement parts are available 24 hours a day, seven days a week from the

HARRIS Service Parts Department. Telephone 217/222-8200 to contact the service parts department or address correspondence to Service Parts Department, HARRIS

CORPORATION, Broadcast Systems Division, P.O. Box 4290, Quincy, Illinois

62305-4290, USA. The HARRIS factory may also be contacted through a FAX facility (217/221-7096).

NOTE:

The # symbol used in the parts list means used with (e.g. #C001 = used with C001 ).

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WARNING: Disconnect primary power prior to servicing.

1/31/06

Manual Revision History

REV.

Preliminary

A

DATE

16jan2004

1/31/2006

ECN

Created

Mini-HD™ series

Pages Affected

All

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MRH-1

MRH-2

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Guide to Using Harris Parts List Information

The Harris Replaceable Parts List Index portrays a tree structure with the major items being leftmost 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:

Replaceable Parts List Index Part Number Page

Table 7-1. Transmitter

Table 7-2. Control Cabinet

994 9283 001 7-2

992 9244 002 7-3

Table 7-3. Controller Board 992 8344 002 7-6

Table 7-4. PA Cabinet 992 9400 002 7-7

Table 7-5. PA Amplifier 994 7894 002 7-9

Table 7-6. PA Amplifier Board 992 7904 002 7-10

Table 7-7. Output Cabinet 992 9450 001 7-12

Control Cabinet

992 9244 002

Controller Board

992 8344 002

Transmitter

994 9283 001

PA Cabinet

992 9400 002

PA Amplifier

992 7894 002

Output Cabinet

992 9450 001

PA Amplifier Board

992 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 - HARRIS PART NUMBER - this line gives the information that corresponds to the

•

Replaceable Parts List Index entry;

•

HARRIS P/N column gives the ten digit Harris 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.).

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 Harris has purchased and has not manufactured or modified. If the last three numbers are other than 000, the item is either manufactured by Harris or is purchased from a vendor and modified for use in the Harris product.

•

The first three digits of the ten digit part number tell which family the part number belongs to - for example, all electrolytic (can) capacitors will be in the same family (524 xxxx 000). If an electrolytic

(can) capacitor 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 Harris factory and will therefore show up farther down into the individual parts list (because each table is normally sorted in ascending order).

Most Harris 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

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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:

THE CURRENTS AND VOLTAGES IN THIS EQUIPMENT ARE DANGEROUS.

PERSONNEL MUST AT ALL TIMES OBSERVE SAFETY WARNINGS, INSTRUC-

TIONS 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 CORPORATION 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

INTERNAL 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.

1/31/06

!

WARNING:

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 DEFEC-

TIVE CAPACITOR. DO NOT ATTEMPT TO SERVICE A DEFECTIVE CAPACITOR

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WHILE IT IS HOT DUE TO THE POSSIBILITY OF A CASE RUPTURE AND SUBSE-

QUENT INJURY.

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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)

Table of Contents

Section 1

Introduction/Specifications

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Harris DEXSTAR HD Radio Exciter . . . . . . . . . 1-4

IP2D Precorrector . . . . . . . . . . . . . . . . . . . . . . . . 1-4 ePAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4

NeuStar Codec Conditioner (Optional) . . . . . . . 1-5

Section 2

Installation & Initial Turn-On

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Weight and Dimensions . . . . . . . . . . . . . . . . . . . 2-2

Factory Test Data . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Reverse Shipping-Related Modifications . . . . . . . 2-2

M2HD: Remove PA Tray Spacers . . . . . . . . . . . 2-2

M3HD/M4HD: Install PA Modules . . . . . . . . . . 2-3

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Transmitter Placement . . . . . . . . . . . . . . . . . . . . 2-5

Air System And Cooling . . . . . . . . . . . . . . . . . . 2-6

Grounding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Grounding Basics. . . . . . . . . . . . . . . . . . . . . . . 2-6

Mini-HD Rack Grounding Connections . . . . . 2-7

AC Mains Connections. . . . . . . . . . . . . . . . . . . . 2-8

Top: 110 - Bottom: 220 . . . . . . . . . . . . . . . . . . 2-9

Single-Source - 110/110 or 220/220 . . . . . . . 2-10

Internal Grounding Connections . . . . . . . . . . . 2-12

RF Connections . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Circulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Basic Connections . . . . . . . . . . . . . . . . . . . . . . 2-13

Audio Input . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Audio Output . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Initial Turn On. . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Remote I/O Connections . . . . . . . . . . . . . . . . . . . 2-17

DEXSTAR Exciter I/O . . . . . . . . . . . . . . . . . . . 2-17 ePAL Remote I/O Connections . . . . . . . . . . . . 2-17

IP2D - A1J9 for VT100 . . . . . . . . . . . . . . . . . . 2-19

Remote I/O Connections . . . . . . . . . . . . . . . . . 2-19

M3HD/M4HD Remote I/O Connector . . . . . . . 2-21

Section 3

Operation

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1

Front Panel Functions and Displays . . . . . . . . . . . .3-1

Metering Switches and Indicators . . . . . . . . . . . .3-2

Fault LED Indications . . . . . . . . . . . . . . . . . . . . .3-2

RF Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Power Switches . . . . . . . . . . . . . . . . . . . . . . . . . .3-2

Carrier Switch . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

M3HD/M4HD PA Fuses and LED Indications . .3-3

Metering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-3

M1/M2 Metering . . . . . . . . . . . . . . . . . . . . . . . . .3-3

M3/M4 Metering . . . . . . . . . . . . . . . . . . . . . . . . .3-4

Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . .3-5

Daily Pre-Operational Checkout . . . . . . . . . . . . .3-5

Transmitter Turn-On. . . . . . . . . . . . . . . . . . . . . . .3-5

Transmitter Turn Off . . . . . . . . . . . . . . . . . . . . . .3-6

To Set Desired RF Power Output (M1HD/M2HD)3-6

DEXSTAR Exciter Operation . . . . . . . . . . . . . . .3-7 ePAL Operation . . . . . . . . . . . . . . . . . . . . . . . . . .3-7

Emergency Operation . . . . . . . . . . . . . . . . . . . . . . .3-8

No Front Panel LEDs or GUI. . . . . . . . . . . . . . . .3-8

FAULT LED Illuminated . . . . . . . . . . . . . . . . . . .3-8

M1/M2 Fault Indications . . . . . . . . . . . . . . . . . .3-8

M3/M4 Fault Indications . . . . . . . . . . . . . . . . . .3-9

Front Panel Buttons Unresponsive . . . . . . . . . . . .3-9

DEXSTAR . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-9

Section 4

Theory of Operation

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1

IP2D Precorrector. . . . . . . . . . . . . . . . . . . . . . . . .4-1

Harris DEXSTAR HD Radio Exciter . . . . . . . . . .4-1

ePAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-2

Section 5

Maintenance and Alignments

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

Alignments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5-1

IP2D Precorrector - Correction Setup Procedure .5-1

1

Table of Contents

(continued)

Section 6

Troubleshooting

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

IP2D VT100 Interface. . . . . . . . . . . . . . . . . . . . . 6-2

General Troubleshooting Information . . . . . . . . . . 6-4

Schematics, Wiring and Block Diagrams . . . . . . 6-4

Turn MxHD On With No RF Power Output . . . . 6-4

Power Supply System Troubleshooting. . . . . . . . . 6-5

PA Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . 6-5

Audio Troubleshooting . . . . . . . . . . . . . . . . . . . . . 6-5

2

Section 1

Introduction/

Specifications

1

1.1

Introduction

This manual provides the information needed to install, operate and service any one of the M1HD, M2HD, M3HD, or M4HD Mini-HD Transmitter Systems. An M3HD or

M4HD System will include an M1HD transmitter as a driver amplifier.

NOTE:

A transmitter will have either an "s" or a "c" suffix indicating use in a Separate

(dual transmitter), or Common (low-level combined single transmitter) combining method HD Radio™ system.

A typical Mini-HD System will include the following:

•

MxHD PA & Controller (See Table 1-1 on page 2)

•

DEXSTAR™ Exciter

•

IP2D™ Precorrector for linearity enhancement

• ePAL™ - Program Audio Link audio/exciter interface

•

UPS: Uninterruptable Power Supply (Optional)

•

19" Rack Housing with Wiring Harness

•

Circulator (Optional)

•

NeuStar™ Audio Conditioner (Optional)

Several of these pieces of equipment may have a separate Document Package, possibly including a corresponding technical manual and schematic package. See the table below for specific documentation information for the different models.

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1-1

Section 1 Introduction/Specifications

Mini-HD™ System

Table 1-1 MxHD Series Document Information

Transmitter

Model #

M1HD s

Separate

Combined

M1HD c

Common

Combined

M2HD s

Separate

Combined

M2HD c

Common

Combined

M3HD s

Separate

Combined

M3HD c

Common

Combined

M4HD s

Separate

Combined

M4HD c

Common

Combined

Output

Power

8W - 75W

79W max

(250W peak)

15W - 150W

158W max

(250W peak)

15W - 150W

158W max

(470W peak)

30W - 300W

315W max

(470W peak)

30W - 300W

315W max

(1000W peak)

60W - 600W

630W max

(1000W peak)

60W - 600W

630W max

(2000W peak)

120W -

1200W

1260W max

(2000W peak)

Schematic Package #

Install Schematic #s

917-2572-058 M1/M2 Transmitter

917-2573-004 DEXSTAR

843-5567-066 Wiring Diagram

852-9232-013 Outline Drawing

917-2572-058 M1/M2 Transmitter

917-2573-004 DEXSTAR

843-5567-066 Wiring Diagram


917-2572-058 M1/M2 Transmitter

917-2573-004 DEXSTAR

843-5567-066 Wiring Diagram


917-2572-058 M1/M2 Transmitter

917-2573-004 DEXSTAR

843-5567-066 Wiring Diagram


917-2572-059 M3/M4 Transmitter

917-2572-058 M1/M2 Transmitter

917-2573-004 DEXSTAR

843-5567-064 Wiring Diagram


917-2572-059 M3/M4 Transmitter

917-2572-058 M1/M2 Transmitter

917-2573-004 DEXSTAR

843-5567-064 Wiring Diagram


917-2572-059 M3/M4 Transmitter

917-2572-058 M1/M2 Transmitter

917-2573-004 DEXSTAR

843-5567-064 Wiring Diagram


917-2572-059 M3/M4 Transmitter

917-2572-058 M1/M2 Transmitter

917-2573-004 DEXSTAR

843-5567-064 Wiring Diagram


Technical Manual #s

888-2524-001 M1HD s/c

888-2498-001 DEXSTAR

888-2534-001 System

888-2524-001 M1HD s/c

888-2498-001 DEXSTAR

888-2534-001 System

888-2525-001 M2HD s/c

888-2498-001 DEXSTAR

888-2534-001 System

888-2525-001 M2HD s/c

888-2498-001 DEXSTAR

888-2534-001 System

888-2526-001 M3HD s/c

888-2524-001 M1HD s/c

888-2498-001 DEXSTAR

888-2534-001 System

888-2526-001 M3HD s/c

888-2524-001 M1HD s/c

888-2498-001 DEXSTAR

888-2534-001 System

888-2527-001 M4HD s/c

888-2524-001 M1HD s/c

888-2498-001 DEXSTAR

888-2534-001 System

888-2527-001 M4HD s/c

888-2524-001 M1HD s/c

888-2498-001 DEXSTAR

888-2534-001 System

1-2 888-2534-001


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DEXSTAR Exciter

UPS (Optional)

IP2D

Precorrector ePAL

M3HD s

M1HD

M3HD Power Block

M3/M4 Power Supply

AC Circuit Breakers

1/31/06

Figure 1-1

M3HD s

Transmitter Front View

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1-3


1.1.1

Harris DEXSTAR HD Radio Exciter


The DEXSTAR In-band, On-Channel (IBOC) Exciter will delay the standard FM audio in the analog path to synchronize the two signals at the receiver.

•

Full VGA Touch Screen

•

Dual Pentium 3 Processors

•

GPS Receiver

•

Direct Z-HD Transmitter interface

•

Easily interfaces with the ePAL Program Audio Link

•

CD-ROM Drive

•

PAD Generation

1.1.2

IP2D Precorrector

Linear amplification of the amplitude modulated IBOC waveform is achieved in the RF path by the IP2D. It dynamically precorrects the input signal to counteract any distortion in the final stages of amplification. It also provides:

•

Internal APC stage

•

Protection/mute point for the overall transmitter system

•

Combines analog and digital signals for Common Combining Mode

•

Provides serial diagnostics via VT100 emulation interface with a PC

1.1.3

ePAL

The ePAL enables IBOC receivers to switch seamlessly between the IBOC and the analog FM signals. All of the required synchronization and sample rate conversion to the analog signal, delayed audio bypass switching, and digital audio distribution is accomplished via the ePAL.

The ePAL interface is capable of handling audio routing for up to two Harris DIGIT FM exciters and two Harris DEXSTAR IBOC exciters along with up to two audio processors, for redundant back up, into a single MxHD transmitter.

Provides the necessary switching for complete control of all of the required IBOC and analog signals. Directly interfaces with the Harris DEXSTAR IBOC Exciter.

•

Digital Audio Synchronization and Rate Conversion

•

Digital Audio Distribution

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•

Delayed Audio Bypass Switching


1.1.4

NeuStar Codec Conditioner (Optional)

•

Optimizes digital audio prior to encoding

•

HDC codec enhancement and optimization for lower bit rates

•

5.1 surround sound

•

Similar conventional audio processor functions and interface:

•

Multiband dynamic compression

•

EQ

•

Noise reduction

•

Mimic capabilities

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1-5



1-6 888-2534-001


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Section 2

Installation &

Initial Turn-On

2

2.1

Introduction

This section details the procedures to receive, install, and prepare the transmitter for use, as well as initial turn-on steps.

!

CAUTION:

THIS SECTION INCLUDES IMPORTANT INSTRUCTIONS FOR REVERSING

SHIPPING-RELATED MODIFICATIONS OF THE MINI-HD TRANSMITTER. BE

SURE TO READ AND PERFORM THESE PROCEDURES AS THEY APPLY TO

YOUR TRANSMITTER MODEL. REFER TO "2.3 REVERSE SHIPPING-

RELATED MODIFICATIONS" ON PAGE 2-2.

2.2

Unpacking

Refer to the second page of this manual for instructions on unpacking, inspecting, and return procedures in the event of any damages from shipment or omissions.

2.2.1

Inspection

Prior to performing the installation of the MxHD transmitter, it should be thoroughly inspected for any connections which may have loosened during shipment. Also check that all ribbon cables are properly locked into their respective printed circuit board

connectors, and that the PA modules are securely inserted (see "2.3.2 M3HD/M4HD:

Install PA Modules" on page 2-3). Check for debris or loose hardware.

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2-1

Section 2 Installation & Initial Turn-On


2.2.2

Weight and Dimensions

Refer to the Outline Drawing schematic, or the table below for the shipping weight of the MxHD Transmitter.

Table 2-1 MxHD Transmitter Weight

Model

M1HD

M2HD

M3HD

M4HD

Weight

440lbs/199kg

440lbs/199kg

524lbs/ 238kg

524lbs/ 238kg

The transmitter rack is the same size for all MxHD models:

23.5" Wide by 33.0" Deep by 72.0" High

NOTE:

A minimum of 24 inches should be allowed for maintenance access from both the front and rear of the cabinet.

2.2.3

Factory Test Data

Locate and retain the FACTORY TEST DATA. During installation and initial turn on procedures, reference will be made to FACTORY TEST DATA. This data is normally packed in an envelope and may be inserted in the technical manual, or may be packed with the Transmitter. This data includes meter readings, measured performance data, information and data measured with external equipment, frequency determined parts and adjustments specifically for your Transmitter’s operating frequency.

2.3

Reverse Shipping-Related Modifications

2.3.1

M2HD: Remove PA Tray Spacers

The M2HD Transmitter is shipped with spacers between the PA tray and the back panel.

The spacers prevent damage to internal contacts during shipping. Remove and save the spacers and screws using the following procedure.

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Mini-HD™ Series


STEP 1

Remove screws and spacers from five locations (see Figure 2-1 on page

2-3)

STEP 2

Firmly push the PA tray into the M2HD until the tray panel touches the back panel

STEP 3

Locate the hardware bag attached to the PA Module handle

STEP 4

Install five #6 screws and washers

#

#

#

Figure 2-1

M2HD PA Tray Shipping Spacer Locations

2.3.2

M3HD/M4HD: Install PA Modules

The M3HD incorporates two modules and the M4HD, four modules. To avoid potential damage during shipment, these power modules are shipped separately. Follow these steps to install the modules:

STEP 1

Remove the front panel of the Power Amplifier (eight screws)

STEP 2

Taking ESD precautions, unpack the power modules and place them on your work area with the circuit sides up

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2-3



Connector

Warning Label

Slide Rail

Figure 2-2

PA Module

STEP 3

The warning labels on the front of the modules should all be positioned to the center of the chassis. Also note the position of the connector on the modules and in the chassis.

STEP 4

Insert the four power modules (two for M3HD), using their slide rails, into the built-in channels of the left and right-side cavities as shown below. Note that the connectors and warning labels are nearest the middle wall or partition of the Power Amplifier.

2-4

Figure 2-3

M4HD PA Module Placement

STEP 5

Be sure the modules are pushed in completely so that the connector makes proper contact

STEP 6

Replace the front panel of the Power Amplifier

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2.4

Installation


!

CAUTION:

ALL CONNECTIONS REFERRED TO IN THIS INSTALLATION PROCEDURE

SHOULD BE VERIFIED USING THE SCHEMATICS SUPPLIED WITH THE

TRANSMITTER. THE SCHEMATICS SHOULD BE CONSIDERED THE MOST

ACCURATE IN CASE OF A DISCREPANCY.

To facilitate proper installation and initial checkout, this data and the technical manual should be carefully studied to obtain a thorough understanding of the principles of operation, circuitry, nomenclature, and performance characteristics.

The transmitter installation is accomplished in the following order:

1.

Transmitter Rack Placement

2.

Air System and Cooling

3.

Grounding

4.

Power Supply Connections

5.

RF Connections

6.

Transmitter Wiring

7.

Initial Turn On

8.

Remote I/O Wiring

When necessary, refer to drawing titled Outline Drawing in your schematic package for important DIMENSIONS, WEIGHT, AIR FLOW, and ELECTRICAL information.

2.4.1

Transmitter Placement

The transmitter rack should be located to permit adequate maintenance access and sufficient ventilation. The grounding strap between the transmitter and the station earth ground must be properly connected before AC power wiring is attached to transmitter

(see "2.4.3.2 Mini-HD Rack Grounding Connections" on page 2-7).

1/31/06

!

CAUTION:

UNIT MUST NOT BE DROPPED. TWO TO THREE PEOPLE MINIMUM ARE

NEEDED TO REMOVE THE CABINET FROM THE PALLETS.

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2-5



If the transmitter is to be positioned into a predetermined wall opening, be sure to allow for any final leveling needed when figuring the wall opening dimensions.

NOTE:

Once the Mini-HD transmitter rack has been placed, it may be necessary to remove the rear door to facilitate the following installation procedures. The door may be opened, lifted off its hinges and set aside until the transmitter is ready for normal operation.

2.4.2

Air System And Cooling

Refer to the Outline Drawing, for information on air flow CFM, heat dissipation and duct work dimensions.

The Mini-HD rack air system is split into two sections by a mid-deck divider. For the lower section, cooling air primarily enters the front of the transmitter and exits the rear of the rack through the door louvers. The upper section cooling air flow primarily enters through the rear door louvers and exhausts through the top of the rack cabinet.

The air ventilation opening on the top of the transmitter must not be restricted. This is an important consideration when a wall will be installed along the front of the transmitter.

2.4.3

Grounding

2.4.3.1

Grounding Basics

The importance of a good grounding system and lightning protection can hardly be overemphasized for reasons of personnel safety, protection of the equipment, and equipment performance. The following is only a brief overview.

Lightning and transient energy via the power line or tower connections can impose serious threats to your personal safety as well as damage the equipment. For these reasons you should have a good protective earthing system to divert these forms of energy to earth ground. Proper grounding of the equipment also guards against electrical shock hazards that would exist if the equipment failed in a way which put a hazardous voltage on the chassis.

A good grounding system should include substantial grounding at the tower base using copper ground rods and/or a buried copper ground screen, with copper strap used to connect the tower base to earth ground. A low impedance will help carry lightning current directly into the ground instead of into your building. Additionally, coax shield(s) should be electrically connected to and exit the tower as near to the bottom as practical to minimize the lightning voltage potential carried by the coax into your building.

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For multiple coax, a single point of entry into the building is best, with all connected to a common grounding plate (or bulkhead panel) having a low impedance connection to the building perimeter ground. Wide copper straps should be used for making the connection from the common grounding plate to earth ground.

A common grounding plate is also the best location for coaxial surge protectors for sensitive equipment such as an STL receiver. Ideally, this plate should also be the entry point for all signal lines, and serve as a single point ground for AC power surge protection.

A good ground system should include perimeter grounding of the transmitter building using copper ground rods and copper strap. There should also be a copper strap running from tower ground to the building perimeter ground.

Good grounding and shielding will help keep stray RF current to a minimum. RF interference usually shows up in one of several ways, intermittent problems with digital or remote control circuits, audio feedback or high pitched noise. Even a small amount of non-shielded wire makes a very efficient antenna for RF and transient energy. If RF is allowed into the audio equipment, it can be rectified and may show up as noise or feedback. Wire and cable shields should normally be connected at both ends to the equipment chassis, audio cables should have the shield connected to ground on one side only.

2.4.3.2

Mini-HD Rack Grounding Connections

A ground strap attachment point, called Ground (E1/E2), is located on the rear floor of the cabinet. Use this connection when utilizing a Single-Point grounding system, attaching your ground strap to this common grounding point. Route a 2" copper strap underneath the MxHD up through the slot, and secure to the grounding point.

Or, if your Single-Point grounding system requires an upper rack ground connection, connect it to the top 1/4" - 20 stud of the copper buss bar located on the right side as

viewed from the rear (See Figure 2-6 on page 2-12).

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2-7


2.4.4

AC Mains Connections


The AC mains is distributed to the upper and lower halves of the Mini-HD transmitter

rack via terminal block TB1 (see Figure 2-4 and Figure 2-5) and circuit breakers CB1

and CB2.

•

"Auxiliary" circuit breaker = CB1 - Serves top half of rack

•

"Amplifier" circuit breaker = CB2 - Serves bottom half of rack

Depending upon the transmitter model and configuration, two sources of AC may be required.

NOTE:

The transmitter is factory set to your voltage requirements. To operate at a different voltage, see the individual unit’s technical manual Section 2.

The possible Mini-HD AC input combinations are as follows: a.

M1HD/M2HD

1.

Top: 110 - Bottom: 110

2.


3.

Top: 220 - Bottom: 220 b.

M3HD/M4HD

4.


5.


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Figure 2-4

AC Input Terminal Block and Ground Points

AC cables may be brought into the MxHD transmitter rack through the holes in the top, or through the holes in the bottom sidewalls (remove knockouts).

2.4.4.1


STEP 1

Carefully route the two cables into the Mini-HD transmitter via the top entrance or bottom-side entrance

STEP 2

Trim off 3" of outer jacket for each AC mains source cable

STEP 3

Trim off 1/2" of inner wire jacket for each connection

STEP 4

Determine where the wires will attach to the Wago connector in the

bottom of the cabinet according to the Wiring Diagram, Figure 2-5 on

page 2-11, and Table 2-2 on page 2-10

STEP 5

One at a time, insert a small screwdriver into the square opening just behind the corresponding terminal opening and insert the wire

STEP 6

Remove the screwdriver and test for a secure connection

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2-9



Table 2-2 AC Wago block (TB1) Terminal Connections

Configuration 1

Top: 110 - Bottom: 110 110

L1

Top: 110 - Bottom: 220 110

L1

Top: 220 - Bottom: 220 220

L1

Single-Source 110/110 110

L1

Single-Source 220/220 220

L1

2

110

L2/N

110

L2/N

220

L2/N

110

L2/N

220

L2/N

3

110

GND

110

GND

220

GND

110

GND

220

GND

4

110

GND

220

GND

220

GND

5

110

L2/N

220

L2/N

220

L2/N

6

110

L1

220

L1

220

L1

Jumper

1 to 6

1 to 6

Jumper

2 to 5

2 to 5

NOTE:

L1 = Line 1

L2/N = Line 2 or Neutral

GND = AC Safety Ground

2.4.4.2

Single-Source - 110/110 or 220/220

STEP 1

Carefully route the cable into the Mini-HD transmitter via the top entrance or bottom-side entrance

STEP 2

Trim off 3" of outer jacket for the AC mains source cable

STEP 3

Trim off 1/2" of inner wire jacket for each connection

STEP 4

Determine where the wires will attach to the Wago connector in the

bottom of the cabinet according to the Wiring Diagram, Figure 2-5 on

page 2-11, and Table 2-2 on page 2-10

STEP 5

One at a time, insert a small screwdriver into the square opening just behind the corresponding terminal opening and insert the wire

STEP 6

Remove the screwdriver and test for a secure connection

STEP 7

Repeat STEP 5 and STEP 6 for all connections

STEP 8

Cut 2 appropriate lengths of 10 ga. wire to make as jumpers

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STEP 9

Attach jumpers across TB1 as shown in Figure 2-5 below following

STEP 5 and STEP 6 (using square opening just in front of corresponding

terminal opening) above for all connections

"Single-Source"

AC Jumpers

(110/110 or 220/220)

Shown in place

AC Service to CB1

AC Service to CB2

Auxiliary (top 1/2)

Amplifier (bottom 1/2)

Figure 2-5

AC Mains Input Terminal Block TB1

(as viewed from the rear)

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2-11


2.4.5

Internal Grounding Connections


Single-Point System

Ground-to-Buss

Connection

(1/4" - 20)

For any equipment that is added to the

Mini-HD rack, an internal chassis ground buss bar is provided on the right side as viewed from the rear. If the equipment has a grounding point on it, it is recommended to connect a safety ground cable (a green, with yellow stripe wire, sized in accordance with the source breaker - typically 14 gauge wire for a 15A breaker) from that point to one of the five studs on the copper bar (see picture to left).

First of 5

Rack Equipment

Ground Connections

(#10 - 32)

2-12

Figure 2-6 Internal Grounding Buss Bar

2.4.6

RF Connections

Transmission line can be brought into the MxHD through the 2.5" diameter opening in the top of the rack cabinet, and passed down through an opening in the mid-deck divider. Connector type is dependent upon transmitter model:

•

M1HD/M2HD is an N connector

•

M3HD/M4HD is a 7/8" EIA flanged bullet

2.4.6.1

Circulator

Depending on the model and antenna system configuration, a circulator may required.

If not already done so, install the circulator at this point.

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2.4.7

Basic Connections

NOTE:

Verify installation and wiring of all DEXSTAR, IP2D, ePAL and UPS units.

2.4.7.1

Audio Input

AES audio is connected to the ePAL A2J15 using a broadcast quality XLR connection.

2.4.7.2

Audio Output

The AES audio that will serve as the analog FM input signal for the IBOC hybrid is output from A2J19 on the ePAL.

!

CAUTION:

ANY REMOTE OR EXTENDED CONTROL CONNECTIONS SHOULD BE

CONNECTED ONLY AFTER THE TRANSMITTER IS CHECKED OUT AND

FULLY OPERATIONAL.

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2-13


2.5

Initial Turn On


Each transmitter system is thoroughly checked out during factory final test but some adjustments may be required during installation due to shipping, variations in primary power, antenna systems, or transmission line differences.

Refer to the Factory Test Data Sheets supplied with the transmitter for typical meter readings. The transmitter was checked into a 50-ohm resistive load at the Factory.

Follow these steps to bring the MxHD transmitter online for the first time.

2-14

!

CAUTION:

IF THERE APPEARS TO BE A MALFUNCTION AT ANY ONE STEP, DO NOT

PROCEED TO THE NEXT STEP UNTIL THERE IS A RESOLUTION TO THE

MALFUNCTION.

STEP 1

If not already done, replace any doors and panels that had been removed during previous steps

STEP 2

Turn the RF Output potentiometer maximum Counter Clockwise

(CCW)

STEP 3

Activate the AC mains source to the transmitter

STEP 4

Turn on the AC distribution circuit breakers, Auxiliary (CB1) &

Amplifier (CB2), located at the bottom front panel of the transmitter cabinet

STEP 5

If optional Harris-supplied UPS is used, turn it on and wait until green light becomes steady (not flashing)

STEP 6

Turn on, then allow time for the DEXSTAR exciter to boot up to normal operational mode - about two to three minutes - and then verify its correct operation

NOTE:

Refer to the DEXSTAR manual (888-2498-001) for detailed information pertaining to the DEXSTAR Exciter.

1sssss

1

STEP 7

Turn on any Circuit Breakers, On/Off or Power switches located at the

rear of all units

STEP 8

Turn on ( | ) the switch labeled Power on the front panel of transmitter

(M3HD/M4HD will have a 2nd Power switch on the Power Supply front panel - turn it on as well)

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STEP 9

Verify fans are operational

STEP 10

Observe Fault LEDs on transmitter front panel(s) and ePAL, and check the DEXSTAR GUI for any fault indications

NOTE:

Refer to the DEXSTAR manual (888-2498-001) for information pertaining to the ePAL.

STEP 11

M3HD/M4HD Only: Verify PA Voltage is approximately 51 Volts before proceeding to next step

STEP 12

Turn on the Carrier button

STEP 13

Step through the Metering selections on the front panel of the transmitter(s) and verify that all readings approximately match the

Factory Test Data

•

Verify that the PA DC Volts (M1HD/M2HD) and/or PA Voltage

(M3HD/M4HD) readings are within a 50Vdc - 53Vdc range

•

Verify Tot Current (M3HD/M4HD) and/or PA DC Amps (M1HD/

M2HD) compared to table below:

Table 2-3 Total Idle Current (no RF Output)

Model

M1HD

M2HD

M3HD

M4HD

Idle Bias Current

0.8A - 1.2A

1.6A - 2.4A

3.2A - 4.8A

6.4A - 9.6A

•

Verify that the PA currents PA1 - PA4 (M3HD) or PA1 - PA8 (M4HD) are approximately 0.8A - 1.2A each (bias at idle)

STEP 14

Slowly turn the RF Output potentiometer Clockwise (CW) until the nominal power output, as shown in the Factory Test Data, is attained

STEP 15

Once again, observe for Fault LEDs on transmitter front panel(s) and check the DEXSTAR GUI for any fault indications

STEP 16

Step through the Metering selections on the front panel(s) of the transmitter and verify all readings approximately match the Factory Test

Data to verify correct transmitter operation

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2-15



Proceed to section "3.4 Normal Operation" on page 3-5 in the third chapter of this

manual for detailed operational information. To continue with remote I/O connections proceed to the next section.

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2.6

Remote I/O Connections

Once the MxHD transmitter has been turned on for the first time, and correct

operation has been verified, remote connections may be made. Using the following tables, and the supplied schematic packages, configure the MxHD remote I/O to match the requirements of your interface equipment.

2.6.1

DEXSTAR Exciter I/O

Refer to the DEXSTAR technical manual (Harris part #888-2498-001) for exciter I/O connection details.

2.6.2

ePAL Remote I/O Connections

Remote control inputs and outputs are connected to the ePAL via the 25 pin-D

connector A1J9, (see pin-out Table 2-4 below).

NOTE:

The device connected to these inputs must be capable of sinking 9mA to pull the pin to ground. The input voltage must stay between 30V and -0.7V and is normally +5 Vdc or ground. The User Input ground is a floating ground and is clamped to a maximum of +/-30V differential by using a Zener diode connected between the User Input ground and chassis ground.

NOTE:

These outputs are capable of sinking 120mA. Maximum ON resistance at

120mA is 35 Ohms, maximum power dissipation in each driver is 500mW. These outputs are pulled up to an isolated +5V; they may be connected to an "input" that is pulled up to a maximum open circuit voltage of 24V with out driver damage.

These outputs are protected against overvoltage conditions by a 30V zener diode connected to the User Control output ground. The User Control output ground is clamped to a maximum of +/- 30V differential by a bi-directional zener diode connected between the User Output ground and chassis ground. The four analog outputs are driven by op-amps capable of driving the output voltage to within

50mV of the positive and negative (ground) supply rails. The analog outputs are capable of sourcing 12mA at 0V and 9.5mA at 5V.

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2-17


Table 2-4 ePAL Remote I/O Connector A1J9 Pin-out


2-18

Pin

1 REMOTE AES LOCK RED

2 REMOTE AES LOCK GREEN

3

4

5

6

7

8

9

10

11

12

13

14

15

16

17

GND

SW1 AES SYNC RED

SW1 AES SYNC GREEN

GND

Signal Name

SW1 BYPASS RED

SW1 OPERATE GREEN

GND

GND

REMOTE EXCITER TWO

OPERATE/BYPASS

REMOTE EXCITER ONE

OPERATE/BYPASS

GND

SW2 AES SYNC RED

SW2 AES SYNC GREEN

GND

SW2 BYPASS RED

Type

TTL

TTL

TTL

TTL

TTL

TTL

TTL

TTL

TTL

TTL

TTL

Description

OUTPUT: +5V = ON

(MIN. –0.5V, MAX. +5.5V)

OUTPUT: +5V = ON

(MIN. –0.5V, MAX. +5.5V)

RETURN

OUTPUT: +5V = ON

(MIN. –0.5V, MAX. +5.5V)

OUTPUT: +5V=ON

(MIN. –0.5V, MAX. +5.5V)

RETURN

OUTPUT: +5V = ON

(MIN. –0.5V, MAX. +5.5V)

OUTPUT: +5V = ON

(MIN. –0.5V, MAX. +5.5V)

RETURN

RETURN

INPUT: Normally +5V

BYPASS = 0V; OPERATE = +5V

(MIN. –1.5V, MAX. +6.5V)

INPUT: Normally +5V

OPERATE = +5V

(MIN. –1.5V, MAX. +6.5V)

RETURN

OUTPUT: +5V = ON

(MIN. –0.5V, MAX. +5.5V)

OUTPUT: +5V = ON

(MIN. –0.5V, MAX. +5.5V)

RETURN

OUTPUT: +5V = ON

(MIN. –0.5V, MAX. +5.5V)

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18 SW2 OPERATE GREEN

19 GND

20 REMOTE MANUAL RED

21 REMOTE AUTO GREEN

22 GND

23 REMOTE AUTO/MANUAL

24 REMOTE PRESENT

25 GND


TTL

TTL

TTL

TTL

TTL

OUTPUT: +5V = ON

(MIN. –0.5V, MAX. +5.5V)

RETURN

OUTPUT: +5V = ON

(MIN. –0.5V, MAX. +5.5V)

OUTPUT: +5V = ON

(MIN. –0.5V, MAX. +5.5V)

RETURN

INPUT: Normally +5V

AUTO = +5V

(MIN. –1.5V, MAX. +6.5V)

INPUT: Normally +5V

0V = Remote Enable

(MIN. –1.5V, MAX. +6.5V)

RETURN

2.6.3

IP2D - A1J9 for VT100

For all IP2D meter readings, faults and configuration programming, the VT100 is the emulation method used to interface a computer with the IP2D. By connecting the

RS232 port A1J9 on the rear of the IP2D (using a serial cable with a DB-9 connector) to a PC running a terminal application (such as Tera Term or HyperTerminal), you’ll have access to the VT100 screen.

Refer to "6.2.1 IP2D VT100 Interface" on page 6-2 of this manual for details on the

steps necessary to physically connect, start the terminal program, electronically handshake with, navigate the VT100 screens, and perform edits.

2.6.4

Remote I/O Connections

The following table lists the I/O connections for the M1HD/M2HD transmitter and

M3HD/M4HD driver. Refer to the transmitter-specific technical manual for the signalproperty details of these connections.

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2-19



NOTE:

Depending on the configuration, this D-connector output will be available on the rear of the unit, or via a short jumper cable.

8

1

15 9

Table 2-5 Remote I/O (15) Pin Connections

13

14

15

Pin Number Function

7

8

5

6

3

4

1

2

9

10

11

12

Ground

(no connection)

N/A

N/A

N/A

Meter: Battery (unregulated DC voltage; 5 volts=50 Vdc)

Meter: RF Watts (1 volt = 100 Watts)

Meter: PA Volts (5 volts = 50 Vdc)

N/A

N/A

ALC

Carrier Off (a continuous connection to ground, pin 1, will turn the carrier off. For the M3HD and M4HD, the Remote AC

Power On command input may be used to control the Power

Block's AC power.)

Fault Summary (line goes high if any fault light is activated

Meter: PA Temperature (5 volts =100 degrees C)

Meter: PA Current (1 volt = 10 amperes DC)

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2.6.5

M3HD/M4HD Remote I/O Connector

The following table lists the I/O connections for the M3HD/M4HD transmitter’s Power

Block. Refer to the transmitter-specific technical manual for the signal-property details of these connections.

NOTE:

Depending on the configuration, this D-connector output will be available on the rear of the unit, or via a short jumper cable.

13

1

25

14

Table 2-6 M3HD/M4HD Remote I/O (25) Pin Connections

9

10

11

6

7

8

Pin #

1

2

3

4

5

Function

PA #8 Current Monitor (a buffered metering output with 1 V = 2 A

PA #7 Current Monitor (a buffered metering output with 1 V + 2 A

Ground

Remote RAISE Power (a momentary switch, on this pin, when held low will raise the power level 10 watts every 0.5 seconds)

Remote RF Power Control (a resistor to ground on this pin reduces RF power output level below internal limits. See Section 2.6, page 2.7.

Ground

Remote AC Power ON (a continuous connection to Ground, pin 6, will turn the

Power Block's AC power supply on. This can be used as a failsafe.)

Fault Summary (the voltage from this pin goes to +5 Vdc if any fault occurs and drops below +2 Vdc when the fault goes away)

Ground

N/A

PA Temperature (a buffered metering output with 1 Vdc = 20 degrees C)

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2-21


Pin #

12

13

14

15

20

21

22

23

16

17

18

19

24

25


Function

SWR (a buffered metering output with a calculated reading of Standing Wave

Ratio in Vdc)

RF Output Power (a buffered metering output with a calculated reading of output power of 1 Vdc = 1000 W)

Input Power Reference (a buffered metering output with a DC voltage representing input power)

Remote LOWER Power (a momentary switch, on this pin, when held low will lower the power level 10 watts every 0.5 seconds)

PA #6 Current Monitor (a buffered metering output with 1 V = 2 A)


Ground


PA #3 Current Monitor (a buffered metering output with 1 V = 2 A

Ground



PA Total Current Monitor (a buffered metering output with 1 V = 20 A)

PA Volts (a buffered metering output with 1 V = 10 V)

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Section 3

Operation

3

3.1

Introduction

This section contains typical operational procedures and information pertaining to the function of the Mini-HD series of transmitters. All of the information in this section assumes the transmitter is in proper working order.

NOTE:

This section outlines basic operation of the MxHD transmitter "system". Refer to

the specific technical manual (see Table 1-1 on page 1-2 for document reference),

of the System device to be operated, for detailed information.

3.2

Front Panel Functions and Displays

The Front Panel of the MxHD is the center for operational status indications of the transmitter.

1/31/06

Figure 3-1

M1HD/M2HD Front Panel Controls & Indicators

888-2534-001


3-1

Section 3 Operation


3-2

Figure 3-2

M3HD/M4HD Front Panel Controls & Indicators

3.2.1

Metering Switches and Indicators

Pressing these buttons scrolls up or down through the listed readings that display on the

numeric LED. The selected meter is indicated by the green LED. See "3.3 Metering" on page 3-3 for meter selections.

3.2.2

Fault LED Indications

Red LED indicators of the faults listed for the MxHD transmitter (see "3.5.2 FAULT

LED Illuminated" on page 3-8).

3.2.3

RF Output

Depending upon the transmitter model, this control can serve two purposes:

•

M1HD/M2HD: This potentiometer is used to adjust the RF power output of the transmitter

•

M3HD/M4HD: This potentiometer sets the APC range. It is typically set to the 12:00

(pointing up) position

3.2.4

Power Switches

To turn the transmitter power supplies on, press these buttons.

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3.2.5

Carrier Switch


To transmit RF carrier, press this button.

3.2.6

M3HD/M4HD PA Fuses and LED Indications

The M3HD/M4HD transmitter front panel houses the PA power supply fuses. In the event of an open fuse, a corresponding red LED indicator illuminates next to the blown fuse.

PA

Figure 3-3

M4HD Transmitter Fuse Panel

3.3

Metering

Pressing the up or down metering buttons scrolls up or down through the listed meters to quickly determine common operating variables.

NOTE:

All meter readings are +/- 5% unless otherwise specified, and meter readings may differ between transmitter models.

3.3.1

M1/M2 Metering

•

RF Power - Default indication at startup -

Actually reads RF Average Power. Tolerance of +/- 10% is normal.

Indicated by kiloWatts (Example: 0.53 = 530W)

NOTE:

For exact measurements on site, an external averaging power meter is recommended.

•

SWR -

Direct reading of the antenna Standing Wave Ratio (the ratio of the actual load impedance to the desired 50 ohm load impedance)

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3-3



•

ALC DC gain control bias used to adjust a variable attenuator. The ALC voltage will be reduced during PA DC overcurrent, SWR, or Temperature fault conditions.

•

PA DC Volts - Supply voltage of the RF power amplifier, volts DC

•

PA DC Amps - Transistor drain current for the RF power amplifier, in amperes

•

PA Temperature -

Highest temperature of all individual RF power amplifier heatsinks, in degrees C

•

Supply DC Volts - Unregulated DC voltage at the input of the Power Supply

•

Voltmeter - Reads the voltage at a test point located on the front edge of the motherboard. A test lead connected to this point can be used for making voltage measurements in the transmitter. The test point is intended as a servicing aid; an alternative to an external test meter. Remember that the accuracy is only as good as the reference voltage used by the metering circuit. Servicing a fault affected by the reference affects the Voltmeter reading. The metering scale is 0 to 199.9 volts

3.3.2

M3/M4 Metering

•

In Ref - N/A

•

SWR -

Direct reading of the antenna Standing Wave Ratio (the ratio of the actual load impedance to the desired 50 ohm load impedance)

•

ALC DC gain control bias used to adjust a variable attenuator. The ALC voltage will be reduced during PA DC overcurrent, SWR, or Temperature fault conditions.

•

Power Out - Default indication at startup -

Indicates RF average power (+/- 10% tolerance)

Indicated by kiloWatts (Example: 0.53 = 530W)

NOTE:

For exact measurements on site, an external averaging power meter is recommended.

•

PA Temp -

Highest temperature of all individual RF power amplifier heatsinks, in degrees

C

•

PA Voltage -

Supply voltage of the RF power amplifier.

Indicated by volts DC

•

Tot Current -

Sum of the currents of all individual RF power amplifiers -

Indicated in amperes

PA1 - PA8 - Displays selected PA’s current on numeric LED - Indicated in amperes

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3.4

Normal Operation


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 more serious problems develop.

NOTE:

Refer to the specific technical manual (see Table 1-1 on page 1-2 for document

reference), of the System device to be operated, for detailed information.

3.4.1

Daily Pre-Operational Checkout

Before normal daily turn-on, review the following areas of the transmitter; a.

Check the transmitter maintenance log to make sure that maintenance performed on the transmitter, or any abnormal conditions, do not restrict the operation of the transmitter.

b.

Ensure the transmitter RF output is connected to the proper load or antenna.

c.

Check the User Interface panel on the front of the transmitter for any abnormal indications.

NOTE:

A voltage reading is considered normal if it is within ±5% of its stated value.

When the preoperational checkout has been performed and no problems are present, the transmitter is ready to turn on.

3.4.2

Transmitter Turn-On

STEP 1

If necessary, turn on AC mains supply to the transmitter

STEP 2

If necessary, turn on Mini-HD lower front panel AC circuit breakers

STEP 3

If optional Harris-supplied UPS is used, turn it on and wait until green light becomes steady (not flashing)

STEP 4

Turn on, then allow time for the DEXSTAR exciter to boot up to normal operational mode - about two to three minutes - and then verify its correct operation

STEP 5

If necessary, turn on any Circuit Breakers, On/Off or Power switches on rear of all remaining units including the ePAL and IP2D

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3-5



STEP 6

M3HD/M4HD Only: Press Power button to the on ( | ) position on the

M3HD/M4HD power supply (PS) front panel - Allow approximately 30 seconds for the power supplies to stabilize

STEP 7

Press Power button to the on ( | ) position on the M1HD/M2HD front panel

STEP 8

Press Carrier button to the on ( | ) position on the transmitter front panel

MxHD transmitter should be outputting nominal RF power, and all indications normal.

3.4.3

Transmitter Turn Off

The following steps describe the procedure to turn the Mini-HD transmitter off at the end of a broadcast period. This method assures that all units are properly shut down.

STEP 1

Press Carrier button to the off ( 0 ) position on the transmitter front panel

STEP 2

Press Power button to the off ( 0 ) position on the M1HD/M2HD front panel

STEP 3

M3HD/M4HD Only: Press Power button to the off ( 0 ) position on the power supply (PS) front panel

STEP 4

STEP 5

Power down the DEXSTAR exciter:

•

Press System on DEXSTAR GUI Home page

•

Press Shut Down

•

Press OK/Yes to shut down question

•

Wait for indication on GUI ("Power down." in green letters) that it is

OK to shut down the exciter

•

Turn the unit off with the rear panel On/Off switch

Turn off the (optional Harris-supplied) UPS via the front panel switch

STEP 6

Turn off any Circuit Breakers, On/Off or Power switches on rear of all remaining units including the ePAL and IP2D

3.4.4

To Set Desired RF Power Output (M1HD/M2HD)

STEP 1

Adjust RF Output potentiometer while observing an external Wattmeter, or RF Current meter to the desired level

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3.4.5

DEXSTAR Exciter Operation


NOTE:

Refer to the DEXSTAR manual (888-2498-001) for information pertaining to the

DEXSTAR Exciter.

3.4.6

ePAL Operation

NOTE:

Refer to the DEXSTAR manual (888-2498-001) for information pertaining to the ePAL.

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3-7


3.5

Emergency Operation


In the unlikely event of a MxHD transmitter malfunction, the Front Panel indications, on the MxHD amplifier, DEXSTAR, or ePAL should quickly assist the technician in determining a probable cause.

NOTE:

Refer to the specific technical manual (see Table 1-1 on page 1-2 for document

reference), of the System device malfunctioning, for detailed information.

Depending on the Front Panel indications, early steps in troubleshooting a MxHD transmitter failure can be based on one or more of the following:

3.5.1

No Front Panel LEDs or GUI

1.

Reset CB1/CB2

2.

Check AC Mains

3.5.2

FAULT LED Illuminated

If a red Fault LED is blinking, this is an indication of a currently active fault. The following is a list of possible front panel fault indications.

3.5.2.1

M1/M2 Fault Indications

•

SWR -

Load SWR exceeds 1.5:1. ALC voltage is reduced to limit the reflected RF power

•

Lock - Not Used

•

Input - Not used

•

PA DC -

Power supply current for the PA is at the preset limit, or there is a difference of more than 2.5 amps in current between the individual PAs. When this indicator is on, the ALC voltage is reduced automatically to maintain the supply current at the preset limit.

•

PA Temp -

PA heatsink temperature is greater than 90°C (power foldback will begin above this point)

NOTE:

While the fault LED will begin blinking at 90°C, foldback will not occur until

92°C is reached - with full attenuation at 95°C.

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3.5.2.2

M3/M4 Fault Indications


•

Antenna -

Load SWR exceeds 1.5:1. ALC voltage is reduced to limit the reflected

RF power

•

RF Drive -

Not used

•

PA Temp -

PA heatsink temperature is greater than 90°C (power foldback will begin above this point)

NOTE:

While the fault LED will begin blinking at 90°C, foldback will not occur until

92°C is reached - with full attenuation at 95°C.

•

PA DC -

Power supply current for the PA is at the preset limit, or there is a difference of more than 2.5 amps in current between the individual PAs. When this indicator is on, the ALC voltage is reduced automatically to maintain the supply current at the preset limit.

3.5.3

Front Panel Buttons Unresponsive

If the MxHD transmitter or GUI screen appears to not be responding to button pushes it is possible the controller has had a glitch, and needs to be reset. The following steps may be taken to return control to the control panel.

3.5.3.1

DEXSTAR

Restart software: To clear a possible glitch in the software application, it may be necessary to restart it.

STEP 1


STEP 2

Press App Restart

STEP 3

Allow time for application to exit and then restart itself

Reboot: To clear a possible glitch in the operating system, it may be necessary to restart it.

STEP 1


STEP 2

Press System Restart

STEP 3

Allow time for application to exit and then restart itself

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3-9



Shutdown: It may be necessary to completely shut down the DEXSTAR to clear a malfunction. Follow the next procedure to properly shut down the exciter application, then turn the unit off with the rear panel On/Off switch.

STEP 1


STEP 2

Press Shut Down

STEP 3

Wait for indication on GUI that it is OK to shut down the exciter

STEP 4

Turn the unit off with the rear panel On/Off switch

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1/31/06

Section 4

Theory of

Operation

4

4.1

Introduction

This section of the manual provides more detailed information of several components of the Mini-HD transmitter system.

4.1.1

IP2D Precorrector

In order to meet the FCC IBOC RF mask, the transmitter must be capable of linear operation. In addition to the individual PAs being optimized for linearity, the IP2D

Precorrector further enhances the transmitter’s linearity utilizing predistortion technology.

The IP2D also serves as the control point for the APC loop, protection (mute), and it provides its own monitoring, protection and diagnostics. A second IP2D may be installed in the transmitter cabinet for backup redundancy.

For IBOC common amplification mode, the exciter outputs (FM and IBOC) are combined in a mixer and applied to the IP2D Precorrector for linearity precorrection and RF level adjustments. This RF output is then sent to the PA module.

The output power of the IP2D determines the power output of the transmitter. APC loop, foldback and pressing the RAISE and LOWER controls on the front of the transmitter will vary the APC voltage which in turn will vary the gain of the

Precorrector resulting in raised or lowered transmitter power.

All settings are factory calibrated.

4.1.2

Harris DEXSTAR HD Radio Exciter

NOTE:

Refer to the DEXSTAR manual (888-2498-001) for information pertaining to the

DEXSTAR Exciter.

888-2534-001


4-1

Section 4 Theory of Operation


The DEXSTAR In-band, On-Channel (IBOC) Exciter will delay the standard FM audio in the analog path to synchronize the two signals at the receiver.

•

Full VGA touch screen

•

Dual Pentium 3 processors

•

GPS receiver

•

Direct Z-HD transmitter interface

•

Easily interfaces with the ePAL Program Audio Link

•

CD-ROM drive

4.1.3

ePAL

NOTE:

Refer to the DEXSTAR manual (888-2498-001) for detailed information pertaining to the ePAL.

The ePAL enables IBOC receivers to switch seamlessly between the IBOC and the analog FM signals. All of the required synchronization and sample rate conversion to the analog signal, delayed audio bypass switching, and digital audio distribution is accomplished via the ePAL.

The ePAL interface is capable of handling audio routing for up to two DIGIT FM exciters and two DEXSTAR IBOC exciters along with up to two audio processors, for redundant back up, into a single Platinum Z-HD transmitter.

Provides the necessary switching for complete control of all of the required IBOC and analog signals. Directly interfaces with the Harris DEXSTAR IBOC Exciter.

•

Digital audio synchronization and rate conversion

•

Digital audio distribution

•

Delayed audio bypass switching

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Section 5

Maintenance and

Alignments

5

5.1

Introduction

This section provides maintenance and alignment information, for the purpose of routine maintenance, and replacement of various components for the Mini-HD series of transmitters.

5.2

Alignments

5.2.1

IP2D Precorrector - Correction Setup Procedure

1/31/06

The following procedure aligns the IP2D Precorrector to correctly match the current transmitter and exciter configuration. To start, have the transmitter set to nominal output power, with a sample of the output connected to a spectrum analyzer (SA).

NOTE:

The following abbreviations apply:

SA = spectrum analyzer

RBW = resolution bandwidth

VBW = video bandwidth

IMD = Intermodulation Distortion a.

Initial SA settings:

1.

Set the SA span to 1MHz (IBOC FM combined), or 1.3MHz (IBOC separate)

2.

Detector Mode = Sample

3.

When using an Agilent ESA spectrum analyzer, set the average to POWER b.

Initial IP2D settings for Linearity adjustment:

1.

ALC switch should be set to INPUT

2.

DAC control switches should be set to OFF

888-2534-001


5-1

Section 5 Maintenance and Alignments


3.

Set Correction switch to ON

4.

Set correction potentiometers fully clockwise : SLOPE 1 - SLOPE 4,

BREAKPOINT 1 - BREAKPOINT 4

5.

While monitoring the transmitter APC voltage on the front panel meter, adjust the IP2D manual gain until the APC voltage is 3V +/-0.2V. In the following adjustment it should be made sure that the APC voltage does not become greater than 4V. If it does then readjust MANUAL GAIN until it is less than 3.8V.

5-2

Figure 5-1

IP2D Adjustments

c.

Set the reference level for the SA:

1.

Select a resolution bandwidth (RBW) between 1 and 3MHz

2.

Select average ON

3.

Set the amplitude scale to 10dB/div.

4.

Adjust the amplitude reference level so that the signal will average to the top line of the display (in IBOC combined) or 20dB below (IBOC separate)

888-2534-001


1/31/06



5.

Make sure that the SA is not overdriven (when increasing the SA input attenuator, with the same amplitude reference, the displayed sidebands should not drop).

6.

Set RBW to 3kHz, VBW between 100Hz and 1kHz, average OFF

7.

Decrease the sweeptime if possible, but not too much so that the sidebands are still discernible on the display

8.

In IBOC separate mode the IMD sidebands peak at an offset of +/-480kHz from the center of the band d.

Adjust BREAKPOINT 1 counter clockwise. Explore the potentiometer for a setting that produces a strong effect on the IMD sidebands (either up or down) and then fine adjust the pot for minimum sideband - in conjunction with SLOPE 1 if necessary. If the action of this stage doesn't yield a sideband minimum, turn

BREAKPOINT 1 to a position where it stops having an effect. At this point the stage is actually unused but ready to be adjusted again in some later iteration. If the stage effect on the left and the right IMD sidebands are different, then optimize breakpoint and slope so as to have both IMD sidebands equal and minimum.

e.

Repeat [d.] for stages 2, 3, and 4, using that stage’s corresponding BREAK-

POINT and SLOPE control f.

Repeat [d.] and [e.] until no further improvement in IMD sidebands are obtained g.

Using two BREAKPOINT controls, one of which must be "in use" (meaning if turned, it has an effect on sidebands), adjust one BREAKPOINT slightly off of its optimum setting and sweep the other BREAKPOINT to reoptimize h.

Check the transmitter APC voltage. It should be within a range of 1.0V to 3.8V

i.

When a good correction setting has been obtained, set the SA in calibrated mode again: RBW=1kHz VBW=1kHz, average ON, sweeptime CAL, attenuation

CAL.

The trace should be below mask, with a nominal 35dB difference between subcarriers

and IMD products. See Figure 5-2 on page 5-4.

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5-3



Separate Waveform Before Alignment Separate Waveform After Alignment

Figure 5-2

Ideal IP2D Alignment Waveforms

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Section 6

Troubleshooting

6

6.1

Introduction

This section is to be used by the service technician to go beyond the steps provided in the Emergency Operation section (in Chapter 3) to troubleshoot a MxHD malfunction.

Use this along with the provided schematic package for detailed circuit understanding and diagnosis.

NOTE:

Before preceding, see "3.5 Emergency Operation" on page 3-8 for initial steps in

restoring a MxHD transmitter to operational status in the event of a fault condition.

The first step will to be to attempt to determine which unit is causing the malfunction

refer to its Schematic Package and Technical Manual (see Table 1-1 on page 1-2 for the

documentation reference):

•

DEXSTAR

•

M1HD, M2HD, M3HD, or M4HD transmitters

• ePAL

•

IP2D

!

WARNING:

DISCONNECT PRIMARY POWER PRIOR TO SERVICING THE MXHD TRANSMITTER.

HIGH VOLTAGE IS PRESENT EVEN WHEN MAIN CIRCUIT BREAKER CB1 IS

TURNED OFF.

!

CAUTION:

DO NOT DISCONNECT, RECONNECT, REMOVE, OR ALTER ANY PC

BOARDS WITH AC MAINS POWER CONNECTED TO MXHD TRANSMITTER.

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6-1

Section 6 Troubleshooting


!

CAUTION:

DO NOT OPERATE M

X

HD TRANSMITTER WITH DOORS, SHIELDS OR

PANELS REMOVED.

6.2

Diagnostics

A wealth of information is obtainable via the front panel LEDs, DEXSTAR GUI, individual board indications, and VT100 parameters of the IP2D to help discern the cause of a failure within the MxHD transmitter.

6.2.1

IP2D VT100 Interface

For all IP2D meter readings, faults and configuration programming, the VT100 is the emulation method used to interface a computer with the IP2D. By connecting the

RS232 port A1J9 on the rear of the IP2D (using a serial cable with a DB-9 connector) to a PC running a terminal application (such as Tera Term or HyperTerminal), you’ll have access to the VT100 screen.

This section outlines the steps necessary to physically connect, start the terminal program, electronically handshake with, navigate the VT100 screen, and perform edits.

STEP 1

Turn transmitter off

STEP 2

Connect RS-232 comm port (J9), on the IP2D, to your PC

STEP 3

Turn transmitter on

STEP 4

STEP 5

Start terminal program (such as HyperTerminal) with following settings

•

Bits Per Second = 57600

•

Data Bits = 8

•

Parity = None

•

Stop Bits = 1

•

Flow Control = None

•

Emulation = VT100

Call, or hit "Enter" twice to initiate handshake

To navigate around the VT100 screen:

•

Up/Down arrows to move cursor within page

To edit a numerical entry:

6-2 888-2534-001


1/31/06



STEP 1

Type the line number or letter in parenthesis - do NOT hit "Enter"

STEP 2

Use up/down arrow keys to increase/decrease numerical value

(with the exception of the Meter Calibration section, where it is required to type in the numerical value)

STEP 3

Press the "Enter" key to store that entry

To toggle (turn on/off) a command:

STEP 1

Type the corresponding number or letter in parenthesis - do NOT hit

"Enter"

STEP 2

Type the same number or letter again to toggle that command

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6-3


6.3

General Troubleshooting Information


6.3.1

Schematics, Wiring and Block Diagrams

The following Harris schematic and signal name conventions apply:

•

Active Low = "/" - A signal name preceded by the forward slash is an active low.

•

Schematic Continuation - A square block ending point of a named signal, accompanied by a number-forward slash-letter-number is an indication of that signal continuing on to another page of schematic.

•

LEDs used to display a given condition when illuminated are designated as DS(n), with (n) indicating the LED’s designator value as shown on the board’s schematic and silkscreen.

6.3.2

Turn MxHD On With No RF Power Output

Under certain conditions it may be desirable to turn the MxHD on with high voltage on but no RF power being output. This will allow for a slow ramp-up of power if necessary.

STEP 1

Press the Power button to on, but do NOT press the Carrier button ON

STEP 2

Turn the RF Output potentiometer maximum Counter Clockwise

(CCW)

STEP 3

If desired, continue with the next steps to slowly ramp RF output power back up

STEP 4

Press Carrier button ON

STEP 5

Slowly turn the RF Output potentiometer Clockwise (CW) until RF output power attains the nominal licensed Watts, or the transmitter faults off again

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1/31/06



6.4

Power Supply System Troubleshooting

!

WARNING:

DISCONNECT PRIMARY POWER PRIOR TO SERVICING THE POWER SUPPLY SYS-

TEM OR THE POWER SUPPLY CONTROLLER BOARD.




•

DEXSTAR

•


• ePAL

•

IP2D

6.5

PA Troubleshooting

For troubleshooting a probable RF power malfunction refer to the M1HD, M2HD,

M3HD, or M4HD transmitter schematic package and Technical Manual (see Table 1-1 on page 1-2 for the documentation reference):

6.6

Audio Troubleshooting




•

DEXSTAR

•


• ePAL

•

IP2D

1/31/06 888-2534-001


6-5



6-6 888-2534-001


1/31/06

HARRIS Mini-HD M1HD, M2HD, M3HD, M4HD Mini-HD Transmitter System Technical Manual

Assistant Bot

TECHNICAL MANUAL

888-2534-001

Mini-HD™

Transmitter System

Mini-HD

™

Transmitter System

Returns And Exchanges

Unpacking

Technical Assistance

Replaceable Parts Service

Manual Revision History

Mini-HD™ series

Guide to Using Harris Parts List Information

FIRST-AID

Table of Contents

Table of Contents

(continued)

Section 1

Introduction/

Specifications

Section 2

Installation &

Initial Turn-On

Section 3

Operation

Section 4

Theory of

Operation

Section 5

Maintenance and

Alignments

Section 6

Troubleshooting

Key Features

Frequently Answers and Questions

What is the purpose of the Mini-HD transmitter system?

What are the different models of Mini-HD transmitter systems available?

What are the key features of the Mini-HD transmitter system?

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ZX 3500

Harris Broadcast

ZHD+ Z6HD+

Harris

ZX5000

Harris Broadcast

Platinum Z12HD+ Z12HD+

Harris

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Table of contents