Harris Maxiva ULX, Maxiva ULX-5500 Series Technical Manual

TECHNICAL MANUAL

888-2629-200

Maxiva ULX COFDM Series

Digital Transmitter

Maxiva ULX COFDM

Series Digital Transmitter

This manual applies to the following modulation types:

DVB-T/H

ISDB-T/H

FLO

CTTB

CMMB

T.M. No. 888-2629-200

© Copyright Harris Corporation 2010

All rights reserved

Oct. 5, 2010

Rev: B

ii 888-2629-200

WARNING: Disconnect primary power prior to servicing.

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Technical Assistance

Technical and troubleshooting assistance for HARRIS Transmission products is available from

HARRIS Field Service (factory location: Quincy, Illinois, USA) during normal business hours (8:00

AM - 5:00 PM Central Time). Telephone +1-217-222-8200 to contact the Field Service Department;

FAX +1-217-221-7086 ; or E-mail questions to [email protected].

Emergency service is available 24 hours a day, seven days a week, by telephone only .

Online assistance, including technical manuals, white papers, software downloads, and service bulletins, is available at http://support.broadcast.harris.com/eservice_enu.

Address written correspondence to Field Service Department, HARRIS Broadcast Communications

Division, P.O. Box 4290, Quincy, Illinois 62305-4290, USA. For other global service contact information, please visit: http://www.broadcast.harris.com/contact .

NOTE: For all service and parts correspondence, you will need to provide the Sales Order number, as well as the Serial Number for the transmitter or part in question. For future reference, record those numbers here: ___________________/____________________

Please provide these numbers for any written request, or have these numbers ready in the event you choose to call regarding any Service, or Parts requests. For warranty claims it will be required, and for out of warranty products, this will help us to best identify what specific hardware was shipped.

Replaceable Parts Service

Replacement parts are available from HARRIS Service Parts Department 7:00 AM to 7:00 PM

Central Time, Monday through Friday, and 8:00 AM to 1:00 PM Central Time on Saturday.

Telephone +1-217-222-8200 or email [email protected]

to contact the Service Parts Dept.

Emergency replacement parts are available by telephone only, 24 hours a day, seven days a week by calling +1-217-222-8200.

Unpacking

Carefully unpack the equipment and perform a visual inspection to determine if any apparent damage was incurred during shipment. Retain the shipping materials until it has been verified that all equipment has been received undamaged. Locate and retain all PACKING CHECK LISTs. Use the

PACKING CHECK LIST to help locate and identify any components or assemblies which are removed for shipping and must be reinstalled. Also remove any shipping supports, straps, and packing materials prior to initial turn on.

Returns And Exchanges

No equipment can be returned unless written approval and a Return Authorization is received from

HARRIS Broadcast 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

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REV.

A

B

Manual Revision History

Maxiva ULX COFDM Series Digital Transmitter Manual

DATE

2010 Mar 15

2010 Oct 5

ECN Pages Affected

Created

59529 Update multiple sections. Corrected PS numbering in Sec. 5

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MRH-1

MRH-2 888-2629-200


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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

Table 7-5. PA Amplifier

992 9400 002 7-7

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.).

NOTE: Inside the individual tables some standard conventions are used:

•

A # symbol in front of a component such as #C001 under the REF. SYMBOLS/EXPLANATIONS column means that this item is used on or with C001 and is not the actual part number for C001.

•

In the ten digit part numbers, if the last three numbers are 000, the item is a part that 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 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.

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!

WARNING:

TTHE 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.

10/6/10

!

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

WHILE IT IS HOT DWHILE IT IS HOT DUE TO THE POSSIBILITY OF A CASE RUP-

TURE AND SUBSEQUENT 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.

10/6/10

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)

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Table of Contents

Section 1

Introduction

Purpose of This Manual . . . . . . . . . . . . . . . . . . . . 1-1

General Description. . . . . . . . . . . . . . . . . . . . . . . . 1-2

Maxiva COFDM Series Transmitter Models . . . 1-4

System Block Diagram . . . . . . . . . . . . . . . . . . . . 1-4

Transmitter Control System . . . . . . . . . . . . . . . . 1-5

Transmitter RF Power Control . . . . . . . . . . . . . . 1-7

Graphical User Interface . . . . . . . . . . . . . . . . . 1-7

Control System Communications . . . . . . . . . . . . 1-7

Software Updates . . . . . . . . . . . . . . . . . . . . . . . 1-8

Remote Control . . . . . . . . . . . . . . . . . . . . . . . . 1-8

PA Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8

Module Control . . . . . . . . . . . . . . . . . . . . . . . 1-12

Transmitter Power Supplies . . . . . . . . . . . . . . . 1-13

Cooling System. . . . . . . . . . . . . . . . . . . . . . . . . 1-13

Cooling System Control Panel. . . . . . . . . . . . 1-15

Pump Module/Heat Exchanger . . . . . . . . . . . 1-18

Heat Exchanger Fan Control . . . . . . . . . . . . 1-19

Pump Operation/Control Logic . . . . . . . . . . 1-19

PA Module and Combiner Cold Plates . . . . . 1-20

M2X Multimedia Exciter . . . . . . . . . . . . . . . . . 1-22

General Specifications. . . . . . . . . . . . . . . . . . . . . 1-23

Section 2

Installation

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

Documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Installation Drawings . . . . . . . . . . . . . . . . . . . . . 2-2

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

Transmitter Cabinet Placement . . . . . . . . . . . . . . . 2-6

Cooling System Installation . . . . . . . . . . . . . . . . . 2-6

Heat Exchanger and Pump Module

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Calculation of Cooling System Capacities . . . . . 2-9

Rigging Heat Exchanger & Pump Module. . . . 2-11

Initial Inspection . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Placement of Heat Exchanger and Pump

Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12

Liquid Cooling System Plumbing Installation . 2-14

Pump Module & Heat Exchanger Electrical . . 2-16

Transmitter AC Connection . . . . . . . . . . . . . . . . 2-20

Safety Ground. . . . . . . . . . . . . . . . . . . . . . . . . . 2-21

AC Connections Procedure . . . . . . . . . . . . . . . .2-22

Checking AC Configuration. . . . . . . . . . . . . . . .2-24

TB1 TB2 Jumpers 1 Cabinet 10 -16 Modules .2-24

TB1 TB2 Jumpers 1 Cabinet 1 - 8 Modules . .2-24

Signal and Ground Connections . . . . . . . . . . . . . .2-29

Intercabinet Connections . . . . . . . . . . . . . . . . . . .2-32

External Interlock Connections. . . . . . . . . . . . . . .2-32

Interlock Connector on Customer I/O Panel . . .2-32

Fault-Off Interlocks (Safety Interlocks) . . . . . . .2-32

RF Mute External Interlock Connections (J2) . .2-33

3 Port Patch Panel Connections . . . . . . . . . . . . . .2-34

Initial Cooling System Turn ON . . . . . . . . . . . . . .2-34

Heat Exchanger & Pump Module

Start-up and Maintenance . . . . . . . . . . . . . . . .2-36

Starting Pumps & Checking Pump Rotation . .2-38

Starting Fans & Checking Fan Rotation . . . . .2-40

Initial System Leak Tests . . . . . . . . . . . . . . . . . .2-41

Initial System Cleaning . . . . . . . . . . . . . . . . . . .2-42

System Flushing . . . . . . . . . . . . . . . . . . . . . . . . .2-43

Final Cooling System Fill . . . . . . . . . . . . . . . . .2-44

Install PA Modules . . . . . . . . . . . . . . . . . . . . . . . .2-45

Initial Turn-On . . . . . . . . . . . . . . . . . . . . . . . . . . .2-47

Final Cooling System Turn ON . . . . . . . . . . . . . .2-50

Setting the Transmitter Flow Rate . . . . . . . . . . .2-51

Heat Exchanger Fan Turn ON Temperatures. .2-52

Verify Pump Switching (Dual Pumps Only) . .2-52

Normal Pump and Fan Operation . . . . . . . . . .2-53

Operational Pressure Values (typical) . . . . . . .2-53

Setting Exciter Parameters . . . . . . . . . . . . . . . . .2-54

RF Initial Turn ON . . . . . . . . . . . . . . . . . . . . . . .2-54

Individual Transmitter Parallel Remote Control

Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-57

Individual Transmitter Commands J3, J4 and J5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-58

Individual Transmitter Outputs J6, J7& J8 . . . .2-59

Individual Transmitter Metering, J9. . . . . . . . . .2-62

External RF Switch . . . . . . . . . . . . . . . . . . . . . .2-62

Install Battery in TCU PCM Card . . . . . . . . . . . .2-63

Section 3

Operation

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

Transmitter Control Panel . . . . . . . . . . . . . . . . . . . .3-1

Hardware Control Buttons . . . . . . . . . . . . . . . . . .3-2

1

Table of Contents (Continued)

Graphical User Interface (GUI) . . . . . . . . . . . . . . . 3-4

Global Status and Navigation . . . . . . . . . . . . . . . 3-4

GUI Home Screen . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Drive Chain Main Menu . . . . . . . . . . . . . . . . . . . . 3-9

Drive Chain Faults . . . . . . . . . . . . . . . . . . . . . . 3-10

Drive Chain Meters . . . . . . . . . . . . . . . . . . . . . . 3-11

Power Amp Main Menu . . . . . . . . . . . . . . . . . . . 3-13

PA Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Output Main Screen . . . . . . . . . . . . . . . . . . . . . . . 3-15

Output Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-16

Power Supply Main Menu . . . . . . . . . . . . . . . . . . 3-17

PS Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-18

System Main Menu . . . . . . . . . . . . . . . . . . . . . . . 3-19

System Faults . . . . . . . . . . . . . . . . . . . . . . . . . . 3-20

System Fault Log . . . . . . . . . . . . . . . . . . . . . . . 3-20

System Service . . . . . . . . . . . . . . . . . . . . . . . . . 3-22

Admin Setup (Local GUI Only) . . . . . . . . . . . 3-23

System Setup . . . . . . . . . . . . . . . . . . . . . . . . . 3-25

Cabinet Setup . . . . . . . . . . . . . . . . . . . . . . . . . 3-27

System and Cabinet Power Calibrate . . . . . . . 3-27

System Version Screen . . . . . . . . . . . . . . . . . . 3-28

System Network Screen . . . . . . . . . . . . . . . . . 3-28

GUI Menu Structures. . . . . . . . . . . . . . . . . . . . . . 3-29

Section 4

Theory of Operation

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

Active Logic Symbols. . . . . . . . . . . . . . . . . . . . . 4-1

Block Diagram Descriptions . . . . . . . . . . . . . . . . . 4-2

AC Distribution . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Transmitter Control System . . . . . . . . . . . . . . . . . . 4-4

Graphical User Interface (GUI) . . . . . . . . . . . . . 4-4

Transmitter RF Power Control . . . . . . . . . . . . . . 4-5

TCU Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

MCM Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

PCM Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9

RF Detector/Pump Control/Interlocks Card . . 4-10

PA Interface Card . . . . . . . . . . . . . . . . . . . . . . 4-13

Predriver and IPA Drive A and B Busses . . 4-13

PA BP (Backplane) Busses 1 Through 4. . . 4-14

Customer I/O Card . . . . . . . . . . . . . . . . . . . . . 4-15

Exciter Switcher Card. . . . . . . . . . . . . . . . . . . 4-16

PS Monitor Card. . . . . . . . . . . . . . . . . . . . . . . 4-18

CPLD (Complex Programmable Logic

Device) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-22

Life Support Functions . . . . . . . . . . . . . . . . . . . 4-22

Controller Area Network (CAN) Bus . . . . . . . . 4-24

System Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-25

Cabinet Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26

Parallel Control Lines . . . . . . . . . . . . . . . . . . . . 4-27

Customer I/O Board . . . . . . . . . . . . . . . . . . . . . . 4-28

Transmitter RF System . . . . . . . . . . . . . . . . . . . . 4-29

Apex M2X Exciter(s) . . . . . . . . . . . . . . . . . . . . 4-29

Predriver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-29

IPA (driver) and PA Module . . . . . . . . . . . . . . . 4-33

AC Distribution Board . . . . . . . . . . . . . . . . . . 4-35

AC/DC Converter Interface Board. . . . . . . . . 4-35

PA PS (AC/DC) Voltage Select Path . . . . . . . 4-36

PA Monitor Board . . . . . . . . . . . . . . . . . . . . . 4-38

J1 - PA or IPA Connector I/O Board . . . . . . . 4-39

Signal Distribution Board. . . . . . . . . . . . . . . . 4-41

PA Module Phase Alignment . . . . . . . . . . . . 4-41

PA Module Splitter . . . . . . . . . . . . . . . . . . . . . 4-41

PA Module Pallet Combiner. . . . . . . . . . . . . . 4-41

RF Pallets . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-42

FET Bias . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-43

Module Combiner . . . . . . . . . . . . . . . . . . . . . . . 4-43

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . 4-44

Heat Exchanger/Pump Module Diagrams . . . . 4-44

Leak Detector and Cabinet Drains . . . . . . . . . . 4-48

Maxiva 16 Module Transmitter Diagrams . . . . . 4-49

RF Block Diagram . . . . . . . . . . . . . . . . . . . . . . 4-49

Section 5

Maintenance and Alignments

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

PA Module Removal and Replacement. . . . . . . . . 5-1

PA Slot Locations . . . . . . . . . . . . . . . . . . . . . . . . 5-2

PA Module Removal. . . . . . . . . . . . . . . . . . . . . . 5-3

PA Module Installation . . . . . . . . . . . . . . . . . . . . 5-4

Operation With Inoperative PA Modules . . . . . . 5-6

PA Module/Rack Alignment. . . . . . . . . . . . . . . . 5-6

PA Module Bias. . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9

PA Module Phasing . . . . . . . . . . . . . . . . . . . . . . . . 5-9

PA Module Component ID . . . . . . . . . . . . . . . . . . 5-9

PA and IPA (driver) Pallet Replacement . . . . . . . 5-11

PA Module AC/DC Converter (PS) Board . . . . . 5-13

PS Board Removal and Replacement . . . . . . . . 5-13

2

Table of Contents

AC/DC Converter (PS) Board Output Voltage . 5-14

Setting Voltage: . . . . . . . . . . . . . . . . . . . . . . . 5-14

Power Calibrations . . . . . . . . . . . . . . . . . . . . . . . 5-15

Forward Power Calibration . . . . . . . . . . . . . . . 5-15

Calibrate Forward Total Power . . . . . . . . . . . 5-16

Calibrate Forward Cabinet Power:. . . . . . . . . 5-18

Reflected Power Calibrate . . . . . . . . . . . . . . . . 5-18

Calibrate Reflected Total Power . . . . . . . . . . 5-19

Calibrate Reflected Cabinet Power . . . . . . . . 5-20

Exciter Output Calibration . . . . . . . . . . . . . . . . 5-21

PDU Calibration . . . . . . . . . . . . . . . . . . . . . . . . 5-21

Threshold Settings . . . . . . . . . . . . . . . . . . . . . . 5-22

Exciter A & B Threshold Settings . . . . . . . . . 5-23

Cabinet Reject Load Thresholds . . . . . . . . . . 5-24

System Reflected Thresholds. . . . . . . . . . . . . 5-24

System Foldback Power. . . . . . . . . . . . . . . . . 5-24

FWD Pwr Warn . . . . . . . . . . . . . . . . . . . . . . . 5-24

Fwd Pwr Flt . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24

PA Cabinet Fan Replacement . . . . . . . . . . . . . . . 5-25

Cabinet Fan Removal . . . . . . . . . . . . . . . . . . . . 5-25

PA Cabinet RF System Removal. . . . . . . . . . . . . 5-27

RF System Removal . . . . . . . . . . . . . . . . . . . . . 5-27

Miscellaneous Maintenance . . . . . . . . . . . . . . . . 5-34

Cooling System Checks . . . . . . . . . . . . . . . . . . 5-34

Heat Exchanger Cleaning . . . . . . . . . . . . . . . 5-34

Alternate Pumps. . . . . . . . . . . . . . . . . . . . . . . 5-34

Pump Module Strainer Cleaning . . . . . . . . . . 5-34

Coolant Level Management: . . . . . . . . . . . . . 5-36

Cooling System Maintenance Notes . . . . . . . 5-37

Coolant Checks: . . . . . . . . . . . . . . . . . . . . . 5-37

Changing Pumps: . . . . . . . . . . . . . . . . . . . . 5-37

Pump Module Operation Without

Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-38

Air Filter Replacement . . . . . . . . . . . . . . . . . . . 5-38

LCD Screen Adjustments . . . . . . . . . . . . . . . . . 5-39

LCD Screen Contrast . . . . . . . . . . . . . . . . . . . 5-39

Touch Screen Calibration. . . . . . . . . . . . . . . . 5-39

Date and Time Settings . . . . . . . . . . . . . . . . . 5-40

Changing the Battery on the PCM Card . . . . . . 5-40

PCM Battery Installation Instructions: . . . . . 5-41

TCU Card Replacement . . . . . . . . . . . . . . . . . . 5-45

MCM Card Replacement . . . . . . . . . . . . . . . . 5-46

Typical Test Equipment. . . . . . . . . . . . . . . . . . . . 5-47

Section 6

Diagnostics

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

GUI System Log . . . . . . . . . . . . . . . . . . . . . . . . . . .6-2

Maxiva Three-Strike Fault Actions. . . . . . . . . . . . .6-3

Reflected Power Faults. . . . . . . . . . . . . . . . . . . . .6-3

Module Faults. . . . . . . . . . . . . . . . . . . . . . . . . . . .6-4

Fault Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6-5

Section 7

Parts List

Replaceable Parts List. . . . . . . . . . . . . . . . . . . . . . .7-1

Heat Exchanger/Pump Module Replacement Parts7-13

Appendix-A

Cutting & Soldering Transmission Line . . . . .A-1

Appendix-B

Cooling System Help . . . . . . . . . . . . . . . . . . .B-1

Appendix-C

Grounding Considerations,

Surge & Lightning Protection . . . . . . . . . . . .C-1

Appendix-D

Lightning Protection Recommendation . . . . .D-1

3

Table of Contents (Continued)

4

Maxiva ULX COFDM Series

Section 1

Introduction

1

1.1

Purpose of This Manual

This technical manual contains the information pertaining to the Maxiva ULX Series, solid-state, UHF, COFDM digital TV transmitter. The various sections of this technical manual provide the following types of information.

•

Section 1, Introduction, provides general manual layout, photos, equipment description, block diagram and general specifications.

•

Section 2, Installation/Initial Turn-On, provides physical and electrical installation procedures for the transmitter, cooling and RF systems and basic remote control connections.

•

Section 3, Operation, provides operation and navigation information for the Graphical User Interface or GUI as well as identification and functions of all external panel controls and indicators.

•

Section 4, Theory of Operation, provides detailed theory of operation for the transmitter and sub-assemblies.

•

Section 5, Maintenance and Alignments, provides preventative and corrective maintenance information and all field alignment procedures.

•

Section 6, Diagnostics, provides detailed fault information and diagnostic procedures to the board level.

•

Section 7, Parts List, provides a parts list for the overall transmitter as well as individual modules.

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1-1


Section 1 Introduction

1.2

General Description

This section contains a general description of the Maxiva ULX Series COFDM digital television transmitters. Included in this section will be descriptions of the control system, power amplifier, block diagrams of the different models and system specifications.

TCU System Controller

Redundant Pre-Driver A

Apex M2X Exciter A

Apex M2X Exciter B

18

Redundant Pre-Driver B

PA Slots 11-18

A

B

11

8

Redundant Drivers

IPA A (slot 10)

IPA B (slot 9)

PA Slots 1-8

1-2

1

Figure 1-1 ULX-8700** Front View

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.

Main Breakers

RF Output Line

3dB Combiner

Redundant Cabinet

Blowers (2)


Control Breakers

Coolant Hoses In/Out

Upper 8 Way Combiner

Upper 8 Way Splitter

Final Reject Load

Lower 8 Way Combiner

Lower 8 Way Splitter

Figure 1-2 ULX 8700** Rear View

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1-3



1.2.1

Maxiva COFDM Series Transmitter Models

The Maxiva ULX Series COFDM transmitter is available in 13 liquid cooled power levels. The models are listed below in Table 1-1.

The last two letters in the transmitter model number, indicate modulation types. For simplicity, the model numbers noted in this maual will be noted as ULX-0000**.

NOTE:

The table below denotes the suffix (**) with the modulation type. The numerical values following the ULX indicate power output in kW for the various models.

Modulation types include: DV=DVB-T/H, IS=ISDB-T/H, FLO, CTTB, &

CMMB.

Table 1-1 Maxiva COFDM Series Transmitter Models

Tx Models Cabinets PA Modules Output Power Primary Cooling

ULX1100**

ULX-1700**

ULX-2300**

ULX-3400**

ULX-4400**

ULX-5500**

ULX-6500**

ULX-8700**

1

1

1

1

1

1

1

1

8

10

12

16

4

6

2

3

1100W

1700W

2300W

3400W

4400W

5500W

6500W

8700W

ULX-9500**

ULX-12600**

ULX17400**

ULX-18900**

2

2

2

3

18(12+6)

24(12+12)

32(16+16)

36(12+12+12)

9.5 kW

12.6 kW

17.4 kW

18.9 kW

ULX-26100** 3 48(16+16+16) 26.1 kW

NOTE: All power levels given in average output power before the bandpass filter.

LIQUID

LIQUID

LIQUID

LIQUID

LIQUID

LIQUID

LIQUID

LIQUID

LIQUID

LIQUID

LIQUID

LIQUID

LIQUID

1.2.2

System Block Diagram

Figure 1-3 on page 1-5 contains a system block diagram showing the basic signal flow and configuration for a Model ULX-8700** Maxiva COFDM transmitter. The block diagram shows the 8.7 kW single cabinet, liquid cooled system with 2 pre-amp

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Maxiva ULX COFDM Series Section 1 Introduction modules, 2 driver modules and 16 PA modules. Note that the predriver and driver modules are redundant.

Web

Remote /

Monitoring

TO OTHER

CABINETS

TO N +1

CONTROLLER

Ethernet

System /CAN Bus

N+1 CAN Bus

Pre-Drivers Driver-PAs

Exciter CAN Bus

Ethernet

Ethernet

EX 1

EX 2

TO PUMP MODULE

INTERLOCKS

PARALLEL

CONTROL

CAN Bus

RF

SWITCH

Front Panel

Buttons

GUI

PUMP CONTROL

INTERLOCKS

PARALLEL

REMOTE

TCU

PS AND

COOLING

MONITOR

PA

INTERFACE

RF

MONITORING

LEAK

DETECTOR

CABINET

FLOW

METER

INLET /

OUTLET

TEMP

I/O PANEL

÷

PA Bus

FANS

L1

L2

L3

16 PA’s

DIR

COUPLER

AC

Distribution Bus

MOV/AC

SAMPLING

Transmitter

Main Cabinet

Figure 1-3 Maxiva ULX-8700** COFDM Block Diagram

1.2.3

Transmitter Control System

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The Maxiva COFDM transmitter uses a simplified control system that minimizes the number of microprocessors. Each transmitter sub-system is responsible for its own monitoring and protection and simply reports back to the TCU (transmitter control unit) for display on the GUI (Graphical User Interface) or to a remote interface. In multicabinet systems the TCU in cabinet 1 functions as the main controller while the TCU in each amplifier cabinet acts as a slave controller. The cabinet 1 TCU will contain the

GUI display for the transmitter. Additional PA cabinets do not contain GUI screens.

The system bus originates in MCM (master controller module) inside the cabinet 1 TCU and goes to the TCU located in each amplifier cabinet. The system bus is used to transfer telemetry information in between the TCU’s.

The cabinet bus is similar to the system bus but it connects the cabinet TCU (MCM card) to all of the nodes inside each individual cabinet. If system bus communications

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Section 1 Introduction with the master TCU (in cabinet 1) are interrupted the cabinet bus allows each cabinet to operate independently.

The heart of the control system is the TCU which is responsible for control, monitoring and protection. The TCU contains the MCM (master controller module) which controls all critical transmitter functions and the PCM (processor control module) which provides enhanced monitoring and control, exciter and cabinet data collection, fault logs and web remote connectivity. In addition to the MCM and PCM the Maxiva

COFDM main TCU contains six modular cards for the following sub-systems:

•

PA Interface -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.

•

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.

•

Customer I/O - Provides parallel remote control, status and meter outputs. Connector

A has all inputs and Connector B has all outputs.

•

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.

•

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.

TCU’s also contain the following components:

•

Base-Plane - provides a common bus for custom plug-in cards

•

Power Supply Modules - two redundant internal power supply modules.

•

Standard Master Control Module (MCM) - FPGA based controller used for all critical transmitter control functions.

•

LED’s - standard front LED mimic display panel.

•

Processor Control Module (PCM) - Coldfire 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.

•

Graphical User Interface (GUI) front panel - 5.25" color 1/4 VGA touch screen that is present only in the main TCU (cabinet 1 in multi cabinet systems).

In multi-cabinet systems, there is a TCU in every cabinet. Each TCU will always contain an MCM but PA cabinet TCU’s don’t require all TCU cards. The TCU in the

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Maxiva ULX COFDM Series Section 1 Introduction first PA cabinet will assume the role of master controller for the system. The TCU’s in the remaining PA cabinets will be slaves.

1.2.4

Transmitter RF Power Control

The PA modules operate in open loop mode (no gain or level adjustment). The transmitter RF power control is done via the Phase and Gain Board located in the predriver modules. The predrivers are the only components in the drive chain (besides the exciter) capable of adjusting their RF power based on commands from the TCU.

Each cabinet can also be placed in the "Manual Power Control Mode". In this mode the automatic level control is disabled.

1.2.4.1

Graphical User Interface

The TCU front panel (in the control PA cabinet on multi-cabinet transmitters) contains the graphical user interface which is a 5.25" 1/4 VGA, LCD touchscreen display. The touchscreen display uses software buttons to monitor and control the transmitter.

Hardware buttons for the primary transmitter functions such as ON, OFF, RAISE and

LOWER are provided on the overlay panel next to the display.

TCU’s in additional PA cabinets will not be equipped with GUI screens.

Figure 1-4 TCU Front Control Panel

1.2.5

Control System Communications

10/6/10

The control system uses a serial communications system called a CAN bus. CAN stands for Controller Area Network. The CAN bus is a closed loop serial network controlled by the main TCU. The CAN bus connects the main TCU with TCU’s in other cabinets.

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Each TCU board connected to the CAN bus is considered a node and therefore has a specific address. This allows the master TCU to use the system bus to gather information from all parts of the transmitter and display it on the GUI. One big advantage of the CAN bus is that it requires only 2 wires of the system control bus ribbon cable, eliminating a large amount of discrete wiring which would otherwise be required.

The system bus ties TCU’s in each cabinet together. The cabinet bus is for the most part a duplicate of the system bus but intended to connect nodes within each individual cabinet. The cabinet bus originates in the MCM module within each TCU. The cabinet bus is designed to keep the PA cabinets operating even if the communications with the master cabinet TCU is lost.

1.2.5.1

Software Updates

The use of the CAN bus for communication between the various Micro Modules in the transmitter also allows updating of the software used in each transmitter sub-system via a serial port connection to an external computer.

NOTE:

Software does not need to be loaded into the transmitter unless new components are installed or an update is sent from Harris. The transmitter, as shipped from the factory, is preloaded and ready to run.

1.2.5.2

Remote Control

The Maxiva Series COFDM transmitter has the basic discrete wired parallel remote control with the standard connections for control, status and analog monitoring located on the customer I/O card inside the main TCU (cabinet 1).

Maxiva transmitters include Web enabled remote GUI interface that provides comprehensive remote control and monitoring of data points within the transmitter. It includes an SNMP (Simple Network Management Protocol) manager which allows integration with most Control Systems via the Internet or LAN.

1.2.6

PA Module

The Maxiva ULX Series PA Module utilizes LDMOS (laterally diffused metal oxide semi-conductor) amplifiers to produce up to 550 W average power output. Each module weighs approximately 22kg and can be removed while the transmitter is running. A single cabinet Maxiva Series transmitter can have 2, 3, 4, 6, 8, 10, 12, or 16 PA modules

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Maxiva ULX COFDM Series Section 1 Introduction to achieve the various power levels shown in Table 1-1 page1-4. A simplified block diagram of the PA module is shown in Figure 1-5 on page 1-9.

The amplifier and driver modules are interchangeable and do not contain microcontrollers but instead use a CPLD based monitor board in each PA to report faults to the TCU and to take appropriate self-protective action if needed.

Figure 1-5 PA Module Simplified Block Diagram

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8 AC-DC Converter Modules

4 RF Pallets

Diagnostic Port

Status LED’s

Figure 1-6 Maxiva PA Module (cover removed)

The diagnostic port shown in Figure 1-6 allows the operator to connect directly to the

PA module with a handheld device and obtain PS voltages, fault status, FWD and REF

RF power levels and internal temperatures. The diagnostic port can also be used to reprogram the CPLD as required. The part number for the handheld diagnostics unit kit is 971-0040-081. The Harris part number for the diagnostics unit technical manual is

888-2765-001.

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Maxiva ULX COFDM Series c e b

In/Out d

Section 1 Introduction f i g

RF Out h

Figure 1-7 Maxiva ULX PA Module (top view, cover removed)

Each PA module consists of the following components: a.

Monitor Board - Responsible for all monitoring and protection of the module.

Reports to the transmitter TCU via the parallel control lines.

b.

Connector I/O Board -I/O Connector Board provides interface connections between PA Module and transmitter back plane. The board includes a single hybrid connector on one side and five (5) connectors on the other side. The large hybrid connector interfaces with mating connector on the back plane board. It contains seven (7) AC contacts, twenty four (24) small signal contacts, and a single RF coaxial connector. c.

AC Distribution Board - The AC distribution board provides three phase AC to the eight power supply boards. It also provides AC line filtering, step-start function and transient protection for the module.

d.

Power Supply Boards - The eight (8) AC/DC power supplies provide 44VDC to

50VDC power to each pair of FET’s on the four (4) PA pallets. Voltage varies with modulation type and channel.

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Maxiva ULX COFDM Series e.

Splitter Board - The splitter board equally divides the RF signal between four (4) power amplifier pallets. The splitter is broadband (covers TV band IV/V). The splitter board also delivers a detected RF sample to the monitor board to indicate input power level and provide protection from excessive input drive power.

f.

Signal Distribution Board - Signal Distribution Board serves to route analog and digital control and monitoring data between four (4) PA module board subassemblies, monitor board, PA pallets, connector I/O board, and 4-way splitter board.

g.

LDMOS Amplifier Pallets - There are four (4) single stage amplifier pallets operating in parallel in the PA module. When combined, they provide up to 800 watts of average power at the output of the module.

h.

Combiner Board - The board combines the RF outputs of the four (4) amplifier pallets, and delivers the combined signal to the output port. The combiner is broadband (covers the entire TV Band IV/V) and requires no tuning. The combining of the signals is accomplished using hybrid combiners in series. The first stage is a 2-way 3dB hybrid, the second stage a 2-way 4.77dB hybrid, and the 3rd stage is a 2-way 6dB hybrid. The use of reject loads in conjunction with the hybrids allows continuous operation of the PA Module in the event of a PA Pallet failure. The combiner contains Forward and Reflected signal directional couplers at its output. Detector circuits deliver the forward and reflected output samples to the Monitor Board, which indicates the forward power level in dBm and uses the reflected signal for VSWR monitoring and VSWR fault protection for the module. Another directional coupler provides an attenuated sample of output RF signal to an optional coaxial port at the front of the PA module.

Each Maxiva COFDM PA Module is a self-contained 550W transmitter including the power supply with its own internal control, monitoring and protection.

The modules only receive basic On/Off, Mute, & Restart commands from the transmitter control system. This means that each module will protect itself without relying on the TCU.

1.2.6.1

Module Control

The primary method for control and monitoring of the PA Modules is via the individual

50 conductor ribbon cable bus to one of the two TCU assembly PA Interface boards.

These busses are called Drive A (for preamp A and IPA A), Drive B (for preamp B and

IPA B), and BP 1 through BP 4 (for PA backplanes A5, A6, A8, and A9 respectively).

Each module contains a CPLD based monitor board that is responsible for reporting faults back to the TCU and for taking action when the ON/STBY command is issued from the TCU. The cabinet bus connects to each PA and IPA Module backplane, but it is only used for the PA_voltage_select line, which sets the DC output voltage of each of the eight AC to DC converters in the IPA and PA modules. The output can be switched between 44, 46, 48, or 50 VDC, depending on the operating frequency.

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1.2.7

Transmitter Power Supplies


Three phase AC mains must be supplied to the cabinets via circuit breaker CB23 and

CB24 on the AC mains input assembly (A15). The transmitter can accept 208-240VAC

(Delta or WYE) or 380-415VAC (WYE) by changing jumpers in three areas:

•

Terminal boards TB1 and TB2

•

Parallel MOV boards (A15A1 & A15A2)

•

IPA (driver) and PA backplane boards

If properly jumpered there will be three phase 208-240V AC inputs supplied to each driver and PA module.

!

CAUTION:

THREE PHASE 440-480VAC AC MAINS CAN ALSO BE USED BUT ONLY WITH

AN EXTERNAL TRANSFORMER WHICH CAN BE ORDERED SEPARATELY

FROM HARRIS.

The 208 to 240VAC is supplied to each PA module’s connector I/O board and then to the modules AC distribution board. There it is applied to eight AC/DC converters (two per pallet). Depending on the operating frequency, the AC/DC converter output can be switched between 44, 46, 48, or 50 VDC, which is supplied to each of the eight FET’s in the module. There are two FET’s on each of the four pallets in each module.

The control system in the transmitter is powered by two low voltage power supply

(LVPS) modules in the TCU.

1.2.8

Cooling System

10/6/10

The Maxiva COFDM transmitter uses a 50/50 glycol/water cooling system to remove the majority of the heat away from the transmitter but also has cabinet flushing fans to remove residual cabinet heat. A simplified block diagram of the liquid cooling system is shown in Figure 1-8 on page 1-14. A simplified diagram of the liquid cooling system inside the transmitter cabinet is shown in Figure 1-12 on page 1-21. The cooling system basically consists of: a.

Cooling system control panel/pump module & heat exchanger units b.

Air purger located at the highest point in the cooling system.

c.

Coolant strainer.

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Maxiva ULX COFDM Series d.

Supply and return line hose and fittings.

e.

PCI (pump control interface) located in the TCU f.

Transmitter PA Module, Splitter and Combiner Cold Plates

The liquid cooling system is an efficient closed loop, pressurized system. Prior to operation the cooling system must be properly prepared for operation and bled to remove trapped air. Instructions for cooling system preparation can be found in Section

2.

The heat exchanger and pump module unit operates on either 208-240 VAC, 50/60 Hz or 380-415 VAC 50/60 Hz. The operating voltages and frequencies should be provided at time of order. The number of heat exchanger fans will vary with model number.

1-14

Figure 1-8 Simplified Liquid Cooling System Block Diagram

!

CAUTION:

SOME MAXIVA ULX SERIES TRANSMITTERS WILL NOT SUPPORT A WATER

COOLED TEST LOAD. AN AIR COOLED LOAD SHOULD BE USED WITH ULX SERIES

TRANSMITTERS.

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1.2.8.1

Cooling System Control Panel


The cooling system control panel controls the operation of the pump module/heat exchanger, and sends fault and status information to the TCU. The cooling system control connects to the RF Detector/Pump Control/Interlocks card in the TCU for monitoring and control.

NOTE:

Some early versions of the pump module were designed for indoor use only. The current pump module is designed for indoor or outdoor use.

The pump control signals are described below:

+12 Vdc - Voltage supplied by Pump Control Unit.

PUMP_INTLK - Output, active high. When high, the transmitter’s RF output is muted and the pumps are forced to OFF regardless of the LOCAL/

REMOTE setting in the pump cooling control panel. If this interlock is active, the pumps can’t be turned ON (even locally). This interlock is driven by the transmitter or PA cabinet leak detector. If a leak is detected, this interlock goes to high.

PUMP RUN - Output, active high to turn on selected pump.

SWITCH PUMP - Output, pulsed active high to switch between Pump A and Pump B.

PUMP A SELECTED - Input, connect to open drain or relay contacts. Active when input is LOW.

PUMP B SELECTED - Input, connect to open drain or relay contacts. Active LOW.

LOCAL STATUS - Input, connect to open drain or relay contacts. Remote = LOW,

Local =HIGH

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A B

Run LEDs

Selected LEDs

Pump

Pump Isolators

ON/OFF

AC Isolator ON/OFF

FAN A or B

Controller

Set Temp. Set Point

System Control

LOCAL/OFF/REMOTE

Screwdriver Lock

1-16

Figure 1-9 Cooling System Control Panel

The cooling system control panel shown in Figure 1-9 has local controls on the front which allow manual selection of: a.

ISOLATOR ON/OFF b.

HEAT EXCHANGER FANS - Manual, OFF, or Remote c.

PUMP SELECT - A or B pump is selected when pressed d.

TEMP CONTROLLER - Sets fan cycle temps. Factory settings are Fan 1 set point will be set at 32 C with a 5 degree hysteresis window. This means Fan 1 turns ON at 34.5 C and shuts off at 29.5 C. Fan 2 set point will be set at 37.5 C also with a 5 degree hysteresis window. This means Fan 2 turns ON at 40 C and shuts off at 35 C. e.

SYSTEM CONTROL - LOCAL/REMOTE - Allows local control or remote control via transmitter.

f.

HEAT EXCHANGER TEMP CONTROL - PID controller used to set fan ON and

OFF temperatures.

The control panel also has the following status indicators: g.

PUMP - A RUN (ON = Green)

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Maxiva ULX COFDM Series Section 1 Introduction h.

PUMP - B RUN (ON = Green) i.

FAN - A RUN (ON = Green) j.

FAN - B RUN (ON = Green) k.

PUMP - A SELECTED (ON = Green) l.

PUMP - B SELECTED (ON = Green) m.

PLC STATUS INDICATOR

When System Control is in Remote mode, see Figure 1-9 on page 1-16, the transmitter is responsible for control of the cooling system, including ON/OFF, manual pump selection and automatic pump switching in the case of a failure. Placing the control panel in Local mode allows manual switching of the pumps.

The red selector at the top of the control panel (labeled ON/OFF) is the AC isolation switch which disconnects AC power from the pump module as well as the control circuitry in the control panel itself.

In the local mode, with the AC isolation switch set to ON, one of the two pumps will be energized unless the Pump Interlock is active. To deenergize the pumps, when in the local mode, set the AC isolation switch to OFF.

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1.2.8.2

Pump Module/Heat Exchanger


The control panel/pump module and heat exchanger are separate units (each in a rack).

The control panel and pump module are self-contained in one rack and include a PID

(programmable logic controller), an expansion tank, air purger, pressure gauges, a strainer and optional dual pumps operating in main/standby mode. The control panel/ pump module is designed for outdoor operation (some older models were suitable only for indoor use). If used indoors the pump module and control panel should be located near the transmitter if possible. The heat exchanger assembly is designed for outdoor mounting.

1-18

Pump Module Front

Pump Module Side

(Outdoor rated model shown. Indoor rated models will not have full cowling over motors )

Figure 1-10 Pump Module/Heat Exchanger

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Maxiva ULX COFDM Series Section 1 Introduction

10/6/10

Figure 1-11 Heat Exchanger (before installation)

NOTE:

The heat exchanger shown in Figure 1-11 is a 2 fan unit. It is shown on a shipping pallet. The two fans that are shown pull air up through the cooling coil/fins (not visible in the photo) of the unit if mounted horizontally (as shown). This unit can be mounted horizontally or vertically depending on how the legs are attached to the heat exchanger. Smaller transmitters may use only one fan.

1.2.8.2.1 Heat Exchanger Fan Control

In multi-cabinet transmitters there will be one heat exchanger and control panel/pump module per PA cabinet. The fans are controlled electronically. The fans are enabled whenever the pump module is activated. Factory settings are Fan 1 set point will be set at 32 C with a 5 degree hysteresis window. This means Fan 1 turns ON at 34.5 C and shuts off at 29.5 C. Fan 2 set point will be set at 37.5 C also with a 5 degree hysteresis window. This means Fan 2 turns ON at 40 C and shuts off at 35 C.

1.2.8.2.2 Pump Operation/Control Logic

Pump operation is automatically controlled using a programmable interface device controller (PID). There are two modes of pump operation, "LOCAL" and "REMOTE".

The PID controller interfaces with the pump control interface (PCI) located in the TCU.

The PID controller receives and sends signals to the transmitter PCI. With "LOCAL" selected a status signal is sent to the PCI reporting the mode selection. Loss of flow for

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Maxiva ULX COFDM Series more than 5 seconds in an active pump will cause activation of the standby pump. Loss of flow for more than 15 seconds will cause both pumps to shut down.

1.2.8.3

PA Module and Combiner Cold Plates

Each PA Module has a liquid cooled cold plate which connects to the cooling system with quick release connectors. There are also cold plates inside the combiner and the splitter to which all of the internal combiner reject loads are attached. See Figure 1-12 for cabinet coolant routing and module slot numbering.

NOTE:

The module slot numbering should not be confused with the IPA and PA module numbering. Module numbering and slot locations will vary depending on model number. See the outline drawing to identify which PA modules go in which slot locations dependent on model.

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Maxiva ULX COFDM Series Section 1 Introduction

10/6/10

Figure 1-12 ULX 8700** Liquid Cooling System (Internal)

888-2629-200


1-21


1.2.9

M2X Multimedia Exciter


The M2X exciter is used with the Maxiva ULX Series transmitter. This exciter is described in a separate instruction book. A second hot standby exciter, and drive chain switcher is available as an option. The exciter is controlled by the transmitter using an internal CAN bus or Ethernet connection. Configuration, editing, diagnostics and monitoring are possible using the front panel on the TCU display, or via Ethernet ports provided with the exciter.

Figure 1-13 M2X Exciter Front

A single exciter unit drives the Maxiva ULX transmitter. The excellent quality and stability of COFDM UHF signal output maximizes the TV transmitter efficiency, improving performance and helping to reduce operating costs.

1PPS

10MHz

DVB-ASI/

SMPTE-310

DVB-ASI/

SMPTE-310

Monitor

Video

Audio

Universal Exciter Platform

D/A

Up

Converter

PFRU

4

Rcvr & Cable

Equalizer

Cable

Driver

Analog Input

Option Board

A/D

A/D

Modulator

FPGA

DUC/

Precorrector

FPGA

A/D

IF

PLL

RF

PLL

GPS

Option

Down

Converter

Transmitter

Interface Board

DSP uC

Battery

Backup

Option

LVPS

8

8

2

2

Figure 1-14 M2X Exciter Block Diagram

RF OUT

GPS Ant

RF IN (HPF)

RF IN (PA)

RF IN (IPA)

AC

Universal

10/100 BaseT

10/100 BaseT

CAN

RS232

1-22 888-2629-200


10/6/10


1.3

General Specifications


NOTE:

Specifications subject to change without notice. Unless otherwise noted specifications apply at the output of the Harris supplied mask filter.

10/6/10

Specifications continue on following page.

888-2629-200


1-23



End of specifications.

1-24 888-2629-200


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Section 2

Installation

2

2.1

Introduction

This section includes the information necessary for installation and initial turn on of a

Maxiva ULX Series solid state, UHF TV transmitter. Due to the modular nature of the

Maxiva, all models have similar installation and testing procedures.

2.2

Documentation

The last two letters in the transmitter model number, indicate modulation types. For simplicity, the model numbers noted in this manual will be noted as ULX-0000**.

NOTE:

The table below denotes the suffix (**) with the modulation type. The 0000 values in the table indicate power output in kW for the various models.

Table 2-1 Model Number & Modulation Type

Model No

ULX-0000 DV

ULX-0000 IS

ULX-0000 FL

ULX-0000 CT

ULX-0000 CM

Type of Modulation

DVB-T/H

ISDB-T/H

FLO

CTTB

CMMB

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2-1

Section 2 Installation Maxiva ULX COFDM Series

The following is a list of documentation that ships with the transmitter. Find and save all documentation. The top level Document Package numbers for each transmitter model are shown below:

•

ULX-1100**, ULX-1700** ULX-2300**, ULX-3400**, ULX-4400**, ULX-

5500**, ULX-6500**, ULX-8700**: 988-2629-200

•

ULX-9500**, ULX-12600**, ULX-17400**: 988-2629-201

•

ULX-18900**, ULX-26100**: 988-2629-202

A Document Package includes:

1.

This technical manual: 888-2629-200

2.

Exciter manuals: a.

888-2624-001 Common Sections b.

888-2624-003 DVB-T/H Section c.

888-2624-004 ISDB-T/H d.

888-2624-006 FLO e.

888-2624-007 CMMB f.

888-2624-008 CTTB

3.

Drawing Package with a complete set of schematics for the transmitter system.

2.2.1

Installation Drawings

It is recommended that you look through the drawing package to familiarize yourself with the information available. Although drawings are provided for most assemblies in the transmitter, most of the installation and planning information is given in the following drawings (see Table 2-2 below for model-specific numbers): a.

Outline Drawing - Shows connections for AC, control, coolant lines and RF output. Also gives cabinet dimensions, required cabinet clearances and a table of basic requirements for all models.

b.

AC Power Flow Diagram - Shows overall AC wiring and has information on proper wire, fuse and breaker sizes as well as location of disconnects.

c.

RF System Layout - Shows a typical placement of the transmitter RF components based on minimum required clearances.

d.

Electrical Installation Diagram - Shows interconnect wiring between transmitter and all external systems, including AC connections.

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10/6/10

Maxiva ULX COFDM Series Section 2 Installation e.

Wiring Diagram (Main Cabinet) and Wiring Diagram Additional PA Cabinet

(for multi-cabinet models) - Interconnection wiring diagram for all assemblies inside the main transmitter cabinet or additional PA cabinets.

f.

Intercabinet Wiring Diagram - Indicates the connections between multiple PA cabinets, and jumper ID settings (for the multi-cabinet models).

g.

Cooling System Outline - Shows specifications, dimensions and basic requirements for the Pump Module and Heat Exchanger units.

h.

Liquid Cooling System Layout - Shows basic plumbing component locations and connections, flow rate and pressure information as well as simplified cooling diagrams.

i.

Cooling System Electrical Diagram - Shows the internal workings of the

Cooling Control Panel and all interconnects with transmitter, pump module and heat exchanger, including AC connections.

Table 2-2 Maxiva ULX System Drawings

System Drawings

Drawing Package

Cover Sheet

Outline Drawing

Block Diagram

AC Power Flow

RF System Layout

Electrical Installation

Wiring Diagram Main

Cabinet

Layout, Plumbing

ULX-1100**

ULX-1700**

ULX-2300**

ULX-34700**

ULX-4400**

ULX-5500**

ULX65200**

ULX-8700**

943-5601-511

843-5601-511

843-5601-279

843-5601-284

843-5601-583

843-5601-281

843-5601-705

843-5601-001

843-5601-281

ULX-9500**

ULX-12600**

ULX-17400**

943-5601-300

843-5601-300

843-5601-597

ULX-18900**

ULX-26100**

943-5601-308

843-5601-308

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2-3


System Drawing Notes:

1.) RF System Layout 843-5601-288 is for systems containing up to 4 modules. 843-

5601-281 is for systems containing 6 to 16 modules.

2.) Pump Module/Heat Exchanger Outline 843-5601-289 is for cabinets containing up to 8 modules. 843-5601-285 is for cabinets containing 10 to 16 modules.

3.) Pump Module/Heat Exchanger Wiring Diagram 843-5601-290 is for cabinets containing up to 8 modules. 843-5601-286 is for cabinets containing 10 to 16 modules.

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2.3

Installation Steps

Section 2 Installation

Steps in the installation section are numbered in each section. As each step is completed, the step number can be circled to indicate completion. This provides a quick confidence check at the end of the procedure that no steps were skipped. The primary goal of each step is indicated by bold letters , with the rest of the paragraph being support information.

NOTE:

In case of discrepancy between the connections listed in schematics versus information given in this installation section, the wiring information in the schematics should be considered the most accurate. All connections listed in this section should be verified with the schematics before initial turn on .

When performing the installation, after the transmitter cabinet(s) are in place, plan to run the transmitter output transmission lines first, then the liquid cooling system plumbing lines, and finally the electrical conduit runs. If air handling duct work is to be installed, plan all of the RF, plumbing and conduit runs to leave room for the duct work.

The reason for this installation order is that rigid coax runs must be installed with minimum elbows. If the RF runs encounter obstacles such as liquid coolant lines, conduit, and duct work more elbows are required. The RF lines should have a minimum number of elbows for best performance.

The liquid cooling system plumbing should installed next. Avoid excessive 45 and 90 degree elbows, especially back to back elbows as they will restrict the flow of the liquid coolant and increase the dynamic head pressure. Heavy duty hose can be used instead of copper line, hose is much easier to install and can be installed last, as long as large radius turns are used and sharp bends of the hoses are avoided. Hose must be supported more frequently than copper. Good support is required to avoid sagging of the hose, because it can trap liquid when the system is drained, stress the hose at the support points, and, if the sagging is deep enough, can cause flow restriction due to the hose collapsing at the support points.

NOTE:

Plumbing elbows or 45 o

bends tend to produce turbulence in liquid coolant lines.

Avoid use of back to back elbows or bends. As a rule of thumb, maintain 10 pipe diameters of straight pipe either side of elbows, bends, valves or flow meters.

Where feasible the electrical installation should be performed last since it is the easiest to run, and is most forgiving as to the number of elbows used. It can more easily be routed around obstacles.

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2-5


2.4

Transmitter Cabinet Placement


The transmitter cabinet should be placed where it will have approximately 1 meter clearance on each side and in the back. The front of the transmitter should have a clearance of at least 1.5 meters to allow access for removal and installation of the PA modules.

There are several drawings included in the drawing package to help plan the cabinet placement:

•

Outline Drawing

•

RF Equipment Layout

•

Liquid Cooling System Layout

STEP 1 Remove the bolts or straps holding the transmitter to the wooden pallet and carefully slide the cabinet off the pallet.

STEP 2 Remove rear door and set aside in a safe place for the rest of the installation process.

MULTI-CABINET MODELS:

STEP 3 Place cabinets in position and carefully align.

ALL MODELS:

STEP 4 Use levelling shims under transmitter cabinet as required to make sure the transmitter is level and solid (not rocking).

STEP 5 Install Drip Tray. The aluminum drip tray slides under the transmitter just below the rear door panel. The drip tray rests on the floor and is centered underneath the rear of the Maxiva transmitter. It should be checked periodically for presence of coolant.

NOTE:

Do not open the packaging for, or install IPA (driver), or PA modules at this time.

These will be installed just before the initial turn on.

2.5

Cooling System Installation

The major components of the Maxiva cooling system include the TCU (pump control card), pump module/heat exchanger, and the interconnecting plumbing. The installation procedures will rely heavily on the following documentation:

2-6 888-2629-200


10/6/10

Maxiva ULX COFDM Series Section 2 Installation a.

Electrical Installation Diagram b.

AC Power Flow Diagram c.

Cooling System Electrical Diagram d.

Liquid Cooling System Layout e.

Cooling System Outline f.

Appendix B chapter in this manual g.

Pump Module/Control Panel & Heat Exchanger manufacturer’s instruction manuals

2.5.1

Heat Exchanger and Pump Module Installation

When planning the installation, keep the following restrictions in mind:

The heat exchanger unit is typically installed outdoors. Locate the unit outside of the building or on the roof, as close as possible to the transmitter to minimize piping and pumping requirements and costs.

If mounted outside the building, but not on the roof, make sure a concrete pad is poured and allowed time to cure before setting the heat exchanger module in place. Plan to unload the heat exchanger module unit directly to its final location.

Allow extra space for the concrete in front of, beside and behind the unit to avoid dirt being blown around by the fans, and to allow walking and working space for maintenance and inspection of the unit.

When mounting on a roof, install unit such that building columns or load bearing walls adequately support it, also, include room around the unit for access during installation and maintenance

The heat exchanger must be installed level. Plan to fasten the mounting legs securely to the supporting steel (for roof installation) or to the concrete pads.

Plan to orient the unit so that plumbing elbows are minimized and complex plumbing assemblies like back to back elbows are not required. If hoses are used in the coolant system, position them to avoid sharp bends where flow could be disrupted. In addition, the heat exchanger should be oriented so that access to the switches, fans, fan motors is convenient.

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2-7


!

CAUTION:

FOR VERTICALLY MOUNTED HEAT EXCHANGERS, THERE SHOULD BE NO

OBSTRUCTION WITHIN TWO METERS IN FRONT OF THE EXHAUST SIDE OF THE

FAN (EXHAUST AIR IS DIRECTED OUT THE SIDE OF THE UNIT) OR WITHIN 1

METER OF THE INTAKE SIDE OF THE FAN. HORIZONTALLY MOUNTED HEAT

EXCHANGERS (EXHAUST AIR DIRECTED UPWARD) SHOULD HAVE NO

OBSTRUCTIONS WITHIN TEN METERS OF OUTPUT EXHAUST.

2-8

A method of protection from direct wind is recommended on the exhaust side of vertical heat exchanger fans. A blocking partition approximately 4 meters from the exhaust side of the fan is recommended.

Other liquid cooling system installation recommendations are listed below.

a.

The pump module, heat exchanger and transmitter’s total coolant plumbing circuit length must not exceed 40 meters (131 feet) total length including supply and return lines. Vertically, a maximum difference of 8 meters (26 feet) between pump module/heat exchanger and the transmitter is allowable.

Layout the liquid cooling system with as few elbows as possible because excessive elbows or back to back 45 or 90 degree elbows will greatly restrict the coolant flow. If hose is used instead of copper lines, avoid sharp bends of the hoses because that can collapse the hose at the bend and greatly restrict coolant flow.

Hoses will require more support than copper lines. If hoses are to be used, lay them in a tray if possible, or plan hose supports a MINIMUM of 1 meter apart.

b.

Any turbulence causing device in the coolant plumbing system can restrict flow and increase the dynamic head pressure of the pump. If two turbulence causing devices are connected back to back, the flow restriction and pressure drop across the pair of devices is greatly multiplied over the restriction of the individual devices. Turbulence causing devices include, but are not limited to elbows (45 and 90 degree), tees, ball valves, gate valves, globe valves, flow sensors, pipe diameter changes, and etc. To minimize the effects of any turbulence causing device added to the coolant plumbing system, a good rule to follow is to have 10 diameter lengths of straight pipe between turbulence causing devices. This will allow the turbulence to dissipate and the flow to become uniform. It has an effect called “static pressure regain” which will cancel out much of the flow restriction and pressure drop caused by the device. c.

An electrical control panel is integrated into the pump module assembly. Some early versions of the pump module and electrical panel were specifically designed for indoor use only and should be positioned near the transmitter so the electrical panel can be readily viewed and is easily accessible. Later model pump modules can be used either indoors or outdoors. Outdoor models are equipped with weatherproof covers on the pump motors and on the control panel.

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Maxiva ULX COFDM Series Section 2 Installation

NOTE:

If any of these restrictions cannot be met, a site-specific modification may be required. Contact your Harris representative for modifications.

All fluid piping practices should be in accordance with local codes. Standard installations will use heavy duty hose for connecting the transmitter to the heat exchanger and pump module but copper field piping using type M, hard drawn copper pipe and sweat joints made with soft silver solder is an acceptable alternative. Other piping materials such as steel, galvanized steel, cast iron, brass or plastic should not be used.

NOTE:

Do not use any type of galvanic piping or components in the Maxiva cooling system.

Whenever components made from different materials are piped in a system, use dielectric isolation of the materials to help prevent galvanic corrosion. All threaded pipe connections must be sealed and any flanged connections gasketed; use a sealant or

Teflon tape on threaded connections or the glycol/water solution will leak.

Correct sizing of pipe or hose is critical to assure smooth operation and keep operating costs to a minimum. Calculation of total system friction pressure loss determines optimum pipeline size. For closed-loop systems, do not include the static head pressure of the system piping, as equal and opposite forces cancel out upward and downward flow. All elbows, tees, valves and system component pressure drops must be considered when determining pipe/hose size. Pump selection at rated flow is based on 150 feet total length. Refer to installation drawings for recommended pipe and hose sizes.

Proper use of valves (gate type, ball type or globe type) is required to allow for isolation of components (bypassing) in the event of maintenance to reduce closed circuit system glycol/water loss. Bypassing of the transmitter cabinets is also desirable to avoid contamination of the transmitter during initial coolant system flushing.

2.5.2

Calculation of Cooling System Capacities

Calculation of cooling system capacities is important in order to know how much coolant and distilled water is needed for initial installation and future maintenance. For the initial installation, have enough distilled water on hand for the initial fill up with water, the initial system cleaning, two to four system flushes (to remove the cleaning solution) and the initial fill up with a 50% glycol/water solution. Have enough glycol on hand to perform the initial fill up, and enough Glycol and distilled water for a complete system refill in case of a catastrophic leak where all of the system coolant is lost.

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2-9


The capacities shown in Table 2-3 include all cabinet components such as modules, combiners and splitters. The values do not include the pump module coolant or the main interconnection plumbing lines between the transmitter, pump module, and heat exchanger. In multiple cabinet systems each cabinet will have it’s own pump module/ heat exchanger and associated plumbing.

The capacities shown in Table 2-4 include all components in the pump module/heat exchanger unit. In multiple cabinet systems each cabinet will have it’s own pump module/heat exchanger unit and associated plumbing.

To approximate the volume of interconnection plumbing line use Table 2-5 on page 2-

11 to determine the corresponding factor needed. Then multiply total of all line lengths by factor to derive tubing volume. Add this volume to the corresponding volumes given in Table 2-3 and Table 2-4 to determine approximate “Total” System Coolant Capacity.

Table 2-3 PA Cabinet Cooling Capacities

Transmitter Model

ULX-1100**

ULX-1700**

ULX-2300**

ULX-3400**

ULX-4400**

ULX-5500**

ULX-6500**

ULX-8700**

Approximate PA Cabinet Capacity

(less plumbing lines)

1.95 gallons (7.38 liters)





3.21 gallons (12.15liters)



Table 2-4 Heat Exchanger & Pump Module Capacities

Transmitter Model

2 Fan Unit

3 Fan Unit

Approximate PA Cabinet Capacity

(less plumbing lines)



2-10 888-2629-200


10/6/10


Table 2-5 Line length to Capacity Conversion Factors


Nominal Type M

Copper Tube or

Hose Size

1-1/4 inch (OD hose)

1½ inch (ID tube)

2 inch (ID tube)

2½ inch (ID tube)

42 mm (OD tube)

39.6 mm (ID tube)

54 mm (OD tube)

51.6 mm (ID tube)

66.7 mm (OD tube)

64.3 mm (ID tube)

Feet to Gallons

0.064

0.092

0.163

0.255

0.099

0.168

0.261

Feet to Liters

0.242

0.348

0.618

0.965

0.375

0.637

0.990

Meters to

Gallons

0.210

0.301

0.535

0.837

0.325

0.552

0.858

2.5.3

Rigging Heat Exchanger & Pump Module

Meters to

Liters

0.794

1.140

2.027

3.167

1.232

2.091

3.247

The equipment should be kept on the original pallet until ready for final instalaltion.

When using lifting belts ensure that a spreader bar is used and belts do not compress sheet metal or plumbing. The exact method of handling and setting the heat exchanger and pump module depends on the available equipment, the size of the unit, its final location and other variables. It is the installer’s or mover’s responsibility to determine the specific method of safely handling each unit. If possible, when the units arrive at the site and are unloaded from the truck, plan to set and secure the heat exchanger in its permanent place on its concrete pad or on the roof. The pump module (with control panel) should immediately be moved to an indoor location. Refer to the section Figure

2.5.5 for heat exchanger & pump placement information. If required, complete any required assembly of the unit. See paragraph 2.5.5, Placement of Heat Exchanger and

Pump Module

2.5.4

Initial Inspection

When the equipment and accessories are received, they should be immediately inspected for shortages and damage. If the equipment has been damaged in shipment or shortages are noticed, immediately notify the carrier and file a claim.

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2-11


NOTE:

It is recommended that the heat exchanger and pump module plumbing be pressurized to 15 PSI with air or an inert gas (nitrogen), as a leak check prior to rigging and/or final placement.

2.5.5

Placement of Heat Exchanger and Pump Module

The heat exchanger and pump module units must be installed level. Mounting legs should be securely fastened to supporting steel or concrete pads. When mounting on a roof, install heat exchanger unit so that building columns or load bearing walls adequately support it.

STEP 1 The expansion tank may be packed and shipped separately to avoid damage in transit. Refer to manufacturer’s drawings and manual for proper location. Install the expansion tank using pipe joint compound.

!

CAUTION:

AVOID USE OF EXCESSIVE AMOUNTS OF PIPE JOINT COMPOUND OR JOINT

TAPE. APPLY PIPE JOINT COMPOUND ONLY TO EXTERIOR THREADS TO

PREVENT INTERIOR BUILDUP AND CONTAMINATION OF THE PLUMBING

SYSTEM.

STEP 2 The heat exchanger unit should be installed outside . It should be oriented so that plumbing elbows are minimized and complex plumbing assemblies like back to back elbows are not required. If hoses are used in the coolant system they should be positioned to avoid sharp bends where flow could be disrupted. In addition, the heat exchanger should be oriented so that access to the electrical connections, fans, and fan motors can be accomplished. The pump module can be installed inside or outside depending on the model shipped (early versions were designed for indoor use only).

!

CAUTION:

THERE SHOULD BE NO OBSTRUCTION WITHIN TWO METERS IN FRONT OF THE

EXHAUST SIDE OF THE FAN ON VERTICALLY MOUNTED HEAT EXCHANGERS

(EXHAUST AIR IS DIRECTED OUT THE SIDE OF THE UNIT). HORIZONTALLY

MOUNTED HEAT EXCHANGERS (EXHAUST AIR DIRECTED UPWARD) SHOULD

HAVE NO OBSTRUCTIONS TO THE OUTPUT EXHAUST WITHIN TEN METERS.

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10/6/10


STEP 3 Check the area on the intake side of the fans.

It should be free of dirt, dust and debris. Vertically mounted heat exchangers should have no obstructions within 1 meter on the fan intake side and within 2 meters on the exhaust side. A method of protection from direct wind is recommended on the exhaust side of vertical heat exchanger fans. A blocking partition approximately 4 meters from the exhaust side of the fan is recommended.

!

CAUTION:

ENSURE THE PROPER EQUIPMENT IS AVAILABLE TO SAFELY INSTALL THE UNIT.

EXTREME CARE SHOULD BE EXERCISED DURING THE FOLLOWING STEPS TO

AVOID EQUIPMENT DAMAGE OR PERSONNEL INJURY.

STEP 4 Lift the heat exchanger unit and set it into the required position

(vertical or horizontally oriented heat exchangers may be encountered). Follow manufacturer’s assembly and lifting recommendations. They will vary depending on heat exchanger style.

Set into position using manufacturer’s recommended lifting points. Use of spreader bars is recommended to keep loads vertical and to prevent damage to heat exchanger components.

STEP 5 Install the leg channels and brace angles as required .

STEP 6 Carefully place assembled unit onto concrete pad.

STEP 7 Secure the unit to the concrete pad using anchor bolts.

STEP 8 Install safety warning labels. Locate and install according to instructions.

STEP 9 Lift the pump module unit and set it in the required (indoor only on early models) location.

STEP 10 Secure the pump module unit to prevent movement during operation.

STEP 11 Install safety warning labels. Locate and install according to instructions.

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2-13


2.5.6

Liquid Cooling System Plumbing Installation

2-14

Install components as described in the Liquid Cooling System Diagram. Globe or ball valves should be used in the supply side of each cabinet. Globe valves allow for fine adjustment of coolant flow through components. Gate or ball valves should be used on the return line side of cabinets and component.

The pump module has a 1/2” NPT fill and drain valves (3/4" female garden hose connections). The heat exchanger is fitted with 1/2" bleed and drain valves. An air purger and automatic air vent (return side) are incorporated into the unit for removal of air bubbles, which are induced in the system during filling. Additional air bubbles will continue to be purged and vented as the system operates at higher temperatures.

The main system air purger must be located inside the building, preferably within view of the transmitter, at the highest point of the plumbing installation. The system air purger will be equipped with a sight tube to allow the operator to monitor coolant level and formation of air bubbles that may indicate that the system needs to be charged with additional coolant. Drain valves should be located at all low points in the system to allow the system to be fully drained.

A closed expansion tank is provided in the pump module unit utilizing a rubber diaphragm to compensate for surges in the system. The diaphragm is actuated by air pressure (approximately 12 PSI charged); a valve is located on the top of the tank for changing the air charge. Charging the expansion tank is not normally required in the field. The tank is pressurized at the factory prior to shipment. Contact Harris Field

Service if you feel there is a need to change the air pressure in the expansion tank.

STEP 1 Install supply and return plumbing . Carefully locate and solder

(copper fittings) or clamp (hoses) to all pipe, valves, plugs, meters, elbows, adapters, and hose, to the transmitter, pump module, heat exchanger, reject and test loads according to the drawings (see

"Appendix B" section for this step). Supply and return hose should be installed without sharp bends. Hose should be supported frequently to avoid excessive movement as pumps turn on and off. Hose should be supported using padded clamps.

STEP 2 On long runs of pipe or hose, slope the run (toward a drain point) at a rate of 1 to 2 inches per 100 feet to facilitate draining the system or bleeding air from it when filling it.

STEP 3 Install the system (automatic) air purger, shown in Figure 5-23 on page 5-36, it should be installed at the highest point in supply line.

The system air purger should be visible from the transmitter area since it will need to be monitored frequently for cooling fluid level and air bubbles.

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STEP 4 Install drain valves at each low point in the plumbing system.

These drain valves allow the closed loop system to be thoroughly drained of liquid as required for flushing or draining the system.

!

CAUTION:

BEFORE ROUTING PLUMBING BE SURE THAT SPACE IS RESERVED FOR LATER

ROUTING OF RF TRANSMISSION LINE. IT IS IMPORTANT TO MINIMIZE THE

NUMBER OF RF COMPONENTS IN THE SYSTEM AND TO AVOID BACK TO BACK

ELBOWS.

Once all piping and accessory installation has been completed, the system is ready to leak test.

!

CAUTION:

ISOLATE THE BLADDER (PRESSURE) TANK PRIOR TO PRESSURE TESTING BY

CLOSING THE BALL VALVE AT THE TANK INPUT. CLOSING THE VALVE

PROTECTS THE BLADDER FROM DAMAGE DURING THE PRESSURE TESTING.

!

CAUTION:

DO NOT PRESSURE TEST THE PIPING OR HOSE SYSTEM TO HIGHER THAN 20

PSI.

STEP 5 Charge system with 15 PSIG of air. If system is pressurized with air for leak checking apply water/soap solution to each joint and look for bubbles. Repair leaks as required until system holds pressure.

Depressurize the system and open the ball valve at the pressure tank.

The system should now be charged with coolant using the fitting shown in Figure 2-1.

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2-15


Charge/Fill

Point

Figure 2-1 Suggested Charge Point

!

CAUTION:

DO NOT PRESSURIZE THE SYSTEM USING THE VALVE ON THE EXPANSION

TANK. THIS TANK HAS BEEN PRESSURIZED AT THE FACTORY AND IT SHOULD

NOT BE CHANGED.

!

CAUTION:

IF THE SYSTEM IS INITIALLY CHARGED WITH WATER DO NOT ALLOW THE

SYSTEM TO BE EXPOSED TO TEMPERATURES BELOW FREEZING. FREEZING

WATER IN THE COOLING SYSTEM MAY RESULT IN DAMAGE TO THE SYSTEM

COMPONENTS.

2-16

2.5.7 Pump Module & Heat Exchanger Electrical

The electrical installation of the heat exchanger and pump module unit should be in accordance with the National Electrical Code and any local codes and regulations. The incoming power supply is either 208-240V or 380-415V, 3 phase 50/60Hz. Fan and

888-2629-200


10/6/10

Maxiva ULX COFDM Series Section 2 Installation pump motors are three phase. Over current protection for the motors is provided by motor starters in the electrical control panel.

!

WARNING:

DISABLE AND LOCK OUT STATION PRIMARY POWER BEFORE PRIMARY POWER

CABLES ARE CONNECTED TO THE EQUIPMENT.

STEP 1 Install conduit and route AC mains cabling to the pump module and from the pump module control panel to the heat exchanger isolator switches.

Install and wire according to the Harris Electrical Schematic

Diagram and follow local wiring codes.

STEP 2 Install another conduit and route wiring for status and control lines between the pump module and transmitter cabinet. Install and wire according to electrical schematic diagram and local wiring codes.

!

CAUTION:

SMALL SIGNAL (CONTROL/STATUS) WIRES AND AC WIRING SHOULD NEVER BE

RUN IN THE SAME CONDUIT.

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2-17


Status &

Control


AC

Mains

2-18

Figure 2-2 Pump Module & Heat Exchanger Control Panel Connections

STEP 3 Turn OFF the isolator switch on the pump module control panel and the isolator switches on the heat exchanger unit. They will be turned

ON later in the procedure to check for wiring problems.

STEP 4 Connect the control and status wires on the cooling control panel with the supplied multi-conductor cable. These connections are described on the Electrical Installation Drawing. These low level signals connect the terminals in the pump module control panel to the transmitter cabinet. Table 2-6 is a connection reference chart.

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NOTE:

Condensation can occur in the conduits connecting the heat exchanger (outside) and the transmitter (inside). These conduits should be caulked or sealed after the system is tested and operational. Sealing the conduit prevents warm air inside the building from entering the portion of the conduit that is located outside the building.

Table 2-6 Transmitter to Pump Module Control and Status Connections

J1 Customer I/O on

Transmitter

1

2

5

6

3

4

7

8

9

10

11

12

Wire Color

BLK

RED

BLU

WHT

BRN

GRY

TAN

PNK

Pump Module Control Panel

1 - GND

2 - +12 VDC

3 - PUMP_INTLK

4 - PUMP_RUN

5 - SWITCH_PUMP

6 - GND

7 - NC

8 - NC

ORG

YEL

GRN

PUR

9 - PUMP_A_SELECTED

10 - PUMP_B_SELECTED

11 - REMOTE STATUS

GND

These connections should be verified using schematic.

STEP 5 Connect the control and status wires to connector J1 on the customer I/O panel (located at the top of the transmitter) with the supplied multi-conductor cable.

These low level signals, outlined in

Table 2-6, connect from terminals inside the pump module control panel to J1-1 through J1-12 (see Figure 2-3), on the pump module connector at the customer I/O panel on top of the transmitter.

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Interlocks

Status &

Control

Figure 2-3 Customer I/O Pump Module and Interlock Connector on Transmitter

!

CAUTION:

MAXIVA ULX SERIES TRANSMITTERS WILL NOT SUPPORT A WATER COOLED

LOAD USING WATER SUPPLIED BY THE ULX PUMP MODULE. ONLY AIR COOLED

TEST LOADS SHOULD BE USED WITH ULX SERIES TRANSMITTERS.

2.6

Transmitter AC Connection

Refer to the Outline Drawing Top View for details on AC inputs to top of cabinet.

NOTE:

AC Connections will be similar across all cabinets in multi-cabinet transmitter models. Be sure to verify all connections using the correct schematic drawings.

!

WARNING:

DISABLE AND LOCK OUT STATION PRIMARY POWER BEFORE PRIMARY POWER

CABLES ARE CONNECTED TO THE EQUIPMENT.

!

CAUTION:

WHEN CONNECTED TO A 380-415VAC 3 PHASE WYE POWER CONFIGURATION,

NEUTRAL CURRENT CAN BE EQUAL TO OR EXCEED PHASE CURRENTS DUE TO

SWITCH MODE POWER SUPPLY HARMONICS. FINAL INSTALLATION SHALL

ENSURE NEUTRAL CONDUCTOR IS PROPERLY SIZED AND THAT ALL LOCAL

REGULATIONS ARE MET.

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NOTE:

The Maxiva ULX cabinets can use the following AC Mains configurations assuming the jumpers in the backplanes and AC distribution panels are properly configured at the factory:

•

208-240VAC, 3 phase Delta or Wye

•

380-415VAC, 3 phase WYE, with neutral wire

NOTE:

If a 440-480VAC, 3 phase Delta AC supply is required a transformer must be utilized.

2.6.1

Safety Ground

A safety ground wire is required for each AC mains input and they should be connected to the copper ground stud shown in Figure 2-4. The grounding stud on this panel is directly attached to the ground strap that runs from the grounding block located on the cabinet top to the ground block located inside the rear of the cabinet on the floor.

AC Mains

Connections

Safety Ground

Connections

10/6/10

Figure 2-4 Safety Ground Connections Inside Cabinet (rear)

The Maxiva ULX Series transmitters require 3 phase 208/220/240Vac or 3 phase 380/

400/415Vac at 50/60Hz. Voltage, frequency and configuration (Delta or WYE) should be identified at the time order is placed. If voltage variations in excess of ±10% are anticipated, the transmitter power input must be equipped with automatic voltage regulators (optional equipment) capable of correcting the mains voltage.

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2.6.2

AC Connections Procedure


!

CAUTION:

WHEN CONNECTED TO A 380-415VAC 3 PHASE WYE POWER CONFIGURATION,

NEUTRAL CURRENT CAN BE EQUAL TO OR EXCEED PHASE CURRENTS DUE TO

SWITCH MODE POWER SUPPLY HARMONICS. FINAL INSTALLATION SHALL

ENSURE NEUTRAL CONDUCTOR IS PROPERLY SIZED AND THAT ALL LOCAL

REGULATIONS ARE MET.

NOTE:

It is important that the correct voltage, frequency and connection type be specified as the MOV protection board jumpers, IPA backplane jumpers, and PA backplane jumpers are configured different for delta or wye voltage configurations.

STEP 1 Route the Primary AC conduit through clamps at the top of the transmitter cabinet.

The top of the transmitter cabinet has pre-cut holes for clamps to secure conduit to the cabinet as shown in the Outline Drawing.

NOTE:

For the following two steps the access cover at the top of the transmitter and the panel surrounding the circuit breakers in the top rear of the transmitter should be removed to facilitate connection of the AC mains to the transmitter.

STEP 2 Connect the AC wires to the primary AC terminal blocks CB23 and

CB24 (for higher power levels two AC inputs are required) . Refer to the wiring diagram for details on specific power levels. The AC input wires will connect to CB23 and CB24 located behind the access plate on top rear of the cabinet (another panel on the top of the transmitter see Figure

2-9, below must be removed for access). It will be necessary to use a straight slot screw driver to loosen the circuit breaker screws to allow insertion of the cable. Once the cable is in place tighten the screws to secure the cables firmly in place.

!

CAUTION:

BE CERTAIN THAT THE INSULATION ON EACH AC SUPPLY CABLE HAS BEEN

SUFFICIENTLY CUT BACK TO ALLOW FULL CONTACT BETWEEN THE

CONNECTOR BLOCK AND THE COPPER CABLE. FAILURE TO REMOVE THE

INSULATION MAY RESULT IN HEATING AND FAILURE OF THE CONNECTION.

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STEP 3 Connect the safety ground wire to the stud shown in Figure 2-4.

There should be separate safety ground wires for each AC mains input.

AC Primary

Connections

L1 L3

N L1

L2 L3 N

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Figure 2-5 AC Connections to Terminal Blocks CB23 & CB24

STEP 4 Verify that the Primary AC line voltage is correct for the MOV board and jumper configurations.

Measure the primary AC line voltage from phase to phase and write it in the blank below. The transmitter was setup in the factory with 208/220/240VAC Delta or

Wye, or 380/400/415VAC WYE 3 phase configuration on the IPA and

PA backplanes, on TB1 and TB2 on the AC distribution panel, on the

MOV boards, and by including a neutral connection from the AC service disconnect to CB23 and CB24 for 380 to 415 VAC WYE connections. Make sure that the transmitter is setup for the same AC power configuration that is used at the site. Check the on site measured

AC voltages against the factory test data sheet or the metal ID plate affixed to the transmitter cabinet.

STEP 5 Record measured voltage for each phase and record them below.

1 to 2: VAC

2 to 3: VAC

1 to 3: VAC

NOTE:

There must be less than a 10% imbalance between any one phase and the average of all three phases to allow the transmitter to operate, however the phase imbalance and frequency variation must be 5% or less to meet transmitter specifications.

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2.6.3

Checking AC Configuration


The voltage specifications on the transmitter ID panel should be compared to the supply voltages to be sure they are compatible. Should questions arise the jumpers in TB1 and

TB2 on the AC distribution panel, the IPA and PA backplane jumpers (TB1, TB2, and

TB3), the MOV board jumpers, and the possible neutral connection from the AC service disconnect to CB23 and CB24 can be verified. These jumpers are described in the Wiring Diagram, PA Cabinet Main Maxiva ULX 843-5601-001. Select the proper diagram for the system that is being used. Use the wiring diagrams for proper set up.

The connections are also briefly described below.

•

Terminal boards TB1 and TB2 on the AC distribution panel.

Figures 2-7 and 2-8, referred to below, contain outline drawings of TB1 and TB2, with black boxes representing the jumpers between segments. The critical jumpers are indicated by the dashed boxes around them.

2.6.3.1

TB1 TB2 Jumpers 1 Cabinet 10 -16 Modules

For 208 to 240 VAC connections in Delta or WYE, TB1 and TB2 have a jumper between terminals 5 and 6, and none between 6 and 7, see Figure 2-7, top.

For 380 to 415 VAC, connection must be WYE and the jumper is removed from between terminals 5 and 6 and installed between terminals 6 and 7, see Figure 2-7, bottom.

2.6.3.2

TB1 TB2 Jumpers 1 Cabinet 1 - 8 Modules

For 208 to 240 VAC connections in Delta or WYE, TB1 has a jumper between terminals

5 and 6, and none between 7 and 8, see Figure 2-8, top.

For 380 to 415 VAC , connections must be WYE and the jumper is removed from between terminals 5 and 6 and installed between terminals 7 and 8, see Figure 2-8, bottom.

Correct positioning of the jumpers ensures that 208 to 240 VAC is always applied to circuit breakers CB19 through CB22.

•

Parallel MOV boards (A15A1 & A15A2). MOV board jumpers are shown on sheet 8 of the PA Cabinet Main Wiring Diagram, drawing number 843-5601-001.

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•

Driver and PA backplane boards. On the IPA and PA backplane boards, drawing numbers 801-0222-131 and 801-0222-101 respectively, the jumpers on TB1, TB2, and TB3 are connected between terminals 2 and 3 for 208 to 240 VAC Delta or WYE and connected between terminals 1 and 2 for 380 to 415 VAC Wye connections.

•

A neutral connection is required, from the AC service entrance to CB23 and CB24 (if used) for the 380 to 415 volt WYE connection, but no neutral connection is required for the 208 to 240 volt Delta or WYE connections. 440 to 480 VAC Delta or WYE connections require a step down transformer .

Figure 2-6 is a photo of the TB1 and the MOV board (on the left). These terminal boards need to be properly jumpered depending on the AC mains voltage. Figure 2-7 and Figure 2-8 are sketches that show the various configurations of the MOV and terminal block jumpers depending on AC mains and number of PA modules used in the transmitter. The MOV’s and TB’s are accessed by removing a cover plate on the top of the transmitter cabinet at the rear.

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MOV


Jumper

TB1

Figure 2-6 Photo of MOV & TB1

Figure 2-6 shows an AC distribution panel removed from the transmitter. TB1 in this case is for an amplifier cabinet with 8 modules or less.

NOTE:

The dashed rectangles in Figure 2-7 and 2-8 indicate jumpers that need to be moved to change between 208-240V and 380-415V operation.

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MOV

Board

L1 L2

TB1

N L3 L1 L2

TB2

N

MOV

Board

L3

1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11

Ground

Block

AC Power

Entrance

AC Power

Entrance

Top View of Back of PA Cabinet, Jumpered for 208 to 240 VAC Delta or WYE

MOV

Board

L1 L2

TB1

N L3 L1 L2

TB2

N

MOV

Board

L3

1 2 3 4 5 6 7 8 9 10 11 1 2 3 4 5 6 7 8 9 10 11

Ground

Block

AC Power

Entrance

AC Power

Entrance

Top View of Back of PA Cabinet, Jumpered for 380 to 415 VAC WYE

Figure 2-7 TB1 and TB2 Jumpers For Single Cabinet With 10, 12, or 16 PA Modules

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2-27


MOV

Board

L1 L2

TB1

N L3


1 2 3 4 5 6 7 8 9 10 11 12

Ground

Block

AC Power

Entrance

AC Power

Entrance

Top View of Back of PA Cabinet, Jumpered for 208 to 240 VAC Delta or WYE

MOV

Board

L1 L2

TB1

N L3

1 2 3 4 5 6 7 8 9 10 11 12

Ground

Block

AC Power

Entrance

AC Power

Entrance

Top View of Back of PA Cabinet, Jumpered for 380 to 415 VAC WYE

2-28

Figure 2-8 TB1 and TB2 Jumpers For Single Cabinet With 1 to 8 PA Modules

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2.7

Signal and Ground Connections


NOTE:

Control and signal wires should never be run in the same conduit with any AC wiring. A separate conduit should be used for control/signal cables.

STEP 1 Connect the RF Inputs to the customer I/O panel at the top of the transmitter (see Figure 2-9).

Figure 2-9 Customer I/O Panel (top of transmitter)

NOTE:

Refer to the Apex M2X technical manual for RTAC sample levels.

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2-30

Table 2-7 Customer I/O panel Connections for Exciter A

J4

J5

J6

J7

J8

Jack

J1

J2

J3

Connector

SMA - 50

Ω

BNC - 50

Ω

BNC - 50

Ω

BNC - 75

Ω

BNC - 75

Ω

BNC - 75

Ω

BNC - 75

Ω

BNC - 75

Ω

Label

GPS (antenna)

1PPS

10 MHZ

ASI HP1

ASI LP-1

310 HP-2

310 LP-2

TS Loop Out

Table 2-8 Customer I/O panel Connections for Exciter B

J4

J5

J6

J7

J8

Jack

J1

J2

J3

Connector

SMA - 50

Ω

BNC - 50

Ω

BNC - 50

Ω

BNC - 75

Ω

BNC - 75

Ω

BNC - 75

Ω

BNC - 75

Ω

BNC - 75

Ω

Label

GPS (antenna)

1PPS

10 MHZ

ASI HP1

ASI LP-1

310 HP-2

310 LP-2

TS Loop Out

STEP 2 Connect sample cables from Forward and Reflected directional couplers (at the system output, after the filter), from reject load directional couplers, and from the PA RTAC to the customer I/O panel at the top of the cabinet.

These samples are listed in Table 2-9. If necessary, these samples will be calibrated using the GUI after initial turn-on (see "5.8 Power Calibrations" on page 5-15). These sample cables are not supplied since the required length is determined at each site.

NOTE:

Refer to the Apex M2X technical manual for RTAC sample levels.

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Table 2-9 RF Samples Connections on Customer I/O Panel

Jack

J17

J18

J19

J20

J21

J22

Connector

N - 50

Ω

N - 50

Ω

N - 50

Ω

N - 50

Ω

N - 50

Ω

N - 50

Ω

Label

SYS FWD

SYS REF

REJECT 1

REJECT 2

REJECT 3

PA RTAC

NOTE:

J23 is the WAN/LAN connector.

STEP 3 Connect a ground strap from each cabinet’s E1 block (located at the bottom, rear, center inside each cabinet) to the station ground.

The

E1 block is shown in Figure 2-10. A roll of copper strapping is shipped with the transmitter. Roll this strap out and attach it beneath the cabinet ground block in the cabinet and to station ground on the other. If any additional copper strap is needed, it must be at least 5cm wide and

0.5mm thick.There is an additional E1 block located on top of each cabinet (see Figure 2-9) for additional grounding as needed.

Cabinet

Ground

Figure 2-10 Cabinet Ground Connection Block

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2.8

Intercabinet Connections


For multi-cabinet transmitter models ULX-12800**, ULX-17000** and ULX-

24600**, the inter cabinet connections will need to be installed next. See Intercabinet

Wiring Diagram for reference.

2.9

External Interlock Connections

2.9.1

Interlock Connector on Customer I/O Panel

The interlock connector (12 pin) is located on the customer I/O panel at the top of the transmitter. The WAGO style connector has contacts for up to four external interlocks.

Two are fault-off interlocks named System Safety Interlock and Cabinet Safety Interlock. The other two are RF-mute interlocks named System RF Mute Interlock and Cabinet RF Mute Interlock. More interlocks may be incorporated by placing 2 or more interlocks in series. The transmitter is shipped from the factory with jumpers in the external interlock positions which will allow the transmitter to operate without external interlock connections.

The Electrical Installation drawing shows that Interlock #1, J2-2 to J2-3, is used by a 3

Port Patch Panel or possibly a motorized switch. The External Interlock circuits requires a closed connection on the following interlock connector terminals to allow the transmitter to turn on:

•

J2 pins 2-3 System Safety Interlock (for 3 Port Patch Panel or switch)

•

J2 pins 5-6 System RF Mute Interlock (for load thermal interlock)

•

J2 pins 8-9 Cabinet Safety Interlock

•

J2 pins 11-12 Cabinet RF Mute Interlock

2.9.2

Fault-Off Interlocks (Safety Interlocks)

System Safety interlocks are Fault-Off interlocks and will shut the transmitter off if opened. They are provided for use in protection of personnel. Cabinet Safety interlocks are also Fault-Off interlocks and can be used in multi-cabinet transmitters to Fault-Off individual PA cabinets. A manual turn on is required to recover from the Fault-Off conditions caused by System or Cabinet Safety interlocks.

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Table 2-10 J2 Interlock Connector on Customer I/O Board

Pin Number

1

2

3

6

7

4

5

10

11

8

9

12

Description

NC

System Safety Interlock

System Safety Interlock Return

NC

System RF Mute Interlock

System RF Mute Interlock Return

NC

Cabinet Safety Interlock

Cabinet Safety Interlock Return

NC

Cabinet RF Mute Interlock

Cabinet RF Mute Interlock Return

2.9.3

RF Mute External Interlock Connections (J2)

There are 2 interlock connections that can be used to apply a temporary RF Mute condition (vs. a Fault-Off condition as discussed above). The transmitter will RF mute when the interlock is open and automatically unmute when the interlock is restored to a close condition. These are:

•

J2-5 to J2-6 (for test load thermal interlock)

•

J2-11 to J2-12

!

WARNING:

RF MUTE INTERLOCKS SHOULD NOT TO BE USED IN ANY SITUATION WHERE

PROTECTION OF PERSONNEL IS DESIRED.

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J2 Interlock

Connector

The transmitter is shipped from the factory with jumpers in the RF Mute interlock positions on J2 which will allow the transmitter to operate without external interlock connected.

2.10 3 Port Patch Panel Connections

Refer to the Electrical Installation drawing for Patch Panel connections.

!

CAUTION:

ALWAYS SHUT THE TRANSMITTER OFF BEFORE REMOVING THE PATCH PANEL

TO PREVENT POSSIBLE DAMAGE TO THE CONTACTS.

2.11 Initial Cooling System Turn ON

2-34

The liquid cooling system (external to the transmitter) consists of a one or two fan air cooled heat exchanger (depending on model), two pumps and an integrated electrical control system. Typically, cabinets with eight PA modules or more will use a two fan heat exchanger unit. Cabinets with less than eight modules would use a single fan fan unit.

Fan control is by an electronic controller. The controller automatically turns fans on and off according to sensed temperature in the cooling system piping. Additionally, each fan can be turned off by an isolator switch on the heat exchanger to allow for maintenance.

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Pump operation is automatically controlled using a PID process/termperature controller

(PID is short for proportional integral derivative). There are two modes of pump operation, “Local”, and “Remote”. The PID controller interfaces with the transmitter’s

“Pump Control Interface” (PCI). The controller receives signals from the PCI and sends signals to the PCI.

NOTE:

For additional Cooling System start up information see the pump module/heat exchanger manufacturer’s technical manuals, one for the pump module & heat exchanger and another for the PID controller, and Appendix B section.

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2.11.1 Heat Exchanger & Pump Module

Start-up and Maintenance

The electrical installation should have already been completed and should be in accordance with the National Electrical Code and any local codes and regulations. The incoming power supply can be 208 to 240V-3Ph-50 or 60Hz, or 380 to 415V-3Ph-50 or

60Hz. Exact line voltage and configuration should be specified at the time the order is placed. Fan and pump motors are three phase and have current overload protection.

Overload protection for the motors is achieved via current limiters in the electrical control panel.

Prior to start-up, each fan motor should be checked for freedom of movement and that the fan blade is securely fastened to its fan motor shaft. All motors have been synchronized at the factory. Pump and fan direction of rotation must be checked at the initial power up of the pump module and heat exchanger. Verification of pump and fan rotation is outlined in "Section 2.11.1.1” on page 2-38.

!

CAUTION:

INCORRECT (REVERSE) ROTATION OF THE PUMPS OR FANS WILL CAUSE POOR

COOLANT OR AIR FLOW AND DAMAGE TO THE PUMPS. CORRECT PUMP OR FAN

ROTATION BY SWITCHING ANY TWO INCOMING AC PHASES. DO NOT ALTER ANY

PANEL WIRING TO CHANGE PUMP OR FAN DIRECTION

Fans and motors are direct connected. Motors are permanently lubricated for the life of the motor. Use compressed air (low pressure) to clear dust and debris from the coil. Fin material is sensitive; DO NOT WIRE BRUSH!

Mild cleaning solution or low pressure steam cleaning may be used to clean the unit.

All pumps have maintenance-free pump seals.

NOTE:

Job site environmental conditions should be evaluated periodically to assure coil and component life expectancy. Schedule maintenance activities to accommodate changing environmental conditions at the site.

STEP 1 Turn the AC mains to the transmitter cabinets and pump module

OFF at the main breaker or fuse box. Also turn off the isolator switches at the front of the cooling control panel and on the heat exchanger.

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STEP 2 Close cabinet supply and return line valves . Keep closed until initial leak testing, is completed to keep contaminants out of the combiner and splitter chiller plates.

STEP 3 Open cabinet(s) bypass valve(s). The cabinets should remain bypassed until leak testing is complete.

STEP 4 Close all cabinet manifold drain valves .

STEP 5 Open all system supply and return valves.

Opening the system valves allows coolant to flow through the entire system except for the cabinets.

STEP 6 Fill the cooling system with distilled water.

The cooling system must be initially charged with distilled water to a static pressure of 10 PSIG.

This is accomplished by attaching the charging pump to a low point in the coolant system or to the fill connection on the pump module assembly (see Figure 2-1). As the system is charged with water air will be bled from the automatic purger. Additional air can be bled from the system by opening vents located at system high points until water comes out of each vent. During the filling and bleeding operation, keep the static pressure at or slightly below 10 psig. The static pressure will drop as air is bled from the system. Once air bubbles stop forming in the sight glass and the sight glass is full of liquid turn off the charge pump.

a.

Record the amount of liquid required to initially fill the system, including the make up water required when the pumps have been run and the remainder of air is bled from the system. This information will be used later, during flushing, to determine the amount of trapped water remaining in the system after it is drained.

One method of tracking the amount of coolant used in the system is to start the fill process with a 30 gallon container (clean 30 gallon plastic garbage can will work). Fill the container with distilled water to a level about two inches below the rim. Mark this initial full level with a permanent marker. Use a suction filter attached to the inlet side of the charge pump and draw water for the initial fill from the container and mark the new level. The difference between the full mark and this mark is the system capacity.

After the initial rinse and leak tests drain the system back into the container and mark that level. The difference between the initial full level and this new level is the amount of water trapped in the system. This trapped value can be used later when adding the glycol water solution. Extra glycol will need to be added to account for this trapped water in the system to get the specified 50/50 glycol/water mixture desired.

NOTE:

Static pressure is the system pressure measured with the pumps deenergized.

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!

CAUTION:

IF FREEZING CONDITIONS EXIST DURING CHECKOUT AND FLUSHING

PROCEDURES, THE FLUSHING PROCEDURE AND SUBSEQUENT FILL WITH FINAL

GLYCOL/WATER MUST BE FINISHED BEFORE STILL WATER IS ALLOWED TO

REMAIN IN HEAT EXCHANGER. IF PROCEDURE CANNOT BE FINISHED, CARE

MUST BE TAKEN TO PREVENT WATER FROM FREEZING IN OUTSIDE COOLING

SYSTEM EQUIPMENT. SHOULD A DELAY BE ENCOUNTERED DURING THE

FLUSHING/CLEANING PROCESS THE HEAT EXCHANGER COULD BE COVERED

WITH A TARP AND HEAT APPLIED FROM AN EXTERNAL SOURCE LIKE A

PORTABLE HEATER (WITH THE PUMP RUNNING) TO PREVENT THE WATER

FROM FREEZING UNTIL FLUSHING CAN BE RESUMED (SEE PARAGRAPH 2.11.1.1,

STARTING PUMPS & CHECKING PUMP ROTATION). IF WATER REMAINS IN

OUTSIDE EQUIPMENT LONG ENOUGH TO FREEZE, THE UNITS WILL BE

DAMAGED. PUMP A MIXTURE OF GLYCOL/WATER INTO OUTSIDE EQUIPMENT

TO PREVENT DAMAGE.

!

CAUTION:

THE USE OF DISTILLED WATER IS SUGGESTED ONLY FOR VERY SHORT TERM

TESTING. THE SYSTEM IS DESIGNED TO OPERATE ON A 50/50 MIXTURE OF

DISTILLED WATER AND PROPYLENE OR ETHYLENE GLYCOL. THE 50/50 MIXTURE

IS REQUIRED FOR PROPER SYSTEM PERFORMANCE. THE GLYCOL/WATER

RATIO SHOULD BE VERIFIED, PREFERABLY WITH AN OPTICAL

REFRACTOMETER.

NOTE:

The system cannot be filled to full capacity at this time. Water must be added as pumps are run and air is bled from the system. Refer to section 2.11.1.1 before attempting to energize the pumps. Monitor the sight glass throughout this process for air bubbles and presence of coolant.

STEP 7 Check heat exchanger fans to be sure they are free to rotate without obstruction.

2.11.1.1 Starting Pumps & Checking Pump Rotation

It is necessary to verify pump rotation of both pumps. If rotation is incorrect fluid flow will be low and the pump could be damaged.

!

WARNING:

TO AVOID DAMAGE TO PUMPS, OPERATE THEM FOR 5 SECONDS OR LESS IF

PUMPS ARE RUNNING DRY OR THEIR ROTATION IS INCORRECT.

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STEP 1 Turn the AC (isolator) switch on the Cooling Control Panel to OFF.

AC power from the AC mains at the main breaker is routed to the Pump

Module and then to the Heat Exchanger via the AC Isolator switch on the Cooling Control Panel. Pumps and fans each have separates contactors and current limiters as shown in the pump module & heat exchanger wiring diagram provided by the manufacturer. The wiring diagram can be found in the manufacturer’s technical manual shipped with the unit. A typical wiring diagram is also shown in Figure 4-19 on page 4-45.

STEP 2 Energize the AC mains supply to the Cooling Control Panel .

STEP 3 Turn the Local/Off/Remote switch on the Cooling Control Panel to

Local .

STEP 4 a.

There are two operational modes for the cooling system: Local and

Remote. The selection is made on the Cooling Control Panel.

b.

In the Remote mode, pump startup and changeover is controlled by the transmitter. c.

In local, the pump control panel selects the pump, the selected pump will run when the AC (Isolator) switch in the front of the cooling control panel is set to ON.

1.

When active, the pump interlock will deenergize the pumps in either the local or remote modes. The pump interlock is activated by the transmitter leak detector when it senses a cooling system leak in the transmitter cabinet.

d.

While in Local the operating pump is selected on the cooling control panel using the Pump Select switch. The local mode can be used for start-up, testing and troubleshooting.

Have an assistant momentarily turn ON the AC (isolator) switch on the Cooling Control Panel for 5 seconds or less. The green Pump Run lamp for either Pump A or B on the Cooling Control Panel should illuminate briefly.

STEP 5 While the selected pump is coasting to a stop, verify its rotation . The pump rotation can be verified by noting the direction of shaft rotation at the front of the pump relative to the rotation arrow marked on the top of the pump covers.

STEP 6 Select the alternate pump by pressing the Pump Select button and then having an assistant momentarily turn ON the AC (isolator) switch on the Cooling Control Panel for 5 seconds or less. The green

Power On lamp for the alternate pump should illuminate momentarily on the Cooling Control Panel.

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STEP 7 While the alternate pump is coasting to a stop, verify its rotation .The pump rotation can be verified by noting the direction of fin rotation at the back of the pump relative to the rotation arrow marked on the pump cover.

STEP 8 If rotation of both pumps are incorrect, remove and lockout primary power, then reverse two of the incoming AC mains phases.

STEP 9 Repeat steps 5 through 7 to verify correct rotation of both pumps.

STEP 10 If the rotation of only one pump is incorrect, r emove and lockout primary power, then reverse two of the AC phases to that pump.

STEP 11 Repeat 4 through 5 or 6 through 7 to verify correct rotation of the formerly incorrect pump.

2.11.1.2 Starting Fans & Checking Fan Rotation

It is necessary to verify rotation of both heat exchanger fans. If rotation is incorrect air flow will be low and the cooling system will not cool properly.

STEP 1 The proper rotation of both pumps should be confirmed prior to checking fan rotation.

See 2.11.1.1

STEP 2 Energize the AC mains supply to the Cooling Control Panel .

STEP 3 Turn the Local/OFF/Remote switch on the Cooling Control Panel to

Local .

STEP 4 Turn the heat exchanger fans switch to Manual.

STEP 5 Turn ON the AC (isolator) switch on the cooling control panel.

STEP 6 Briefly Turn ON the AC (isolator) switch on the Heat Exchanger fan being checked.

STEP 7 While the selected fan is coasting to a stop, verify its rotation . The fan rotation can be verified by noting the direction of blade rotation relative to the rotation arrow marked on the side of the fan connection box. Improper fan rotation can be corrected by changing any two of the phases (inside the control panel) supplying the fan.

STEP 8 Activate the other fan by briefly turning ON AC (isolator) switch near the heat exchanger fan being checked.

STEP 9 While the selected fan is coasting to a stop, verify its rotation . The fan rotation can be verified by noting the direction of blade rotation relative to the rotation arrow marked on the side of the fan connection

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Maxiva ULX COFDM Series Section 2 Installation box. Improper fan rotation can be corrected by changing any two of the phases (inside the control panel) supplying the fan.

2.11.2 Initial System Leak Tests

During the leak tests in the following steps, check the static pressure of the cooling system while the pumps are momentarily deenergized. During pump operation the static pressure of the system will drop as the air purger and automatic air vents bleed trapped air from the system. With the pumps deenergized, the cooling system must be charged with coolant to a pressure of 10 psig. This is accomplished by attaching the charge pump to a low point in the system or to the charge point (see Figure 2-1) in the pump module assembly and pumping in additional water until the static pressure again reaches 10 psig

NOTE:

System flow can be monitored by viewing the sight tube which is located atop the system air purger. Low coolant level or the presence of bubbles in the sight tube indicates air in the system and a need for recharging the system with additional coolant.

STEP 1 Turn on pump A for several minutes.

Upon the establishment of a steady (no air bursts) volume of water throughout the system, begin visual check for leaks. Turn off Pump A after thorough leak checks.

STEP 2 Turn on pump B for several minutes.

Upon the establishment of a steady (no air bursts) volume of water throughout the system, continue visual check for leaks. Turn off Pump B after thorough leak checks.

NOTE:

If flow is insufficient, the flow switch will activate and turn the pumps off for protection

STEP 3 Check immediately for any leaks at the following cooling system points .

•

Transmitter inlet and outlet pipe connections

•

Pump module inlet and outlet pipe connections

•

Heat exchanger inlet and outlet pipe connections

•

All solder joints, system valves and drain valves

STEP 4 Repair any detected leaks. If leaks have developed, depending upon the given leak’s location, water may have to be drained from the system before making repairs.

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2.11.3 Initial System Cleaning


Once the cooling system has been determined to be free of leaks it will have to be cleaned and flushed before continuing the installation.

STEP 1 Create cleansing solution. Using a mixture of distilled water (see

Appendix B) and a cleaning solution (a mixture of 2 cups of a trisodium phosphate-based low sudsing detergent, such as Cascade, mixed in 2 gallons of water), proceed with the following steps.

NOTE:

The detergent must be thoroughly mixed and dissolved into the water. The presence of undissolved detergent particles in the cleaning solution can cause problems in the cooling system. The particles can be trapped in valves and flow meters causing malfunctions to occur.

STEP 2 Drain system of all water.

Monitor the level of water that is returned to the container to determine trapped water in system. To more easily drain the system open all of the system and cabinet drain and vent valves.

Once draining is complete close all cabinet drain valves. The charge pump can be reversed to aid in draining the system.

NOTE:

To facilitate draining one or more vent valves at high points in the system must be opened.

STEP 3 Use a marker to note the level of the liquid in the container.

The difference between this level and the previous low level is the amount of liquid required to completely refill the system. Empty the container and refill (to the same level) with clean distilled water.

STEP 4 Pour the cleaning solution through a porous cloth (to filter out clumps of detergent) into the container containing clean distilled water and mix thoroughly.

STEP 5 Use the charge pump to fill the system with the cleaning solution.

Monitor the sight glass to confirm fluid level and lack of air bubbles before turning off charge pump . Insure that a static pressure of 10 psi is achieved (with pumps off) .

STEP 6 Run the system for 40 minutes. Alternate pumps A and B for 20 minutes each.

STEP 7 Turn off pump. Close bypass valve and open cabinet intake and outlet valves to allow cleaning solution to flow through transmitter cabinet.

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STEP 8 Run the system for an additional 20 minutes. Alternate pumps A and

B for 10 minutes each. Note flow rate of system.

STEP 9 Drain the system . To drain the system open the drain hoses and the system vent valves. Once draining is complete close all drain and vent valves.

STEP 10 Dispose of cleaning solution in container and rinse.

Refill the container with clean distilled water.

STEP 11 Clean the pump module strainer screen. The strainer is located near the pressure gauge on the return side of the pump module.

2.11.4 System Flushing

Flush the system to remove the cleaning solution. Before the initial transmitter operation the cooling system must be purged of all cleaning solution residue.

The flushing is accomplished by alternately filling, running and draining the system, two to four (or more if needed) times using distilled water. The following steps outline the flushing process.

NOTE:

The length of flushing time and number of fill/drain cycles needed to achieve desired water quality will vary with system size and the amount of residual

(trapped) liquid in the system. Residual liquid is trapped in the system and cannot be removed when the system is drained. Smaller systems with less residual liquid may require a lower number of flush cycles.

STEP 1 Fill system with distilled water (see appendix section "B.1 Coolant and

Water Recommendations" on page B-1) .

STEP 2 a.

Confirm previous estimates of the amount of liquid required to fill the system.

Run system for approximately 20 minutes. Alternate pumps A and B for 10 minutes each.

STEP 3 Drain system . Drain valves must be opened at each low point in the system, along with the vent valves at the system high points, to ensure full drainage.

STEP 4 Repeat above steps (flushes) until coolant is clear of contaminants and detergent residue. Typically 3 distilled water flushes are needed.

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2.11.5 Final Cooling System Fill


2-44

!

CAUTION:

THE SYSTEM MUST BE TESTED FOR LEAKS AGAIN ONCE THE REQUIRED 50/50

GLYCOL/WATER MIXTURE HAS FILLED THE ENTIRE SYSTEM. A GLYCOL/WATER

MIXTURE WILL EXPOSE SMALL LEAKS WHICH ARE NOT EVIDENT WHEN TESTING

FOR LEAKS WITH PURE WATER OR AIR.

STEP 1 Charge the cooling system with equal amounts of glycol and water

(see section "B.1 Coolant and Water Recommendations" on page B-1).

The amount of residual water in the system must be taken into account when adding glycol and water to the system. The amount of residual water (water that remains trapped in the system and can’t be readily removed by opening drain valves) and will vary from system to system.

The amount of residual water can be estimated if the amount of initial fill water (recorded earlier) was tracked and compared to the amount of re-fill water required during the flushing, this was also recorded earlier.

If the amount of residual water is significant and is ignored the concentration of coolant may be less than the specified 50/50 mixture.

Extra glycol, equal to the amount of trapped water in the system, must be added in order to achieve the proper glycol water mixture.

STEP 2 Run pumps for several minutes and open vent valves to remove all air from the system.

Alternate pumps A and B.

STEP 3 During the final system fill with the coolant/water mixture, frequently check the static pressure of the cooling system with the pumps deenergized.

During pump operation the static pressure of the system will drop as the trapped air is bled from the system. With the pumps deenergized, the cooling system must be charged with coolant mixture to a pressure of 10 psig. This is accomplished by attaching a small pump to a low point in the system or to the pump fill connection

(see Figure 2-1 on page 2-16) on the pump module assembly and pumping in additional coolant mixture until the static pressure reaches

10 psig.

STEP 4 Recheck system for leaks.

STEP 5 Repeat steps 1 through 4 until coolant level has stabilized.

STEP 6 Check system sight tube to be sure that all air has been vented and the system is full of coolant.

Drain a sample of coolant from the system and check the 50/50 mixture. Use a conventional float hydrometer and jar or a MISCO DFR 200 or equivalent digital refractometer to verify

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Maxiva ULX COFDM Series Section 2 Installation the 50/50 mixture. The hydrometer should be capable of measuring specific gravity in the 1.02 to 1.08 range. Information regarding specific gravity measurement is given in Appendix B.

2.12 Install PA Modules

STEP 1 Be sure the PA power supply breakers (in rear of cabinet as shown in Figure 2-11) are in the OFF position.

10/6/10

Figure 2-11 PA & IPA (driver) Module Circuit Breakers

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!

WARNING:

THE PA MODULES ARE LARGE AND RELATIVELY HEAVY, WEIGHING APPROXI-

MATELY 26.5KG. (59 LBS) CARE SHOULD BE TAKEN TO AVOID PERSONAL INJURY

AND/OR DAMAGE TO THE MODULES.

STEP 2 Prior to inserting modules remove all packing surrounding the connectors in rear of the PA cabinet and be sure that all connectors on the module are undamaged and free of debris of any kind.

STEP 3 Refer to the factory test data to identify which modules go in which slot location.

Refer to the outline drawing to identify slot numbers and module locations. Module location will vary with transmitter model and is outlined in "Table 5-1 PA Slot Allocations for Single Cabinet Models" on page 5-2.

STEP 4 Unpack and install the PA modules into the front of the transmitter cabinet.

Be sure to position the module so the RF connector is to the left rear as you slide it into the rack. When lifting modules, rather than lifting the modules with one hand on each side of the module, it may be easier to place one arm beneath the module, supporting it with that arm while holding the side of the module with your other hand.

NOTE:

The IPA (driver) and PA Modules can be placed into any of the IPA (driver) or PA module slots but it is advisable to place them in the same location as they were tested in. The module location is given in the factory test data which ships with each transmitter.

STEP 5 Apply pressure to the front of each module to make sure it is fully seated.

To make sure all the connections are made press each of the modules toward the rear, being sure that the module is fully seated and then tighten the module hold down screws with a #3 phillips screwdriver.

!

CAUTION:

IF THE MODULES DO NOT SEAT WITH MODERATE PRESSURE REMOVE THE

MODULE TO CHECK FOR INTERFERENCE. IF MISALIGNMENT IS SUSPECTED SEE

THE MODULE/RACK ALIGNMENT PROCEDURE IN SECTION 5. DO NOT FORCE

MODULES INTO THE RACK AS THIS MAY CAUSE DAMAGE TO THE WATER OR RF

CONNECTORS ON THE BACK OF THE MODULE OR IN THE RACK.

2-46

!

WARNING:

THE MAXIVA PA MODULES ARE DESIGNED TO HANDLE VERY HIGH TEMPERA-

TURES AND MAY BE EXTREMELY HOT, UP TO 32

O

C (90

O

F) ABOVE ROOM TEM-

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PERATURE. DO NOT TOUCH THE MODULES WITH BARE HANDS AFTER THE

TRANSMITTER HAS BEEN RUNNING. SPECIAL GLOVES CAN BE OBTAINED FROM

HARRIS, PART #0990006483 OR GRAINGER ITEM #4JF36. PRIOR TO MODULE

REMOVAL TURN OFF THE PA MODULE CIRCUIT BREAKER IN THE REAR OF THE

CABINET AND THEN ALLOW THE MODULE TO COOL FOR 30 SECONDS BEFORE

REMOVAL FROM THE RACK.

STEP 6 Verify all drain and vent valves are closed and make sure all coolant system globe, gate and ball valves in the cooling loop are open before proceeding with the initial turn on .

STEP 7 Verify that the static pressure of the liquid cooling system is at 10 psig before the initial turn on. Check the sight tube to verify the coolant level and lack of air bubbles.

NOTE:

Each PA module that is installed may introduce air into the system. The system will likely need to be recharged after modules are installed. The site glass should be checked for fluid level and for air bubbles prior to turning on the transmitter

RF. Low coolant level or bubbles in the sight glass indicate that the cooling system needs to be recharged.

2.13 Initial Turn-On

Read and understand the entire initial turn-on procedure before starting. Detailed use of all GUI screens is given in.

STEP 1 Insure that the 3 phase AC mains has been connected to the transmitter and cooling system.

Be ready to quickly disconnect the power if necessary.

STEP 2 Engage the primary AC breaker switch(es) CB23 & CB24 on the AC

Mains Input Assembly at the rear of each transmitter cabinet.

STEP 3 Turn on the Control circuit breakers CB19 and CB20. The Control breakers are located at the cabinet rear, on the AC Mains Input

Assembly A15. This will activate the TCU power supplies, fans, and predrivers.

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2-47


Figure 2-12 Home Page

STEP 4 Turn on Exciter circuit breakers CB21 & CB22.

STEP 5 Check the TCU Low Voltage power supplies and AC Mains voltages.

Press the PS (power supply) button to view the PS screen shown in

Figure 2-13. Check for +5, +3.3, +5 and +/-VA levels. The AC Mains readings should be close to the measured AC voltages.

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Figure 2-13 Power Supply Screen

STEP 6 Press the PS FAULTS button to check for power supply faults. There should be no red indications or faults present. If a fault is present, see

Section 6, Diagnostics for more information.This screen is shown in

Figure 2-14

NOTE:

A COMMON FAULT IS A 3 PHASE SEQUENCE FAULT, INDICATING THE

3 PHASES HAVE BEEN CONNECTED IN THE WRONG SEQUENCE. IF

THIS IS PRESENT, REMOVE ALL PRIMARY POWER TO THE TRANS-

MITTER AND SWITCH ANY 2 WIRES ON TRANSMITTER TERMINAL

BLOCK CB23 & CB24.

The 3 phase AC sequence fault can be displayed for either AC1 or AC2 inputs on the

PS Faults screen. When faulted the AC Phase Sequence line is displayed with a red background.

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Figure 2-14 PS Faults Screen

STEP 7 Customize the transmitter System Setup.

SYSTEM>SERVICE>SYSTEM SETUP on the GUI. The System Setup screen displays the settings for Sys Pwr Out, Center Frequency,

Modulation Type, AC Line Volt (VAC), Number of exciters, Number of

Cabinets and System Setup Entry. Touch the screen at each field to enter the data pertinent to the setting. Once all the correct information in this screen has been entered, press the CONFIG button. This screen is shown in Figure 3-22 on page 3-26.

STEP 8 Customize the cabinet Setup.

Press SYSTEM>SERVICE>SYSTEM

SETUP>CABINET SETUP on the GUI. Touch the screen at each field to enter the correct data for CAB Pwr Out (W), Number of PA’s,

Number of IPA’s and Cooling Pumps (number present).

2.14 Final Cooling System Turn ON

Use the following steps to complete the cooling system turn on:

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2.14.1 Setting the Transmitter Flow Rate


ULX-1100**

ULX-1700**

ULX-2300**

ULX-3400**

ULX-4400**

ULX-5500**

ULX-6500**

ULX-8700**

ULX-9500**

STEP 1 Check the transmitter flow rate. Press SYSTEM>SYSTEM

COOLING>COOLING METERS. The first line shows the transmitter flow rate.

STEP 2 Adjust the Flow Rate if necessary. Adjust the inlet valve for the transmitter cabinet until the flow rate indicated on the GUI matches the nominal flow rate of the transmitter model as shown in the table below or as indicated in the Liquid Cooling System Layout drawing

NOTE:

Actual flow rate may deviate from nominal depending on site specifics like pipe diameter, number of elbows, and run length. The flow rate must be above the trip point level in order to prevent frequent faults and pump switches. Refer to the

Outline drawing and Plumbing layout drawing for more details.

Table 2-11 Cooling System Flow Rates

MODEL NOMINAL TRANSMITTER FLOW RATE

ULX-12600**

ULX-17400**

ULX-1890**

ULX-26100**

38 liters per minute






121.0 liters per minute

129.0 liters per minute

121.0 liters per minute - for 12 PA cabinet

65 liters per minute - for 6 PA cabinet

121.0 liters per minute - for each cabinet




53

70

53

70

53

70

53

30

Trip Point

(LPM)

15

19

23

30

38

46

PA Modules

(12+12)

(16+16)

(12+12+12)

(16+16+16)

8

10

12

16

(12+6)

4

6

2

3

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NOTE:

If the pump is unable to deliver the required flow rate, check for correct wiring of the 3 AC phases. Incorrect wiring of the 3-phase sequence would cause the pumps to operate but with much degraded performance. If this is the case, see

"2.11.1.1 Starting Pumps & Checking Pump Rotation" on page 2-38 .

STEP 3 Verify that the flow switch operates correctly by decreasing the amount of flow through the cabinet.

The flow warning should activate and the system should switch to the other pump if set to Automatic. If set to Manual the pump will shut down.

STEP 4 Go back to the nominal flow rate recommended for the cabinet. The warning should go away.

2.14.1.1 Heat Exchanger Fan Turn ON Temperatures

Fan operation is controlled by a PID controller in the cooling system control panel.

Review the temperature controller confguration and instruction table in the manufacturers cooling system manual that ships with each unit. The controller automatically turns fans on and off according to temperature sensed in the heat exchanger return line. The fans can also be turned off with isolator switches on the heat exchanger to allow for maintenance.

Factory settings are Fan 1 set point(set value SV) at 32 window (O1HY). This means Fan 1 turns ON at 34.5

o offset (deviation A2DV) will be set at 5.5

o

(37.5 o o

C with a 5 o

degree hysteresis

C and shuts off at 29.5

o

C. Fan 2

C. center temperature) with a 5 degree hysteresis window (A2HY). This means Fan 2 turns ON at 40 o

C and shuts off at

35 o

C.

STEP 1 Use the electronic controller in the pump control panel to verify the factory settings for Fans 1 and 2. Adjust if necessary.

2.14.1.2 Verify Pump Switching (Dual Pumps Only)

STEP 1 Go to the cooling control panel and select REMOTE on the System

Control switch.

STEP 2 From the HOME screen press SYSTEM on the GUI to view cooling system control and performance data.

This screen is shown in Figure

3-14 on page 3-19.

STEP 3 Under Pump Control Select MANUAL.

The Manual button should be yellow when selected.

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STEP 4 Press pump select button for PUMP A ON then PUMP B ON.

The pumps should switch. This is indicated on the TCU GUI screen (pump that is on is colored green) as well as in the Cooling Control Panel status light indicators. Monitor the flow produced by each pump when it is activated.

STEP 5 Switch the LOCAL/REMOTE switch on the control panel to

LOCAL. Then use the Pump Select switch on the cooling control panel to switch pumps ON and OFF. The pump that was in standby should activate after pressing the Pump Select button.

STEP 6 Select REMOTE on the Cooling Control panel.

STEP 7 Go to the GUI SYSTEM screen and select AUTO.

STEP 8 Reduce coolant flow to the cabinet by closing the globe or ball valve on the inlet hose. The pump should switch as the flow limit is reached when flow remains low the pumps should shut down.

STEP 9 After verification of pump switching performance and flow protection restore the globe or ball valve to it’s previous condition to restore flow.

2.14.1.3 Normal Pump and Fan Operation

In normal operation (Cooling Control Panel System Control set to REMOTE and Heat

Exchanger Fans set to AUTO), the transmitter commands the pump selection and Fan operation. If there is a need for operating the pumps or fans independently from the transmitter, the Local switch position on the Cooling Control Panel System Control should be selected. If the fans need to be operated independently then MANUAL should be selected on the Heat Exchanger Fans switch. The coolant level can be easily checked by viewing the sight tube located above the system air purger.

2.14.1.4 Operational Pressure Values (typical)

Transmitter input:

Transmitter output:

Botttom of filter:

Heat exchanger input:

23.4 psi

15.1 psi

34.25 psi

9 psi

Heat exchanger output: 38.5 psi

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2.14.2 Setting Exciter Parameters


See M2X Exciter manual to set exciter parameters.

NOTE:

Exciter A is always factory installed as the upper exciter unit in the exciter control cabinet. The optional exciter B is installed immediately below the top exciter unit (see layout photo Figure 1-1 on page 1-2).

2.14.3 RF Initial Turn ON

!

CAUTION:

THE TRANSMITTER SHOULD BE INITIALLY POWERED INTO THE TEST LOAD.

STEP 1 Press OUPUT then OUTPUT METERS.

This screen shows (Figure 2-

17 on page 2-56) the forward and reflected powers for the Cabinets and

Total System power. The ALC level is also indicated.

STEP 2 Set Cab Fwd Power Reference (W), on Ouptut screen, to zero by entering the value or by entering the zero value or by holding the lower button (with ALC on) for at least 20 seconds.

STEP 3 Turn down the transmitter ALC voltage level prior to initial start up. Press MAN button on the TCU control panel for at least for at least

5 seconds. Then hold down the LOWER button on the TCU control panel for at least 20 seconds. This assures that the transmitter will come on at a low RF output level.

STEP 4 Switch ON the IPA (driver) and PA circuit breakers IPA A-B and PA slots 1-8 and 11-18 (the number of PA modules depends on the transmitter model) inside the cabinet rear on the left side (refer to

Figure 2-11 on page 2-45).

STEP 5 Verify that the PA cabinet has Remote Enabled.

STEP 6 Press the transmitter ON button .

STEP 7 Verify that the cabinet and system reflected power levels are under

100 watts (see Output screen) .

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Figure 2-15 Power Amps Screen

10/6/10

Figure 2-16 IPA Screen

STEP 8 See Figure 2-15 and Figure 2-16. All IPA’s and PA’s should show a green (OK) or yellow (indicating low drive) status indication on the

GUI (Power Amps screens) .

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Cabinet power will

go to this level if TCU set to Auto

2-56

Figure 2-17 Output Screen

STEP 9 Slowly bring up the transmitter power (see Output screen) by pressing the RAISE button on front panel to the nominal value, as indicated by the bar graphs . Monitor the cabinet forward and reflected powers, as well as the VSWR reading. A large VSWR (above 1.1) is indicative of a bad RF connection to the test load.

STEP 10 Adjust cabinet phasing (in multi-cabinet systems) to reduce reflected power into the cabinet combiner reject loads . Inter-cabinet phasing is accomplished via the GUI to adjust the preamplifier modules in each cabinet relative to the other cabinets to reduce reflected power to the common reject loads.

STEP 11 Verify that the transmitter meter readings are close to the factory test data meter readings, especially all of the current and voltage readings.

NOTE:

Rebias of the FET’s in the PA modules is not required in this transmitter. They have been pretested at the factory to minimize drift.

STEP 12 Verify power output on GUI corresponds with the external power meter.

If there is a discrepancy, perform the power calibration procedure

"5.8 Power Calibrations" on page 5-15 in this manual.

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STEP 13 Press Auto on the TCU.

Note that Cab. Fwd. Pwr reference value on output screen now reads cabinet output power.

2.15 Individual Transmitter Parallel Remote Control

Connections

The customer I/O board is located at the top of the individual transmitter cabinet. Table

2-18 shows the board and also lists the connector names and numbers.

Once proper operation of the transmitter has been confirmed then remote control connections can be made. The following tables list the connectors and their corresponding signal names and functions.

NOTE:

The Customer I/O board connections can be found at the top of the transmitter near the front. See Figure 2-18 for connector locations.

Control 1-J3

Control 3-J5

Status 2-J7

Meters 1-J9

Control 2-J4

Status 1-J6

Status 3-J8

RF Switch

J10

Figure 2-18 Parallel Remote Control Connections

10/6/10

External Parallel remote control units can interface at the Customer I/O Board at the top of the cabinet. J13 through J17 are for remote Control, Status and Analog readings. The connectors are organized as follows:

•

J3, J4 and J5 - Remote Transmitter Control Functions

•

J6, J7 and J8 - Remote Status Outputs

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2-57


•

J9 - Remote Analog Metering Outputs


NOTE:

The forward slash (/) in front of a signal name means active low. The signal named "/INPUT 1" for example is activated by bringing that input low. Signal names without the forward slash are considered active high. This convention is used throughout the schematics.

2.15.1 Individual Transmitter Commands J3, J4 and J5

All control inputs use opto-isolators for surge protection. The opto-isolators are powered by an internal +5Vdc from an isolation protection circuit.

All transmitter control functions (except Remote RF Mute, RF Switch Position A and

RF Switch Position B, which are active LOW or HIGH level input states) are momentary ground switching and require the remote control equipment to sink at least

15mA to activate the function. The Pinouts of J3, J4 and J5 are listed in Table 2-12.

2-58

Table 2-12 J3, J4 & J5, Customer I/O Board, Remote Control Connectors

J3-7

J3-8

J3-9

J3-10

J3-11

J3-12

J4-1

J4-2

J4-3

Connector and pin #

J3-1

J3-2

J3-3

J3-4

J3-5

J3-6

Function

GROUND

TRANSMITTER_ON

TRANSMITTER_OFF

RAISE_POWER

LOWER POWER

/RF_MUTE

GROUND

EXCITER_ A_SELECT

EXCITER_B_SELECTt

EXCITER_AUTO_SELECT

EXCITER_MANUAL_SELECT

GROUND

GROUND

IPA_A_SELECT

IPA_B_SELECT

Command Type and

Polarity

Pulsed LOW

Pulsed LOW

Pulsed LOW

Pulsed LOW

Pulsed LOW

Pulsed LOW

Pulsed LOW

Pulsed LOW

Pulsed LOW

Pulsed LOW

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Table 2-12 J3, J4 & J5, Customer I/O Board, Remote Control Connectors

J4-10

J4-11

J4-12

J5-1

J5-2

J5-3

J5-4

J5-5


J4-4

J4-5

J4-6

J4-7

J4-8

J4-9

J5-6

J5-7

J5-8

J5-9

J5-10

J5-11

J5-12

NC

NC

NC

NC

NC

Function

IPA_AUTO_SELECT

IPA_MANUAL_SELECT

GROUND

PUMP_SWITCH_COMMAND

SPARE

PUMP_AUTO_SELECT

PUMP_MANUAL_SELECT

GROUND

Command Type and

Polarity

Pulsed LOW

Pulsed LOW

GNDA

Pulsed LOW

Pulsed LOW

Pulsed LOW

GNDA

GNDA GROUND

GROUND

POWER_CONTROL_AUTO_SELECT Pulsed LOW

POWER_CONTROL_MANUAL_SELECT Pulsed LOW

GROUND

RF_SWITCH_A_SELECTt

RF_SWITC_B_SELECT

GROUND

Pulsed LOW

Pulsed LOW

2.15.2 Individual Transmitter Outputs J6, J7& J8

All of the remote status outputs are open collector and will sink 100mA at up to +24Vdc to provide an indication status is active. The pull up supply voltage for the status indications can be supplied via J6, J7 & J8 or can be supplied by an external voltage source. The status output connections are listed in Table 2-13

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2-59


.

Table 2-13 J6, J7 & J8 Customer I/O Board, Remote Status Outputs

Status Type and Polarity

J6-11

J6-12

J7-1

J7-2

J7-3

J7-4

J7-5

J7-6


Status Output

J6-1

J6-2

GROUND

TRANSMITTER_OFF/ON_STATUS

J6-3

J6-4

J6-5

J6-6

EXCITER_A/B_ACTIVE_STATUS

EXCITER_AUTO/MANUAL_STATUS

GROUND

IPA_A/B_ACTIVE_STATUS

J6-7

J6-8

J6-9

J6-10

IPA_AUTO/MANUAL_STATUS

GROUND

PUMP_A_B_ACTIVE_STATUS

PUMP_AUTO/MANUAL_STATUS

GROUND

GROUND

GROUND

REMOTE_CONTROL_ENABLED/

DISABLED_STATUS

RF SWITCH_A/B_ACTIVE_STATUS

POWER_CONTROL_AUTO/MANUAL_STATUS

J7-7

J7-8

GROUND

RF_MUTED

VSWR_FOLDBACK

GROUND

L=ON

H=OFF

L= B ON

H= A ON

L= AUTO

H= MANUAL

L= B ON

H= A ON

L= AUTO

H= MANUAL

L= A ON

H= B ON

L= AUTO

H= MANUAL

L = Remote ENABLED

H = Remote DISABLED

L= B ON

H= A ON

L= AUTO

H= MANUAL

L= RF MUTE ON

H= RF MUTE OFF

L= ON

H= OFF

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Table 2-13 J6, J7 & J8 Customer I/O Board, Remote Status Outputs


J7-9

Status Output

VSWR FAULT

J7-10

J7-11

J7-12

J8-1

J8-2

J8-3

J8-4

J8-5

J8-6

J8-7

J8-8

J8-9

J8-10

J8-11

J8-12

Status Type and Polarity

TRANSMITTER_FAULTED_OFF

L=FAULT

H= OK

L= FAULT OFF

H= OK

GROUND

GROUND

GROUND

EXCITER_FAULT

PA_FAULT

IPA_FAULT

L=FAULT

H= OK

L=FAULT

H= OK

L=FAULT

H= OK

GROUND

COOLING_FAULTt

POWER_SUPPLY_FAULT

GROUND

SUMMARY_FAULT

CUSTOMER_SUPPLIED_VCC1 ( voltage for digital output opto-couplers and pull-ups)

CUSTOMER_SUPPLIED_VCC2 (voltage for digital output opto-couplers and pull-ups)

L=FAULT

H= OK

JP1 in the TCU customer I/O card must be set correctly to use this output.

JP1 in the TCU customer I/O card must be set correctly to use this output.

GROUND

L=FAULT

H= OK

L=FAULT

H= OK

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2.15.3 Individual Transmitter Metering, J9

Each analog metering output will provide 0 - 4.096Vdc output into a 400 ohm load

(where 3Vdc = Full Scale). The connections for J9 are listed in Table 2-14.

Table 2-14 J9, External I/O Board, Remote Power Metering

J9-8

J9-9

J9-10

J9-11

J9-12

J9-4

J9-5

J9-6

J9-7

Connection Metered Parameter

J9-1 SYSTEM_FORWARD_POWER

J9-2

J9-3

SYSTEM_REFLECTED_POWER

GROUND

CABINET_FORWARD_POWER

CABINET_REFLECTED_POWER

GROUND

IPA_A_FORWARD_POWER

IPA_B_FORWARD_POWRE

GROUND

SPARE_1

SPARE_2

GROUND

2.15.4 External RF Switch

The external RF switch connector is a 12 pin connector provided to allow control of motorized switch that is external to the transmitter. The connections for J10 are listed in

Table 2-15.

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Table 2-15 External RF Switch J10

J9-8

J9-9

J9-10

J9-11

J9-12

J9-4

J9-5

J9-6

J9-7

Connection Metered Parameter

J9-1 SWITCH_COMMON

J9-2

J9-3

GROUND

RF_SWITCH_POSITION_A_SELECT

RF_SWITCH_POSITION_B_SELECT

GROUND

RF_SWITCH_STATUS_A

RF-SWITCH_STATUS_B

GROUND

GROUND

NC

NC

NC

2.16 Install Battery in TCU PCM Card


When the transmitter is ready for operation install the real time clock battery in the

TCU PCM card. This battery maintains the time and date when the transmitter loses AC power. Refer to "5.11.4 Changing the Battery on the PCM Card" on page 5-40. The battery can be found inside a plastic bag that also contains battery installation instructions.

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Section 3

Operation

3

3.1

Introduction

This section gives detailed operational information for the Maxiva ULX Series Solid-

State UHF TV transmitter. Information will pertain mostly to the operation and navigation of the TCU graphical user interface (GUI) touchscreen display.

NOTE:

Operation of the M2X exciter is covered in a separate manuals which ships with the transmitter.

3.2

Transmitter Control Panel

The front panel user interface is a 5.25" 1/4 VGA, LCD touchscreen display. This touchscreen display uses software buttons to monitor the transmitter. Hardware buttons for the primary transmitter functions such as ON/OFF, RAISE/LOWER and Remote

Enable/Disable are provided on the overlay panel next to the display as shown in Figure

3-1.

NOTE:

When transmitter is turned off using the OFF button under normal conditions, the pump module pump will continue to operate for several minutes before shutting down. If immediate pump shutdown is desired then pump module can be turned off at the control panel.

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Section 3 Operation Maxiva ULX COFDM Series

3-2

Figure 3-1 Transmitter Control Unit (TCU)

NOTE:

A similar set of GUI screens is available via web browser with an ethernet network connection and the optional eCDi hardware interface.

3.2.1

Hardware Control Buttons

To the right of the touchscreen, there are 6 pairs of hardware control buttons which are part of the front panel overlay. Located to the left of the buttons are

Status LED’s which are green under normal, no fault conditions. The hardware buttons provide immediate control of 6 main transmitter functions: a.

Power Control - Auto/Manual b.

Remote - Enable/Disable c.

Power - Raise/Lower d.

Exciter - A/B e.

Drive - A/B f.

Transmitter - On/Off

SYSTEM

The Status LED’s light amber (yellow) for a warning and red for a fault condition in the transmitter subsystems. LED’s light green if the sub-system is normal. This provides quick sub-system status information without having to be familiar with a menu structure.

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Maxiva ULX COFDM Series Section 3 Operation

NOTE:

The system control buttons described above will be referred to as hardware control buttons in the following manual text.

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Figure 3-2 TCU Front Panel Lowered

There are two power supply cards located on the left side of the TCU chassis and seven cards in the right side of the TCU. The boards are numbered 1 through 8, right to left.

The 1st board (furthest to the right) is the MCM (main control module), the 2nd board is the PCM (processor control module), the 3rd board is the RF detector, the 4th is the customer I/O board, the 5th is the exciter switcher, 6th is PS monitor the 7th & 8th are

PA interface (digital I/O) boards. The 8th card (PA interface) is only present in transmitters with more than 8 PA modules. The two power supplies on the left are redundant.

To gain access to the internal boards, simply pull outward and then down on the front of the TCU panel. The openings on the left and right of the TCU front panel can be used as handles.

Should the GUI screen go gray, i.e., the software buttons or symbols are still visible but have turned shades of gray instead of the usual color scheme, a TCU reset may be

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Section 3 Operation Maxiva ULX COFDM Series required. To reset the TCU, pull down the GUI panel exposing the circuit cards in the

TCU chassis as shown in Figure 3-2. The second board from the right is the PCM board. The TCU reset button is located about toward the center of the board and it faces outward toward the user. Use the tip of a pencil or pen to gently depress the small black button.

NOTE:

It will take approximately two minutes for the TCU to reset. If the transmitter is on the air, resetting the TCU will NOT affect transmitter operation.

A TCU reset can also be accomplished by pressing the Local GUI SYSTEM ADMIN screen REBOOT button.The screen and button are shown in Figure 3-19 on page 3-24.

There is another reset button toward the bottom of the MCM board (farthest board to the right). This reset button will also reset the TCU but it will take the transmitter off the air for a short time.

Just above the MCM Reset button is a removable memory card containing system software. This card should be installed in any replacement MCM card that is installed.

3.3

Graphical User Interface (GUI)

The GUI ("Gooey") was designed to provide an intuitive interface into the transmitter control system. Once you become familiar with content, finding information is simply a matter of following the screens to the desired section of the transmitter. Menu Trees of all available screens are given at the end of this section, see "3.10 GUI Menu

Structures" on page 3-29

For the most part, all navigation through the GUI screens is via the touchscreen and softkeys (software buttons). The exceptions are the 6 pairs of hardware control buttons mentioned above. The touchscreen display is also divided into an active display area, which will change with each screen selected, and the global areas which are present on all screens.

3.3.1

Global Status and Navigation

The top 2 sections of the touchscreen display (dark blue background) are considered global because they show up on all screens. The top line indicates the transmitter name and model number.

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System Forward Power Bargraph Transmitter Model Number

Section 3 Operation

Fault & Operational

Status

Reflected Power Bargraph

Forward and Reflected

Power Outputs

100% Mark - Based on

Nominal Power Output setting in System Setup screen

Figure 3-3 Global Display Header

The second line of the display has operational and status information including: a.

ON , Standby , Fault OFF , ON/FB (transmitter foldback), PS MUTE , and RF

MUTE status indication.

•

ON: Normal operating mode

•

Standby: Transmitter turned off manually or remotely

•

Fault OFF: Transmitter forced off due to fault condition

•

ON/FB: Transmitter power folded back. Conditions causing the foldback may by temporary and could possibly be cleared by pressing the ON button.

If, after pressing the ON button to reset the foldback, the ON/FB indication resumes the malfunction will need to be determined and the transmitter repaired (see Section 6 for fault log listings).

•

PS MUTE: A temporary fault condition caused by a power supply related fault. If underlying fault clears, the mute condition will be lifted and the transmitter returned to normal operating mode. If the mute continues, the underlying fault will need to be determined and the transmitter repaired (see

Section 6 for fault log listings).

•

RF MUTE: A temporary fault condition caused by an RF related fault. If underlying fault clears, the mute condition will be lifted and the transmitter returned to normal operating mode. If the mute continues, the underlying fault will need to be determined and the transmitter repaired (see Section 6 for fault log listings).

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3-5

Section 3 Operation Maxiva ULX COFDM Series b.

Transmitter Forward power output reading in numerical format (for multiple cabinet transmitters this would be a system power reading and not for a single cabinet). It is important to note that this is the power output after the filter.

c.

Transmitter Forward power output reading in a Bargraph format. The 100% mark is based on the nominal power level or TPO (Transmitter Power Output) entered into the configuration screen. The bargraph will also turn yellow if the power level is more than 10% higher or lower than the nominal 100% level.

NOTE:

Indications on the global display header in Figure 3-3 should be all green under normal (no fault) operating conditions. A yellow or red symbol or status indication on the global display header should be investigated by the station engineer.

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3.4

GUI Home Screen


The HOME screen shown in Figure 3-3 is the primary operator screen and the default screen after boot up. The HOME screen contains the most important general operator information such as: a.

Cooling status b.

Power supply status c.

Drive chain selection (pre-driver and IPA status) d.

Amplifier status

To Figure 3-5 on page 3-9





Figure 3-4 ULX-8700** Home Screen

It also has the global status and operation information at the top of the screen which shows the transmitter status, power output and any faults present.

The HOME button (shown to the right) is a software button located in the upper left quadrant of all 5 main menu screens for quick navigation to the

HOME screen. If a submenu screen is displayed on the GUI (see Figure 3-

4), the lower right-hand button will typically be the BACK (arrow) button; use this back arrow button to go back up a level.

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3-7


The quickest way to access the HOME screen is to press either the HOME button on a main menu screen or the BACK button arrow on a submenu screen followed by a

HOME button press on the main menu screen.

There are five touchscreen navigation buttons on the right side of the GUI Home display. These buttons vary from screen to screen. The software menu buttons can also act as status indicators and turn red if a fault condition is detected.

There is a navigation button (shown to the right) to allow access to information specific to the PA cabinet. Pressing this button will take you to the Power Amp screen shown in Figure 3-8 on page 3-13.

This button is also a status indicator for the PA cabinet as it will change from green to red, if a problem is detected in that cabinet.

NOTE:

To simplify the discussion of GUI navigation, the following sections describe the screens under the 5 main menu buttons located on the right side of the GUI Home page.

Similarly, pressing the exciter, PDU or IPA icons will take you to the main drive chain menu.

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3.5

Drive Chain Main Menu


If you press the Drive Chain button on the HOME screen, it will take you to the screen shown in Figure 3-5. The Drive Chain Menu structure is shown in Figure 3-26 on page 3-30.

10/6/10

To Figure 3-6

To Figure 3-7

To Figure 3-4

Figure 3-5 Drive Chain Screen

The Drive Chain screen is basically an exciter, pre-driver and IPA control and monitoring screen. It has a power reading for each exciter and IPA output and allows the operator to select exciters and pre-driver/IPA’s. It also allows selection of AUTO or

MANUAL switching mode for the drive chain when the optional dual exciter system is installed. Specifically it includes: a.

The operational and on-air status of 1 or 2 exciters (the second exciter is optional) pre-drivers and IPA’s.

NOTE:

The standard M2X exciter comes with a main and aux input. b.

The status of Exciters and Drivers A and B. The screen also allows exciter and driver selection.

c.

A Dual Exciter Control box (located at the bottom of the screen on the left). This section will be grayed out for single exciter systems. For dual exciter systems this box has two exciter buttons and Auto/Manual buttons:

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3-9


1.

Auto/Manual - Auto should be the standard position for normal operation.

Placing it in Manual mode prevents an autoswitch to the alternate drive chain. In AUTO mode, if the on-air exciter drops below 50% of nominal power, or if the on-line exciter experiences a fault, the controller will automatically switch to the backup drive chain (if available). Manual mode could be used if an exciter or driver has been removed for service or for any application where an automatic switch to the alternate drive chain is not desired.

2.

Exciter A/B - These buttons select operational exciter. To use these buttons, place the Auto/Manual button to Manual, then press the A or B button to select the on-air drive chain.

d.

Pre-Driver/IPA Control box (located at the bottom of the screen on the right).

This dual driver has 2 switches:

1.

Auto/Manual - This toggle button should always be in the Auto position for normal operation. Placing it in Manual mode prevents an autoswitch to the alternate IPA (Preamp/Driver). In AUTO mode, if the on-air predriver/IPAdrops below 50% of nominal power, the controller will automatically switch to the backup pre-driver/IPA. Manual mode could be used if a exciter or driver has been removed for service or for any application where an automatic switch to the alternate IPA(Preamp/Driver) chain is not desired.

2.

Pre-driver/IPA A/B - These are the manual selection buttons. To use these buttons, place the Auto/Manual button to Manual, then press A or B to activate the on-air predriver/IPA combination.

3.5.1

Drive Chain Faults

When the "Faults" button in Figure 3-5 is pressed, it will bring up the screen shown in

Figure 3-6. This screen is basically a fault display for exciters and pre-driver/IPA’s. For more information on these faults and what to do if one should occur, refer to the M2X exciter manual.

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To Figure 3-7

To Figure 3-5

Figure 3-6 Drive Chain Faults Screen

NOTE:

Exciter A is always factory installed as the upper exciter unit. The optional exciter B is installed immediately above the TCU and below the top exciter unit

(see layout photo Figure 1-1 on page 1-2).

3.5.2

Drive Chain Meters

When the "Meters" button in Figure 3-6 is pressed, it will bring up the screen shown in

Figure 3-6. This screen displays input and output information for exciters and predriver/IPA units. Current values for the pre-driver and IPA’s are also given.

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3-11


To Figure 3-6

Figure 3-7 Drive Chain Meters Screen

To Figure 3-5

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3.6

Power Amp Main Menu


If you press the Power Amps button on the HOME screen, it will take you to the screen shown in Figure 3-8. The Power Amps Menu structure is shown in Figure 3-26 on page 3-30.

To Figure 3-9

Viewed Cabinet

PA Section

Select

To Figure 3-4

Figure 3-8 Power Amps Screen

(PA Cabinet 1 ULX2300** shown)

This screen shows the current and forward power for individual PA modules in the indicated cabinet. Additional modules in the same cabinet are viewed by selecting the

PA’s 1-8 or 11-18 buttons in the lower left portion of the bottom of the screen. The PA,

Input and On/Off indications on the screen are also status indicators with 3 possible states indicated: a.

OK - Green background b.

Fault - Red background c.

OFF - The background is gray.

The On/Off field will can be used to toggle individual amplifier modules on or off as needed.

NOTE:

For multi-cabinet Maxiva Series transmitters (ULX13400 - ULX36900) the cabinet select buttons are located to the right on the screen. Selecting "Next Cabinet" will allow viewing of information for the next cabinet. Once the desired cabinet is selected, submenus are navigated in the same way as the others cabinets’.

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3-13


NOTE:

Always be sure that you are accessing the desired cabinet number. The cabinet being viewed is indicated in the upper left corner of the screen.

To get detailed information on a particular PA Module, press the Faults button on the right section of the screen. The Faults button will take you to the PA Faults screen shown in Figure 3-9.

3.6.1

PA Faults

This screen is basically a list of all faults monitored in each PA Module.

•

An active fault will be highlighted in RED

•

A warning condition will be highlighted in YELLOW.

The PA Faults screen in Figure 3-9, shows that PA Module #1, in PA Cabinet #1 has no faults and 1 temperature warning. It also shows a power supply fault on module 3 and an input power warning on module 4.

NOTE:

For a detailed explanation of all PA Faults in Figure 3-9 refer to Section 6, Diagnostics.

3-14

To Figure 3-8

Figure 3-9 PA Faults Screen (PA Module 1 Selected)

PA Modules will fault off at 200W reflected power. Also, it will display a temperature fault at 65° C ambient temperature (measured by a thermistor on the monitor board) or

90° C pallet temperature.

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3.7

Output Main Screen


If you press the Output button on the HOME screen, it will take you to the screen shown in Figure 3-10. The Output Menu structure is shown in Figure 3-25 on page 3-29.

To Figure 3-11

Cabinet Indicators

To Figure 3-4

Figure 3-10 Output Screen

The main Output screen is has 3 main areas:

•

RF Output System - This panel gives the total system Forward and Reflected power, measured after the filter. It also has a VSWR and Foldback status indications with backgrounds that are red for fault or yellow for warning. A

VSWR fault is indicated when the system VSWR is > 1.9:1. Foldback warning is indicated when system VSWR is > 1.4:1

NOTE:

Both VSWR fault and foldback levels are adjustable via software.

•

Power Amplifier Cabinet - Amplifier cabinet icons (triangle) give a status indication of OK (green) or Fault (red) along with cabinet Forward and

Reflected power (before the filter) for each cabinet.

•

Output Control - The control area at the bottom of the screen is used to control an external RF switch so that the transmitter can be switched from

Antenna to the Test Load. The diagram indicates the position of the RF switch based on micro-switches located on the switch.

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3-15


NOTE:

If the load interlock is open and the transmitter is switched to the "Test Load" position, the transmitter output will be muted. If a test load interlock is not used the appropriate connection on the interlock connector on the customer I/O panel must be jumpered. For more information see "2.9 External Interlock Connections" on page 2-32.

3.7.1

Output Faults

This screen shows faults which are considered Cabinet or System level such as VSWR,

Power High, foldback etc....

•

An active fault will be highlighted in RED

•

A warning condition will be highlighted in YELLOW

A detailed explanation of each of these faults is given in Section 6, Diagnostics.

ON becomes

ON/FB in fold-

back condition.

Background turns yellow in foldback.

To Figure 3-10

Figure 3-11 Output Faults Screen

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3.8

Power Supply Main Menu


If you press the Power Supply button on the GUI screen it will take you to the screen shown in Figure 3-12. The Power Supply Menu structure is shown in Figure 3-26 on page 3-30.

This is the power supply metering screen for both the low voltage power supply units

(in the TCU) and the AC Mains. It also allows access to Power Supply Fault screens:

•

PS Faults - Fault list and status

•

Next Cabinet - Access to PS screens on other cabinets if applicable.

To Figure 3-13

Figure 3-12 Power Supply Screen

To Figure 3-5

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3-17


3.8.1

PS Faults


This is the PS (power supply) Faults screen which lists of all of the monitored power supply faults for the AC mains and low voltage power supplies. An active fault will be highlighted in RED, while a warning condition will be highlighted in YELLOW. For a detailed explanation of these faults, refer to Section 6, Diagnostics.

Figure 3-13 PS Faults Screen

To Figure 3-12

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3.9

System Main Menu


If you press the System button on the GUI screen, it will take you to the screen shown in Figure 3-14. The System Menu structure is shown in

Figure 3-26 on page 3-30.

To Figure 3-15

To Figure 3-16

To Figure 3-17

10/6/10

To Figure 3-4

Figure 3-14 System Main Menu

This screen contains the System Main Menu which gives overall status information and access to additional System screens. This includes: a.

CAB1 - Provides coolant temperatures, air temperatures and coolant flow (liters per minute). The CAB1 block also provides the status of the RF Mute and Safety

Interlocks. Interlocks can read Open (red background) or Closed (gray background) b.

Pump Status - Pump icon has a green background color if no faults are present or a red background color if faults are active. For more information on faults press

"Faults" c.

Pump Control - Pump A & Pump B for dual pump systems are indicated. This panel would be grayed out (inactive) for single pump systems. The active pump will have a green background. Pumps can be switched from this screen, by pressing A or B only if the pump control panel switch is in the REMOTE mode.

Placing the pump control panel in LOCAL mode will disable pump selection on the System GUI screen. For additional information on LOCAL operation and the pump control panel see "1.2.8.1 Cooling System Control Panel" on page 1-15.

AUTO or MANUAL can also be selected here. Selecting AUTO allows automatic switchover in case of pump failure in dual pump systems. AUTO is the normal operating mode if the system has dual pumps.

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3-19


3.9.1

System Faults


This screen is accessed by pressing the Faults button on the System screen. An active fault condition is highlighted in RED while a warning condition is highlighted in

YELLOW.

For more information on these faults refer to Section 6, Diagnostics.

3-20

To Figure 3-14

Figure 3-15 System Faults Screen

3.9.2

System Fault Log

This screen is accessed by pressing the System Fault Log button on the System screen in Figure 3-14 on page 3-19. It is a complete listing of all transmitter and system faults in the order in which they occurred. It can hold up to 99 faults and then becomes a FIFO

(First IN - First Out) memory buffer, with the latest fault entry on top . Active Faults will be highlighted and cannot be reset. All other faults will be cleared when the RESET button is pressed. Use the NEXT and PREVious buttons to view the entire list.

A complete listing of all faults which can show up in this log, along with a brief explanation of each fault, is given in the following tables in Section 6, Diagnostics.

•

Table 6-1, “Maxiva Drive Chain Fault List,” on page 6-5

•

Table 6-2, “PA and IPA Module Fault List,” on page 6-7

•

Table 6-3, “Power Supply Faults List,” on page 6-8

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•

Table 6-4, “Output Faults List,” on page 6-10

•

Table 6-5, “System Faults List,” on page 6-12


These tables are a quick reference list and in most cases is all that is required for an advanced user to diagnose the problem. However, detailed information on each of these faults is also given in context with the fault page where it originated, also in Section 6.

Note:

Date format is

DD/MM/YY

Press to clear all faults

Figure 3-16 System Fault Log Screen

To Figure 3-14

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3-21


3.9.3

System Service


This screen provides a way to change 3 pieces of information which are then used throughout the GUI. The System Service screen us shown in Figure 3-17 on page 3-22.

•

Station Name: This can be up to 24 characters and will appear at the top of every

GUI screen

•

Model Number: This value is entered at the factory. The model number chosen must match the transmitter name plate. It is used to gray out portions of the GUI screens which are not used by some models.

•

Serial Number: This is entered at the factory. Refer to this number if calling for support.

To Figure 3-24

To Figure 3-25

Figure 3-17 System Service Screen (Remote)

The System Service screen varies depending on whether it is viewed on the local GUI screen or remotely via web browser. The local screen shown in Figure 3-18 on page 3-

23 contains additional entry windows to allow manual entry of date and time values.

The TCU will automatically set date and time values at turn on if it is connected to a network.

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To Figure 3-24

To Figure 3-19

10/6/10

Figure 3-18 System Service Screen (Local)

3.9.3.1

Admin Setup (Local GUI Only)

The Admin screen is accessed by pressing the Admin button shown on the Local GUI

System Service screen shown in figure 3-18. The following parameters are accessed via the System Service Admin screen.

•

Login: Allows access as Guest, Operator or Expert. Guest level allows user to view screens but does not allow adjustments. Operator allows viewing and operational adjustments. Expert allows viewing, operational and maintenance adjustments.

Local GUI login is admin. Web browser login is admin.

•

Password: Allows user password entry. There are different login and passwords for local and web browser GUI usage. The default logins and password from the factory are:

Local GUI password is harris. Web browser password is harris2009.

•

Expire: Sets the expiration time for the user access level.

•

LCD Contrast: The screen contrast can be adjusted dynamically to allow for different room lighting by changing the percentage setting.

•

User (administrators only): This area is used to enter ID’s and passwords for the various user levels.

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3-23


•

Reboot: This button will reboot the TCU.

The transmitter will stay on the air. Reboot takes about 2 minutes

Figure 3-19 System Admin Screen (local)

To Figure 3-22

To Figure 3-21

Figure 3-20 System Admin Screen (remote)

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10/6/10

Figure 3-21 System Update Screen (remote)

The system update screen allows the user to update the PCM software. Browser for a

.tcu file, press load file and then Update Now.

!

CAUTION:

THE TRANSMITTER WILL BRIEFLY GO OFF AIR WHEN THE SOFTWARE IS

UPDATED.

3.9.3.2

System Setup

•

Sys Pwr Out (W): Set this value to the system nominal power output. This value determines the 100% level on the GUI power out bar.

•

Center Freq (MHz): Enter the center frequency for the desired operational channel.

In early software versions this is only sets the frequency display. In later software versions it also sets the exciter frequency.

!

CAUTION:

CHANGING THE TRANSMITTER FREQUENCY SHOULD ONLY BE DONE IF THE

FILTER AND RF SYSTEM COMPONENTS ARE TUNED FOR THE NEW FREQUENCY.

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3-25


•

Modulation Type: Select the system modulation type from the values displayed in the box.

•

AC Line Volt (VAC): Set this to the nominal AC line voltage at the transmitter site.

•

Number of Exciters: Set this to either 1 or 2 depending on how many exciters are in the transmitter.

•

Number of Cabinets: Set this to the number of PA cabinets in the system.

•

System Setup Entry: E nter a number from 1 to 8 in this field. For example if you want to set up the transmitter for CH29 and store it in entry 3, you enter 3 in the System Setup Entry. This will recall the data for entry 3. If no data is there, defaults will be loaded. Once all the calibrations for channel 29 are done you press SAVE SETUP.

This will save the data to entry 3.

To Figure 3-23

To Figure 3-17

Figure 3-22 System Setup Screen

NOTE:

The Save Setup button allows storage of up to eight setups for the purpose of

N+1 operation. All the calibrations for the transmitter are saved in the MCM module. This means the transmitter can change to anyone of 8 channels and be fully calibrated by simply recalling the set up entry. The N+1 controller will send the set up the entry that needs to be recalled, as well as set the exciter frequency.

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3.9.3.3

Cabinet Setup


•

Cab Pwr Out (W): Set cabinet output power here. This is the power out of the cabinet before the combiner or filter. This needs to be set for each cabinet. Sets cabinet nominal power used to set ALC level. Maximum cabinet power is limited to 10% over this value.

•

Number of PA’s: Enter the number of PA modules in the selected cabinet. This needs to be set for each cabinet.

•

Number of IPA’s: Enter the number of IPA modules in the selected cabinet. This needs to be set for each cabinet.

•

Cooling Pumps: Set this to either 1 or 2 depending on how many pumps are in pump module for this cabinet. This needs to be set for each cabinet.

To Figure 3-17

Figure 3-23 Cabinet Setup Screen

3.9.3.4

System and Cabinet Power Calibrate

See "5.8 Power Calibrations" on page 5-15 in Section 5 of this manual for the procedure that utilizes these screens.

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3-27


3.9.3.5

System Version Screen


This screen shows the software revision for the TCU controllers. This information should be known before calling for technical support.

To Figure 3-17

Figure 3-24 System Version Screen

3.9.3.6

System Network Screen

This screen provides information about network settings. MAC, IP, Netmask and

Gateway settings are given.

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To Figure 3-17

Figure 3-25 System Network Screen

The System Network screen when viewed from the local GUI has an additional button called Save & Restart Network. When a change is made to one of the network parameters (IP address, mask, etc.) the networking system has to be restarted before the change is implemented. Save & Restart saves the change and restarts the network system so the change is made permanent and the new parameters become active.

3.10 GUI Menu Structures

Figure 3-26 on page 3-30 shows the menus which can be accessed on the GUI. This menu tree may be helpful when learning to navigate the screens. The blocks on the left represent the main menus which can accessed using one of the 5 software buttons on the right side of the GUI HOME Page. Each successive level (to the right) represents software buttons which will show up on the right side of the GUI submenu screens.

NOTE:

Multi-cabinet Maxiva Series transmitters will require an extra button press at the top level menus to select the desired cabinet.

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3-29


Drive

Chain

Power

Amps

Output

Power

Supply

System


Faults

Meters

Meters

Faults

Faults

Faults

Logs

Service

Faults

Log

Clear

Log

System

Setup

Version

Network

Figure 3-26 GUI Menu Tree

Cabinet

Setup

Calibrate

Save

Setup

Cabinet

Calibrate

Trips

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Section 4

Theory of

Operation

4

4.1

Introduction

This section contains detailed descriptions of the Maxiva ULX Series transmitter, its internal sub-assemblies and any pertinent information regarding the external assemblies such as the pump module and heat exchanger.

The rest of this section will be broken up into 4 main topics:

•

Control System & TCU

•

RF System

•

Power Supplies

•

Cooling System

4.1.1

Active Logic Symbols

Each logic signal has an active and inactive state and a unique name within the system.

To differentiate between active high or active low logic states on the schematics, a forward slash (/) is placed in front of an active LOW signal name such as /RF_MUTE.

This means that if this logic line is pulled low, the transmitter RF will be muted. By the same logic, the signal RF_MUTE_LED (an active high signal with no forward slash) will turn on the RF mute LED when it goes high.

In some cases, a logic signal may act as a toggle with both states active, as with the signal /ON_OFF, where LOW = ON and a HIGH = OFF. If this signal is inverted it would be ON_/OFF.

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4-1

Section 4 Theory of Operation

4.2

Block Diagram Descriptions


See Section 1, Introduction, in this manual for a basic transmitter overview and block diagram descriptions. Figure 4-1 gives a simplified block diagram. There is also a more detailed overall transmitter block diagram at the front of the schematic package that came with the transmitter. As a standard practice, the first page of a PC (printed circuit) board schematic is also a block diagram of that board. Table 4-1 gives the basic Maxiva model numbers and configurations.Using the model ULX-2300** as an example, the model number breaks down as follows.

•

U stands for UHF band.

•

L stands for Liquid Cooled.

•

X stands for Transmitter.

•

2300 stands for 2300 watts average power at the transmitter output before the band pass filter.

•

** stands for the type of modulation. See Table 2-1 on page 2-1

Table 4-1 Maxiva ULX COFDM Series Transmitter Models

Tx Models Cabinets PA Modules Output Power

ULX1100**

ULX-1700**

ULX-2300**

ULX-3400**

ULX-4400**

ULX-5500**

ULX-6500**

ULX-8700**

1

1

1

1

1

1

1

1

8

10

12

16

4

6

2

3

1100W

1700W

2300W

3400W

4400W

5500W

6500W

8700W

ULX-9500**

ULX-12600**

ULX17400**

ULX-18900**

2

2

2

3

18(12+6)

24(12+12)

32(16+16)

36(12+12+12)

13.4 kW

12.6 kW

17.4 kW

18.9 kW

ULX-26100** 3 48(16+16+16) 26.1 kW

NOTE: All power levels given in average output power before the bandpass filter.

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Maxiva ULX COFDM Series Section 4 Theory of Operation

Web

Remote /

Monitoring

TO OTHER

CABINETS

TO N +1

CONTROLLER

Ethernet

System /CAN Bus

N+1 CAN Bus

Pre-Drivers Driver-PAs

Exciter CAN Bus

Ethernet

Ethernet

EX 1

EX 2

TO PUMP MODULE

INTERLOCKS

PARALLEL

CONTROL

CAN Bus

RF

SWITCH

Front Panel

Buttons

GUI

PUMP CONTROL

INTERLOCKS

PARALLEL

REMOTE

TCU

PS AND

COOLING

MONITOR

PA

INTERFACE

RF

MONITORING

LEAK

DETECTOR

CABINET

FLOW

METER

INLET /

OUTLET

TEMP

I/O PANEL

÷

PA Bus

FANS

L1

L2

L3

16 PA’s

DIR

COUPLER

AC

Distribution Bus

MOV/AC

SAMPLING

Transmitter

Main Cabinet

Figure 4-1 Maxiva ULX-8700** COFDM Main Cabinet Block Diagram

4.3

AC Distribution

Three phase AC mains must be supplied to the PA cabinets via circuit breaker CB23 and CB24 on the AC mains input assembly (A15). The transmitter can accept 208-

240VAC (Delta or WYE) or 380-415VAC (WYE) by changing jumpers or connections in four areas:

•

Terminal boards TB1 and TB2 are in the AC distribution panel. The TB1 and TB2

Jumpers are described in Section 2 “Section 2 Installation / Initial Turn-On” on page

2-23.

•

Parallel MOV boards (A15A1 & A15A2). MOV board jumpers are shown on sheet 8 of the PA Cabinet Main Wiring Diagram, drawing number 843-5601-001.

•

Driver and PA backplane boards. On the IPA and PA backplane boards, drawing numbers 801-0222-131 and 801-0222-101 respectively, the jumpers on TB1, TB2, and TB3 are connected between terminals 2 and 3 for 208 to 240 VAC Delta or WYE and connected between terminals 1 and 2 for 380 to 415 VAC WYE connections.

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4-3

Section 4 Theory of Operation Maxiva ULX COFDM Series

•

A neutral connection is required, from the AC service entrance to CB23 and CB24 (if used) for the 380 to 415 volt WYE connection, but no neutral connection is required for the 208 to 240 volt Delta or WYE connections. 440 to 480 VAC Delta or WYE connections require a step down transformer.

If properly jumpered there will be three phase 208-240V AC inputs supplied to each driver and PA module.

4.4

Transmitter Control System

The Maxiva ULX Series transmitters utilize an very advanced but simple to use control system. The liquid-cooled model ULX-8700

**

transmitter consists of 1 power amplifier control cabinet, 2 preamplifiers, 2 IPAs (drivers), 16 PA (power amplifier) modules, a

TCU (transmitter control unit), one or two M2X exciters and a cooling system that includes interconnecting plumbing and a pump module/heat exchanger (cooler) unit. In order to reduce cost and simplify the design, the amplifiers and IPA (driver) modules do not contain micro controllers. A CPLD (complex programmable logic device) based monitor board in each PA and IPA is responsible for reporting faults back to the TCU and taking action when the ON/STBY command is issued from the UCP.

In multi-cabinet systems, there is a TCU in each cabinet and the main cabinet (no. 1)

TCU contains a GUI (graphical user interface) screen and assumes the role of the master controller for the system. The TCUs in the other PA cabinets are considered slaves; they don’t have GUI screens and do not require all of the cards used in the main cabinet TCU. For additional information on the TCU and the various boards that it contains see 1.2.3 on page 1-5.

The TCUs in each cabinet contain an MCM (master control module) module. The

MCM modules in each TCU are connected by the system bus . The system bus originates in the main cabinet TCU and connects to the MCM cards in all other TCUs.

The TCU in each cabinet uses the cabinet bus, Drive A and B busses, and BP 1 through

BP 4 busses for control and communications within each cabinet. These buses tie the

MCM and two PA Interface boards (in the TCU) to all of the RF amplifiers in the cabinet. The use of separate system and cabinet bus allows each cabinet to operate independently in case a cabinet fails.

4.4.1

Graphical User Interface (GUI)

The GUI is a touchscreen LCD display which is a 5.25" color, 1/4 VGA display. This is the primary local interface for the operator but is not required to operate the transmitter.

The primary operator controls, ON, OFF, RAISE, LOWER are located on the front panel next to the GUI. Operation and navigation of the GUI is covered in Section 3

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Operation. The GUI screen is present only in the main TCU (cabinet 1 in multi cabinet systems).

4.4.2

Transmitter RF Power Control

The IPA and PA modules have no gain adjustment. The transmitter RF output power is controlled via the Phase and Gain Board located in the Predriver modules. The

Predrivers are the only components in the drive chain (besides the exciter) capable of adjusting their RF power based on a command from the TCU.

The TCU in the main cabinet contains a PCM (processor control module) which acts as the transmitter controller. However, a depopulated TCU is present in each PA cabinet.

The TCU monitors the power sample from its cabinet and issues the proper voltage to the Predrivers to maintain the cabinet power regulation. This ALC loop resides in each cabinet. There is no System ALC Loop.

In addition to providing main cabinet power regulation, the Main TCU also has the role of issuing the cabinet power reference. This reference is used by the ALC loop in each cabinet to raise or lower the transmitter power as commanded by the end user. This signal is sent via CAN messages. Figure 4-2 on page 4-6 illustrates the power control functionality. If the Main TCU is down, all cabinets maintain their current power output.

In each cabinet, the system power reference is compared to the detected cabinet RF power sample and the resultant error voltage (cabinet # ALC) is produced. The error voltage is used to control the predriver gain, which determines the cabinet output power.

The local TCU power raise and lower buttons provides a means of individual cabinet power control with the ALC Enabled. This provides a means of setting and calibrating the individual cabinet output power to ensure correct cabinet combining in a multiple cabinet system.

The TCU in each cabinet has power control AUTO and Manual buttons. These buttons turn cabinet ALC on and off. If the ALC is disabled, the cabinet power can be raised or lowered via the local TCU power raise and lower buttons. This is an open loop mode and is intended primarily as a cabinet test mode (cabinet operated independently of the main TCU).

The TCU samples the cabinet forward power ten times per second. For digital TV the

ALC loop response does not need to be any faster then this. It’s main role is to maintain cabinet power regulation to compensate for thermal drift in the amplifiers.

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4-5


Analog television requires an additional, faster version of ALC to correct for sync compression/expansion effects versus average picture level. This fast ALC loop is independent of the TCU and is handled exclusively in the analog domain. The down converter board, located inside the transmitter cabinet (on the ceiling), generates a fast error signal, a detected sync pulse from the cabinet or system RF output sample, which adjusts the predriver level to negate the effects of compression or expansion due to changing average picture level.

Tr an sm itter Po we r

Sa m p le

(Use d f or p ow er

M o nitoring on ly . N ot u sed fo r A LC )

System Po we r R efe re nce

F ro m Syste m Bu s

(U se d for po wer ra ise /low er com m an d. No t u sed fo r A LC )

Cab ine t 1 A LC

Fro m M CM

Ca bin et Bu s

16 P As

÷

S

Ca bi net 2 AL C

From M C M

C a bin et Bu s

16 P As

UC P

÷

S

Cab in et 3 A LC

Fro m M CM

Ca bi net Bu s

16 P As

U CP

÷

S

CO MB INE R

T ra nsm itte r P ow er Sa m ple

Figure 4-2 Control System Simplified Block Diagram

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4.4.3

TCU Control


The heart of the Maxiva control system is the TCU (transmitter control unit). Each cabinet contains a TCU. The main cabinet (cabinet 1 in multi cabinet systems) contains an enhanced TCU (with a GUI screen), while additional PA cabinets contain a basic

TCU (without GUI screen). The basic TCU will not be equipped with all of the same components as the enhanced unit. The cabinet 1 TCU assumes the role of master controller in multi cabinet systems. TCUs in added PA cabinets are slaves.

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4-7


4.4.3.1

MCM Card


Each TCU contains an MCM (master controller module) card. The MCM is a microprocessor based controller used for all critical transmitter control functions. The

MCM cards in each cabinet TCU (in multi cabinet systems) are tied together via the system bus . The system bus allows interchange of control and status information between the main cabinet TCU and additional PA cabinets. The MCM is responsible for maintaining life support operation when the PCM card is not operational. The system bus connector (J6) connections are provided in Table 4-11 on page 4-26.

The cabinet bus connector (J5) has limited use in this transmitter. Pin 7 is the only signal used in the cabinet bus. It sends the PA_voltage_select signal to the IPA and PA backplanes, from which it is sent to the IPA and PA modules, where it controls the DC output voltage from the eight AC to DC converters in each module.

4-8

Figure 4-3 MCM Card Block Diagram

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4.4.3.2

PCM Card


The TCU in each cabinet also contains a PCM (processor control module) card. The

PCM card contains the Harris Coldfire based micro module running embedded Linux

OS. The PCM allows use of an optional 5.25" color 1/4 VGA GUI touch screen for enhanced monitoring and control. It also provides exciter and multi cabinet data collection, fault logs, web remote connectivity via TCP/IP connection, SNMP error trap reporting and configuration and setup interface.

Figure 4-4 PCM Block Diagram

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4-9


4.4.3.3

RF Detector/Pump Control/Interlocks Card

The RF detector/pump control/interlocks card is located in the TCU. It is made up of a main and daughter board. The card contains seven RMS detectors with adjustable trips set by EPOTS (electronic potentiometers). Pump control and interlock wiring is combined on one D25 pin connector J3. For analog transmitters the card also serves as an interface to the analog down converter board via another D25 connector J2. Figure 4-

5 on page 4-10 shows the RF Detector/Pump Control/Interlocks card connectors on the rear of the TCU and how the board is connected to the Customer I/O board at the top of the transmitter.

4-10

Figure 4-5 RF Detector/Pump Control/Interlocks Card

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4

5

6

Pin

1

2

3

7

8

9

10

11

12

13

14-17

18-25

Table 4-2 RF Detector/Pump Control/ Interlocks Card Connector J3 Pinout

Signal

CABINET_SAFETY_INTLK

Description

Input - Active high, cabinet safety interlock

CABINET_RF_MUTE_INTLK Input - Active high, cabinet RF mute interlock

SYSTEM_SAFETY_INTLK Input - Active high, system safety interlock

SYSTEM_RF_MUTE_INTLK Input - Active high, system RF mute

PUMP_ON_CMD Output - Active high to turn on selected pump

PUMP_SWITCH_CMD

PUMP_INTLK

COOLANT_FAULT

Output - Pulsed active high to switch between pumps A and B

Output, active high

COOLANT_WARN

Input - connect to open drain or relay contacts.

Active low 20mA sink.


Active low, 20mA sink.

PUMP_A_STATUS

PUMP_B_STATUS

PUMP_RMT/

LOCAL)_STATUS







Remote = High, Local = Low

+12V dc voltage supplied by pump.

EXT_VDD

GND

GNDB

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4-11


The RF detector inputs on the back of the RF Detector/Pump Control/Interlocks card are given in Table 4-3.

Table 4-3 Detector Inputs on RF Detector/Pump Control/Interlocks Card

6

7

4

5

Pin

1

2

3

Signal

CAB FWD

CAB REF

SYS FWD

SYS REFL

REJ 1

REJ 2

REJ 3

Description

Cabinet forward sample from directional coupler DC1 at combiner output.

Cabinet reflected sample from directional coupler DC1 at combiner output.

System forward sample from customer I/) board J16 at top of transmitter.

System reflected sample from customer I/O board J16 at top of transmitter

Reject sample from on customer I/O board J19 at top of transmitter



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4.4.3.4

PA Interface Card


The PA interface card(s) connects the TCU, Predriver assembly, IPA (driver) and PA backplane boards. The interface features 40 digital outputs/inputs and 24 analog outputs/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. Figure 4-6 shows how the

PA interface boards connect to the IPA (driver) and PA backplanes.

B

PA Interface

Board, A4A7

Rear VIew

D C

B

A

BP 1

A

50

J1

PA

Backplane

A5

BP 2

50

J1 PA

Backplane

A6

Drive A

50

J1

J2

Drive B

Predriver

Assembly

A12

50

D

PA Interface

Board, A4A8

Rear VIew

C

BP 4

BP 3

50

J1

PA

Backplane

A8

J1 PA

Backplane

A9

50

J1

J5

IPA

Backplane

A7

10/6/10

Figure 4-6 PA Interface Card Connection to Backplane Boards

4.4.3.4.1 Predriver and IPA Drive A and B Busses

The Drive A and Drive B busses provide control and monitoring of the predriver and

IPA modules A and B. These busses run from connectors J3A and J3B of PA interface

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4-13

Section 4 Theory of Operation Maxiva ULX COFDM Series board A4A7 to connectors on the predriver assembly and the IPA backplane board, see

Figure 4-6. Table 4-4 provides the connections for these busses.

Table 4-4 Predriver and IPA Drive A and Drive B Control Busses

7 N C

8 N C

9 N C

10 N C

11 Gnd

12 N C

13 N C

Predriver Assembly Connectors J1 and J2, and IPA Backplane Connectors J1 and J5

Pin Function Pin Function Pin Function Pin Function

1 +15V from TCU 14 N C

2 IPA A or B Fault 1 15 N C

27

28

N C

N C

40

41

Gnd

N C

3 IPA A or B Fault 2 16 Gnd

4 IPA A or B Fault 3 17 IPA A or B On/Off

29 N C

30 N C

5 IPA A or B Prsnt 18 Off/On Predrvr A or B 31 Gnd

6 Gnd 19 N C 32 TP1 - IPA A or B

42

43

44

45

N C

Gnd

IPA A or B Out Pwr

IPA A or B Sum Current

20

21

22

23

24

25

26

N C

Gnd

N C

N C

N C

N C

Gnd

33 Pwr Cntl Predrvr A or B 46 Gnd

34 Gnd 47 Cnt Predriver A or B

35 Phase Cntl Predrvr A or B 48 In Pwr Predrvr A or B

36 N C 49 Gnd

37

38

Gnd

N C

50 N C - Predrvr, Gnd - IPA

The Ground serves as an

IPA module interlock.

39 N C

4.4.3.4.1 PA BP (Backplane) Busses 1 Through 4.

The BP 1 through BP 4 PA backplane busses provide control and monitoring to backplane boards A5, A6, A8, and A9 respectively. They control and monitor the 16 PA modules (four modules for each backplane). These busses run from connectors J2A and

J2B of the two PA interface boards A4A7 and A4A8 to connectors on the PA backplanes, see Figure 4-6. Each of these busses have 50 conductors. Table 4-5 provides the connections for these busses.

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Table 4-5 PA Backplane Board BP 1 through BP 4 Control Busses

Pin Function

1 VA+

2 PA 1 Fault 1

3 PA 1 Fault 2

4 PA 1 Fault 3

5 PA 1 Present

6 Gnd

7 PA 2 Fault 1

8 PA 2 Fault 2

9 PA 2 Fault 3

10 PA 2 Present

11 Gnd

12 PA 3 Fault 1

13 PA 3 Fault 2

Pin Function

14 PA 3 Fault 3

15 PA 3 Present

16 Gnd

17 PA 4 Fault 1

18 PA 41 Fault 2

19 PA 4 Fault 3

20 PA 4 Present

21 Gnd

22 PA 1 On/Off

23 PA 2 On/Off

24 PA 3 On/Off

25 PA 4 On/Off

26 Gnd

Pin Function

27 Digital Output 5

28 Digital Output 6

29 Digital Output 7

30 Digital Output 8

31 Gnd

32 TP3, Analog_Out 1


34 Gnd



37 Gnd

38 PA 1 Output Power

39 PA 1 Sum Current

Pin Function

40 Gnd


42 PA 2 Sum Current

43 Gnd


45 PA 3 Sum Current

46 Gnd


48 PA 4 Sum Current

49 Gnd

50 Gnd

4.4.3.5

Customer I/O Card

The primary function of the Customer I/O Card is to interface between the internal transmitter control system and all external or peripheral devices.The customer I/O card is located in the TCU and is connected to the Customer I/O board connectors J13 and

J14 inside the cabinet top. For more detail on the customer I/O connections which can be found on the customer I/O board on the top of the cabinet refer to section 4.5 on page

4-28 and to section 2.7 on page 2-28.

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4.4.3.6

Exciter Switcher Card


The exciter switcher card in the main cabinet TCU controls exciter switching with a board mounted relay. It includes 2 RMS detectors with adjustable trip points that use

EPOT’s to monitor exciter power. There are control and status interface connectors J1A and J1B that go to exciters A and B respectively. Table 4-6 shows the signals on the pins of connector J1A. The simplified block diagram for the exciter switcher card is given in

Figure 4-7.

Figure 4-7 Exciter Switcher Block Diagram

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Table 4-6 Exciter A Control/Status Connector J1A on TCU (9 pin female dsub)

6

7

4

5

Pin

1

2

3

8

9

Signal

/EXC_A_MUTE_CMD

/EXC_A_EQUALIZER_HOLD_CMD Open collector output- Exciter A equalizer hold command-100mA sink capability @ 0.8Vdc max.

1K ohm pull up to +5V. TVS protection.

Active’0’ state to command exciter equalizer to hold.

/EXC_A_ACTIVE_CMD Open collector output- Exciter A active command-100mA sink capability @ 0.8Vdc max.


Active’0’ state to command exciter equalizer to

"on air".

NC

GND

GND

/EXC_A_MUTE_STATUS

Description

Open collector output- Exciter A mute command-100mA sink capability @ 0.8Vdc max.


Active’0’ state to command exciter mute.

No connection

Ground

Ground

CMOS input-Exciter A mute status-’0’ on this line indicates exciter is muted. TVS protection.

1K pull up to +5Vdc

/EXC_A_RF_PRESENCE_STATUS

/SUMMARY_FAULT

CMOS input-Exciter A RF presence status-’0’ on this line indicates exciter is present. TVS protection. 1K pull up to +5Vdc.

CMOS input-Exciter A summary fault-’0’ on this line indicates exciter has a fault. TVS protection.

1K pull up to +5Vdc.

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Table 4-7 Exciter B Control/Status Connector J1B on TCU (9 pin female dsub)

6

7

4

5

Pin

1

2

3

8

9

Signal

/EXC_B_MUTE_CMD

/EXC_B_EQUALIZER_HOLD_CMD Open collector output- Exciter B equalizer hold command-100mA sink capability @ 0.8Vdc max.


Active’0’ state to command exciter equalizer to hold.

/EXC_B_ACTIVE_CMD Open collector output- Exciter B active command-100mA sink capability @ 0.8Vdc max.


Active’0’ state to command exciter equalizer to

"on air".

NC

GND

GND

/EXC_B_MUTE_STATUS

Description

Open collector output- Exciter B mute command-100mA sink capability @ 0.8Vdc max.


Active’0’ state to command exciter mute.

No connection

Ground

Ground

CMOS input-Exciter B mute status-’0’ on this line indicates exciter is muted. TVS protection.

1K pull up to +5Vdc

/EXC_B_RF_PRESENCE_STATUS

/SUMMARY_FAULT

CMOS input-Exciter B RF presence status-’0’ on this line indicates exciter is present. TVS protection. 1K pull up to +5Vdc.

CMOS input-Exciter B summary fault-’0’ on this line indicates exciter has a fault. TVS protection.

1K pull up to +5Vdc.

4.4.3.7

PS Monitor Card

The PS monitor card is located in the TCU. The board’s primary function is to provide

AC power supply monitoring, fuse monitoring, inlet and outlet temperature sensing, coolant flow, leak detection, cooling fan tachometer monitoring, and PA Driver switch interface. A simplified block diagram for the board is given in Figure 4-8.

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Figure 4-8 PS Monitor Card Block Diagram

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4-19


Table 4-8 AC1 MOV1 Connector J4A (25 pin stacked female dsub)

Pin

1

4

5

2

3

6

7

8

9

10

11-13

14

15-23

24-25

Signal

/MOV_SENSE

+15Vdc

-15Vdc

PH_AB_SAMPLE

PH_BC_SAMPLE

PH_AC_SAMPLE

FUSE1 Open

FUSE2 Open

FUSE3 Open

FUSE4 Open

NC

+5Vdc

GND

NC

Description

CMOS input -MOV board sense status-’0’ on this line indicates the MOV board is present.

TVS protection. 1K pull up to +5Vdc

+15Vdc @ 200mA maximum limited by 0.2A

PTC.

-15Vdc @ 200mA maximum limited by 0.2A

PTC.

Analog input- AC phase AB sample sine wave input scaled to 2Vrms=245VAC

Analog input- AC phase BC sample sine wave input scaled to 2Vrms=245VAC

Analog input- AC phase AC sample sine wave input scaled to 2Vrms=245VAC

CMOS input -MOV board sense status-’1’ on this line indicates the fuse is ok. TVS protection. 1M pull down




Not connected.


PTC.

Ground

Not connected

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Table 4-9 AC2 MOV2 Connector J4B (25 pin stacked female dsub)

Pin

1

4

5

2

3

6

7

8

9

10

11-13

14

15-23

24-25

Signal

/MOV_SENSE

+15Vdc

-15Vdc

PH_AB_SAMPLE

PH_BC_SAMPLE

PH_AC_SAMPLE

FUSE1 Open

FUSE2 Open

FUSE3 Open

FUSE4 Open

NC

+5Vdc

GND

NC

Description

CMOS input -MOV board sense status-’0’ on this line indicates the MOV board is present.

TVS protection. 1K pull up to +5Vdc


PTC.

-15Vdc @ 200mA maximum limited by 0.2A

PTC.

Analog input- AC phase AB sample sine wave input scaled to 2Vrms=245VAC

Analog input- AC phase BC sample sine wave input scaled to 2Vrms=245VAC

Analog input- AC phase AC sample sine wave input scaled to 2Vrms=245VAC





Not connected.


PTC.

Ground

Not connected

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4-21


4.4.4

CPLD (Complex Programmable Logic Device)

Each PA (power amplifier) module contains a CPLD (Complex Programmable Logic

Device) device. The CPLD is not a microprocessor but is a pre-programmed discrete logic device and therefore very stable and reliable. The CPLD’s in the PA modules are responsible for reporting faults back the TCU and also for taking action when the ON/

STBY command is issued by the TCU.

4.4.5

Life Support Functions

Life Support functions are active when the main control system, controlled by the PCM in the main TCU, is not functioning properly. Life support functions are controlled by the MCM card in the main TCU.

Table 4-10 Life Support Functionality

System Function Description

TX On

TX Off

Power Raise

Power Lower

Transmitter ON command via front panel or parallel remote interface.

Transmitter OFF command via front panel or by parallel remote interface.

Transmitter power raise command via front panel or by parallel remote interface.

Transmitter power lower command via front panel or by parallel remote interface.

Manual Exciter A/B

Select

Automatic Exciter

Switch over

Manual Driver A/B

Select

Automatic Driver

Switch over

Exciter selection via front panel or by parallel remote interface.

Automatic exciter switch over of exciters if in AUTO.

Driver selection via front panel or by parallel remote interface.

Automatic driver switch over of Drivers if in Auto.

Manual PA ON/OFF PA modules can be turned on and off via circuit breaker inside rear of transmitter.

Available in

Life Support

Mode

YES

YES

YES

YES

YES

YES

YES

YES

YES

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PA Three Strike

Sequence

Manual Pump Switch

Over

Automatic Pump

Switch Over

Automatic

Transmitter Power

Control (ALC)

VSWR Protection

Fold Back Operation

PA Module Summary

Fault Monitoring

PA Module Deep

Fault Monitoring

PA Module Meter

Readings

AC Faults

Monitoring

Liquid Inlet/Outlet

Temperature Faults

Flow and

Temperature Meter

Readings

Cabinet Summary

Fault

Safety Interlocks

RF Mute Interlocks

Remote Metering

PA module three strike operation required operational

PCM.

Pump switch over controlled by push button from pump control card or by parallel remote interface.

Automatic switch over of pumps if in Auto.

Transmitter power automatic level control if in AUTO.

Not available due to loss of GUI display.

Not available due to loss of GUI display.

Not available due to web loss but available on parallel remote.

Basic Parallel

Remote Control

Basic Parallel Status

Lines

Available in

Life Support

Mode

YES

YES

YES

YES

YES

YES

YES

YES

NO

YES

YES

NO

YES

YES

YES

NO/YES

YES

YES

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4-23





Exciter Parallel

Control

Exciter Serial

Communications

Web Connectivity

4.4.6

Controller Area Network (CAN) Bus

Available in

Life Support

Mode

YES

YES

NO

The Controller Area Network or CAN bus is a high speed serial communications link which is used between the transmitter control boards for transmission of control, status, fault and metering information. The CAN bus is distributed as part of the Cabinet

Bus and System Bus . The CAN bus can operate at speeds up to 1Mbps and is designed to operate in hostile industrial environments. The transceivers feature cross wire, loss of ground, over voltage and over temperature protections. A CAN transceiver connected to the CAN bus is considered a Node. There can be up to 110 nodes on the bus with a maximum bus length of about 40 meters for 1Mbps operation.

In a CAN system, data is transmitted and received using Message Frames. Message

Frames carry data from a transmitting node to one or more receiving nodes. The messages transmitted from any node on a CAN bus do not contain addresses of either the transmitting node or of any intended receiving node.

Instead, the content of each Message Frame (e.g. ON, OFF, PS 1 Voltage, Coolant Flow

OK etc.) is labeled by an identifier that is unique throughout the network. All other nodes on the network receive the message and each performs an acceptance test on the identifier to determine if the message, and thus its content, is relevant to that particular node. If the message is relevant, it will be processed; otherwise it is ignored.

The microprocessors in the MCM and PCM boards have built in CAN controllers which connect to a CAN transceiver and becomes a node on the CAN bus. The CAN transceiver interfaces the single ended CAN controller to the differential CAN bus for high common mode noise immunity, as shown in Figure 4-9. The master and slave

TCUs can send and receive information over the differential CAN bus, however the

MCM card in the main TCU determines what information is sent and when it is sent for this application.

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NOTE:

The MCM card (in the TCU) contains LED’s that will flicker on and off at a random rate indicating that there is activity on the CAN bus. If the LED’s are off or always on, then the CAN bus is most likely not communicating. The LED pair

DS7 and DS8 are for the cabinet CAN bus (Rx & Tx respectively). LED’s DS11

& DS12 are indicators for the System CAN bus (Rx & Tx respectively).

RS 8

(Differential CAN Bus)

CANH CANL

7 6

Standby

Control Reference

Voltage

5 VREF

TXD and RXD connect to the

CAN controller built into the

Micro Module

TXD 1

Transmitter Receiver

2

GND

3

VCC

Figure 4-9 CAN Transceiver Diagram

4 RXD

All fault reporting, status and metering information displayed on the GUI is sent on the

CAN bus to the MCM. Transmitter control signals are also sent via CAN but are also sent over hardwired parallel control lines.

4.4.7

System Bus

10/6/10

The system control bus is a twenty five conductor ribbon cable which distributes the

CAN (Controller Area Network) bus and parallel control lines from the MCM card in cabinet one to other MCM controllers in a multi cabinet system.

If system bus communications with the master TCU (in cabinet 1) are interrupted, the cabinet bus, drive A and B busses, and BP1 through BP4 busses allow each cabinet to operate independently.

The system bus connector J6 (on the rear of the MCM card) has the following pin assignments:

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4-26

Table 4-11 MCM System Bus Connector

12

13

14

15-25

10

11

8

9

6

7

4

5

Pin

1

2

3

Signal

SYS)_CAN_H

/CAB_AC_LOW

/SYS_OFF_CMD

/SYS_RF_MUTE

SYS_ALC

SYS_PS_ADJUST

/SYS_FAULT_OFF

SYS_SPARE1

/SYS_RESTRIKE

SYS_SPARE2

SYS_CTRLR_OK

/SYS_FAULT

SYS_SPARE3

SYS_CAN_L

GND

4.4.8

Cabinet Bus

Description

CAN (5V) pass-through

3.3V CMOS Input

3.3V CMOS I/O

3.3V CMOS I/O

0-4.095V Analog I/O

0-4.095V Analog I/O

3.3V CMOS I/O

3.3V CMOS I/O

3.3V CMOS I/O

3.3V CMOS I/O

3.3V CMOS I/O

3.3V CMOS I/O

3.3V CMOS I/O

CAN (5V) pass through

The cabinet bus connects the cabinet TCU (MCM card) to the IPA and PA backplanes.

The cabinet bus connections are shown in Table 4-12.

Table 4-12 Cabinet Bus Pin Assignments

Cabinet Bus Pins

1 through 6

7

8 through 13

14 Through 24

25

Function

No Connection

PA_voltage_select

No Connection

Ground

No Connection

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Pin 7 of the cabinet bus carries the PA_voltage_select signal from the MCM card to the

IPA and PA backplanes. Its function is to set the output voltage of the AC to DC converters in the PA (and IPA) modules. Table 4-13 gives the control voltage levels and the corresponding PA and IPA module AC to DC converter output voltage.

10/6/10

Table 4-13 PA Module Power Supply Output Voltage Control

PA_Voltage_ Select Voltage

5.755 Vdc

4.122 Vdc

2.490 Vdc

0.875 Vdc

Power Supply Output Voltage

44Vdc

46 Vdc

48 Vdc

50 Vdc

4.4.9

Parallel Control Lines

The parallel control lines are used for quick actuation of critical functions, such as ON,

OFF, RF mute, PS adjust, and Fault Off. These lines are also the backup control lines in

Life Support mode when the PCM (and therefore the system CAN bus) is not operational. The MCM card in each cabinet can independently activate some or all of the parallel control lines to maintain operation and protect the transmitter in case of a fault or other condition that may adversely affect the transmitter. These parallel control signals are duplicated in the CAN messages. The following is a brief explanation of each of the parallel control lines included in the system control bus.

a.

SYS_ON_CMD

This command corresponds to the transmitter operator pushing the "ON" button,

This signal is high for ON and produced by the MCM card in the TCU.

b.

/SYS_OFF_CMD

This command corresponds to the transmitter operator pushing the "OFF" button.

The signal is low for OFF and produced by the MCM card in the TCU.

c.

/SYS_RESTRIKE

When the transmitter is already turned ON and the operator presses the "ON" button, this line will be pulsed low for a minimum of 100ms. This will cause all controller boards to reset any faults and status and try to return to normal operation. This line is a sense only line for the rest of the control boards.

This command is basically a RESET pulse which will try to turn on any transmitter components which have faulted off due to a critical fault condition. If they are still faulty, this will be detected and the component will simply be shut off again. This will not reset or clear the Fault Log.

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4-27

Section 4 Theory of Operation Maxiva ULX COFDM Series d.

/SYS_FLT_OFF

This command is initiated whenever a fault occurs that requires all RF to be shut off and the amplifiers to be disabled. This is a latching type signal that requires user input to clear the fault and turn the transmitter back on. This signal is active low. The signal is generated by the MCM in the main cabinet TCU.

e.

/SYS_RF_MUTE

The /SYS_RF_MUTE line shuts down all RF output temporarily until the fault condition is cleared. This is a non-latching signal. Non-latching means that if the fault clears the transmitter will resume previous RF output.

f.

SYS_PS_ADJUST

The SYS_PS_ADJUST line changes the output of the PA module power supplies depending on modulation mode. g.

/SYS_FAULT h.

SYS_ALC

Automatic Level Control. The ALC signal is used to control the cabinet power output and is normally sent digitally over the CAN bus. This line carries an analog voltage from the MCM to the predriver modules. The analog signal is an alternate version of the digital ALC signal sent over the CAN bus. It is a backup signal only used if the PCM card in main cabinet (cabinet one in multi cabinet systems) fails. If the PCU and it’s associated CAN bus is operational, this signal is not used.

4.5

Customer I/O Board

4-28

The customer I/O board is located on top of the main cabinet and provides parallel remote control, status and meter outputs. There are 20 command inputs, 20 status inputs, 8 analog inputs and 8 analog outputs. See 2.15.1 on page 2-58 for additional information and details on the remote control connectors available on the customer I/O board.

Input/Output (I/O) ports on the Customer I/O Board include:

J1 Pump Module see Table 2-6 on page 2-19 for connections

J2 Interlocks see Table 2-10 on page 2-33 for connections

J3 Control 1 see Table 2-12 on page 2-58 for connections



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J6 Status 1 see Table 2-13 on page 2-60 for connections



J9 Meters see Table 2-14 on page 2-62

J10 RF Switch see Table 2-15 on page 2-63

4.6

Transmitter RF System

4.6.1

Apex M2X Exciter(s)

The Maxiva ULX series COFDM transmitter comes standard with a single M2X exciter. A second standby exciter is available as an option along with an exciter changeover switch card in the TCU. Operation and information about the M2X exciter is contained in the instruction manuals shipped with the exciter. If there are two exciters the output of the exciters are connected to the exciter switch card in the main cabinet

TCU. In cases where there is a single exciter it’s output goes directly to the pre-driver.

For additional information on the M2X exciter see the exciter technical manual which ships with each transmitter.

4.6.2

Predriver

The Maxiva predriver provides redundant power and phase adjustment of the RF drive signal for the transmitter. The predriver operates over UHF TV frequency bands IV/V.

The unit includes an air cooled 28V 4.5A power supply, phase-n-gain board, RF amplifier and interface board. The predriver is designed to perform following functions:

•

Adjust the power level of the RF signal with adjustment range at least 30dB.

•

Adjust the phase of the RF signal with adjustment range at least 180°.

•

Monitor operating parameters of included subassemblies

•

Amplify RF signal. The max Gain is 31dB.

•

Provide connection with TCU through Interface Board.

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4-29


4-30

Figure 4-10 Predriver Module Photo (module removed from Predriver assembly)

The predriver assembly holds two predriver modules. The modules are redundant and hot swappable. See photo in Figure 4-10 on page 4-30 to aid in identification of predriver module components.

The single rack unit predriver assembly has one RF input and two RF outputs, see

Figure 4-11 on page 4-31 for a schematic orientated block diagram of the predriver assembly. It features two predriver trays (modules), each of which drives its own IPA.

The RF input to the predriver assembly feeds a two way splitter, the output of which feed the two predriver trays. The assembly is designed so that one predriver tray can be removed for servicing while the transmitter operates from the other predriver tray.

It should be noted here that only one IPA drives the PA, the other is terminated in a load.

The IPA outputs feed a coax switch, which is controlled by the power supply monitor board in the TCU assembly. This allows either IPA to drive the PA assembly.

The interconnect board is the interface between the transmitter cabinet wiring and each predriver tray. Each predriver tray has a connector, mounted on its interface board, which mates with a connector on the interconnect board. The interface board connects to the four boards of the predriver tray.

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Predriver Tray A

AC

Filter

Connector and Switch

FL2

Sync

Input

J4

J1

Edge

Con.

JX

RF

Output

Interconnect

Board

801-0222-271

Interface

Board

801-0222-261

AC

J4

J2

J3 J1

J3

28 Volt

Power

Supply

DC

DC and Control

RF

Out

CD2007

Amplifier

RF

In

RF Input

J5

LED

Assembly

RF

Input

JX

2-Way

Splitter

SP1

AC

Filter

Connector and Switch

FL2

Sync

Input

J4

J2

Edge

Con.

JX

RF

Output

J5

Interface

Board

801-0222-261

AC

J4

J2

J1

J3

28 Volt

Power

Supply

DC

DC and Control

RF

Out

CD2007

Amplifier

RF

In

RF Input

J5

LED

Assembly

C14 C1

AC

GND

AC

A14 A1

Blind Mate Connectors, J5, J3, and J1,

Interconnect to Interface Boards,

View From Rear of Predriver Assembly

Figure 4-11 Predriver Backplane Diagram

RF OUT

NC

RF In

J3, DC and Control

RF

Out

J1

Phase & Gain

Board

801-0222-221

RF

In

J2

Predriver Tray B

J3, DC and Control

RF

Out

J1

Phase & Gain

Board

801-0222-221

RF

In

J2

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4-31


The CD2007 output amplifier board and the phase and gain board receive their power form the power supply board mounted on the tray. This power supply produces 28 Vdc at 4.5 amps maximum.

The phase and gain board provides a continuously variable phase change of 180 degrees, which is used to combine multiple PA cabinets. It also has an attenuator, driven by the transmitter’s ALC (automatic level control) circuit, which has a 0 to 15 dB variable range. The phase and gain board is used by the transmitter to control cabinet power (by driving the PA modules with more or less input power) and cabinet phasing.

Figure 4-12 gives a block diagram of the phase and gain board.

4-32

Figure 4-12 Phase and Gain Board Block Diagram

The CD2007 output amplifier has a peak rating of 35 watts and is generally operated over a 0.3 to 4.0 watt average range for digital, to allow adequate peak to average power headroom. In the analog TV mode its output is up to 6 watts peak of sync with 10% aural. At 28 Vdc supply voltage this amplifier requires approximately 5.2 amps to produce 35 watts output. It has an efficiency of 24% at 35 watts output.

The typical gain of the predriver tray is 32 dB, and the gain of the predriver assembly

(which includes the 2-way splitter) is 28 dB.

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4.6.3

IPA (driver) and PA Module


The purpose of Maxiva ULX PA and IPA (driver) module is to amplify modulated RF signal providing approximately 19dB gain over the TV frequency bands IV/V. The module includes its own power supply section that generates drain bias for RF power generating section of the module. The PA module is designed to be used within terrestrial television standards G, H, I, K, KI, L, M, N with color systems PAL, SECAM or NTSC. The PA module can operate in common amplification mode with single or dual aural sub-carrier present along with the visual amplitude modulated carrier. The PA and IPA (driver) modules can be used to amplify digitally modulated RF signals, such as COFDM and 8-VSB. The modulation bandwidth is not to exceed 8MHz.

The PA and IPA (driver) Modules are the same, hereafter, they will be referred to as the

PA module. A schematic orientated block diagram of the PA module is shown in Figure

4-13 on page 4-34. The Connector I/O board is the connecting link to the PA or IPA backplane board for all connectors except for the RF output connector. See the module photo in Figure 1-6 on page 1-10 to aid in IPA/PA module component identification.

The RF input, signal enters the Connector I/O board through the blind-mate connector

J1. It enters the Splitter board through J2, where it is split into four signals, which are the drive signals for the four PA pallets, A13 through A16. The RF signal enters each

PA pallet through E1 and the amplifier signal leaves the pallet through E2. From the PA pallets, the four RF signals enter the combiner board via ports 1 through 4. The combined output leaves the combiner board and the PA module through a blind mate

RF connector.

Blind mate connector J1 is a combination RF and control connector. A discussion of the connector pinout is included in Section 4 “Section 4 Theory of Operation” on page 4-39 a drawing of the connector is shown in Figure 4-16 on page 4-40.

Three phase AC power enters the Connector I/O board at J1 pins E1-8 through K1-8, then via TB1, TB2, and TB3 to the AC Distribution board J10, J11, and J12. In the AC

Distribution board, a single phase of the three phases of AC input power is applied to each power supply in an arrangement which balances the load between the phases.

Three phase AC in 208 to 240 volt delta or 380 to 415 volt wye can be used in these transmitters. Additional information concerning the three phase AC connections is given in Section 4.6.3.1 on page 4-35.

Each power supply provides a DC output voltage which is controlled by the

PA_Voltage_Select signal from the MCM (main control module in the TCU) via the

Cabinet Control Bus pin 7, see Figure 4-14 on page 4-37 for signal path. This DC voltage, on pin 7 of the Cabinet Control Bus, determines the output voltage of the eight

PA module power supplies as indicated in Table 4-15 on page 4-36. Within the PA module, the PA_Voltage_Select signal path is via J1-B5 to J2-8 on the Connector I/O board, J4-8 to J1-8 on the Splitter board, J1-8 to J2-1 on the Monitor board, J9-1 to J1-8 through J8-8 on the AC Distribution board, to J1-8 on each power supply board.

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4-33


See Figure 4-

16 for details of connector J!

AC Power

J10

J1

J11

J2

J12

J3 J4 J5

AC Distribution Board A2

801-0222-021

J6 J7 J8

J9

J1

56P

24P

Connector I/O

Board

801-0222-041

J2

RF Output

J1 J1 J1 J1 J1 J1 J1 J1

PFE500-48

PWR Supply

PFE500-48

PWR Supply

PFE500-48

PWR Supply

PFE500-48

PWR Supply

PFE500-48

PWR Supply

PFE500-48

PWR Supply

PFE500-48

PWR Supply

PFE500-48

PWR Supply

PS Board A3

801-0222-011

PS Board A4

801-0222-011

PS Board A5

801-0222-011

PS Board A6

801-0222-011

PS Board A7

801-0222-011

PS Board A8

801-0222-011

PS Board A9

801-0222-011

PS Board A10

801-0222-011

50V TB1 50V TB1 50V TB1 50V TB1 50V TB1 50V TB1 50V TB1 50V TB1

9 10 11 12 13 14 15 16

J1

J2, RF In

Port 1

RF Out

J3

J4

Splitter Board A11

801-0222-071

Port 2

RF Out

Port 3

RF Out

Signal

Distribution

Board A12

801-0222-061

Port 4

RF Out

J1

J1

E1-RF

In

PA Pallet A13

801-0222-081

9

DC In

10

E2-RF Out

PA Pallet A14

801-0222-081

DC In

11

J1

E2-RF Out

E1-RF

In

12

J1

E1-RF

In

PA Pallet A15

801-0222-081

DC In

13 14

E2-RF Out

15

J1

E1-RF

In

PA Pallet A16

801-0222-081

DC In

E2-RF Out

16

RF In

Port 1

RF In

Port 2

RF In

Port 3

Combiner Board A17, Schematic Number 801-0222-091

RF In

Port 4

J1

J2

Refer To Drawing 843-5601-012 For Greater Detail

Figure 4-13 PA Module Block Diagram (schematics referenced)

J2

Monitor

Board A18

801-0222-051

J1 J3

This is the

PA Control

Board, but it uses a CPLD instead of a microprocessor

J4

J3 is the

Test Jack

Output

RF Sample

Output

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4.6.3.1

AC Distribution Board


The AC distribution board consists of three identical groups of AC line filtering, two stages of transient protections per filter section. First stage of the protection is formed by a network of MOVs which connects to the AC line filter inputs. The second stage of protection provides a hard voltage limit by using high energy TVS devices, which are connected at the output of each filter section. The maximum peak voltage is limited to

582Vpeak, and is below peak allowed voltage to AC/DC converter interface board.

On board 48V/12V DC/DC converter can provide up to 1.25A of continuous current.

Four wire WYE with neutral power system:

Four wire WYE configuration supports 380/400/415 Vac line to line voltages.

Converters are connected between line and neutral, which yields 220/230/240 Vac L-N.

Therefore, minimum Line-N voltage is 187Vrms.

Three wire Delta/WYE line to line power system:

Maxiva ULX power amplifier module employs a total of 8 power supply converters.

This presents an unbalanced load to the three phase power line grid.

4.6.3.2

AC/DC Converter Interface Board

AC/DC Converter Interface board is a 500W output AC to DC switching power supply.

It accepts universal AC input voltage from 85 to 265 Vac and the output voltage is adjustable from 44V to 50Vdc. See section 4.6.3.3 on page 4-36 for additional information on how PS voltages are set.

Converter is equipped with a power factor correction front end to reduce power line harmonics. Because of the large DC reservoir capacitors connected to its DC bus, a step start resistor is added to limit the inrush current to 7Apeak per converter, this is equal to

~1.5x converter’s maximum continuous operating current.

The AC/DC Converter Interface PWB is approximately 2.45” x 5.00”. All mounting holes are electrically connected to ground. It is a 4 layers board. The AC/DC converter boards are field replaceable. AC/DC converter (power supply) replacement instructions can be found in section 5.7 on page 5-13.

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4-36

Table 4-14 PS Connector Pin Assignments

6

7

4

5

Pin

1

2

3

8

9

10

Signal

AC1

NC

AC2

NC

NC

GND

GND

DC Trim

DC Source

DC Sample

Description

Input, 3.4A, 240VAC fused at 5A

Not connected

Input, 3.4A, 240VAC fused at 5A

Ground

Ground

Input, 6.49K ohms, 0.75VDC to 6.0VDC

Output, 0.4A, 50VDC

Output, 9.09 Ohm, 50VDC

4.6.3.3

PA PS (AC/DC) Voltage Select Path

Each PA and IPA has eight AC/DC converters (power supplies) which supply voltage to the drains each power amplifier FET. Depending on the RF frequency of operation, the power supplies can be set for 44 Vdc, 46 Vdc, 48 Vdc or 50 Vdc. The power supply output voltage select path, from the MCM board in the TCU to each power supply in each PA and IPA module is shown in Figure 4-14 on page 4-37. The PA voltage select path from the MCM board in the TCU to the IPA and PA backplanes, shown with bold lines in figure Figure 4-14, is carried on pin 7 of the 25 conductor Cabinet Bus. This represents the only use of the cabinet bus in the Maxiva transmitter.

Table 4-15 PA Module Power Supply Output Voltage Control

PA_Voltage_ Select Voltage

5.755 Vdc

4.122 Vdc

2.490 Vdc

0.875 Vdc

Power Supply Output Voltage

44Vdc

46 Vdc

48 Vdc

50 Vdc

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The Bold line represents the Cabinet Bus path.

IPA Backplane

Board

801-0222-131

J2-7 J3-B5

J4-B5

The IPA Modules are the same as the

PA Modules, therefore, the voltage select signal path is the same as shown for the PA module.

25

TCU

801-0221-031

MCM

Board

801-0221-011

J5-7

PA Backplane

Board

801-0222-101

J2-7 J3-B5

Interconnection

Board

801-0222-041

J1-B5 J2-8

PA Module

J4-8

System

Distribution

Board

801-0222-061

J1-8 J1-8

Monitor

Board

801-0222-051

J2-1 J9-1

J1-8

AC Distribution

Board

801-0222-021

J8-8

J1-8

PS 1

801-0222-081

J1-8

PS 8

801-0222-081

Figure 4-14 Maxiva PA Module Schematic Orientated Block Diagram

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4-37


4-38

Figure 4-15 AC/DC Converter Interface Block Diagram

4.6.3.4

PA Monitor Board

The PA Monitor Board controls and monitors the PA module’s operation. All analog parameters of the power amplifier are monitored and evaluated via the analog comparators to generate the OK/FAULT logic signal, and the signal is sent to a CPLD device to realize a pre-defined control logic algorithm. The fault and warning information is displayed by the red/green LED’s in front of the PA, and the fault signal is coded and delivered to the UCP in the Maxiva ULX transmitter via individual separate wires. The overall control logic is done via a CPLD device and there is no microprocessor on board and there is no serial communication designed into the PA monitor board.

Only one fault can be detected at a time. If two or more fault conditions are detected simultaneously only the highest priority fault is shown through the front panel LEDs

See Table 4-16 on page 4-39 for a description of the LED indications. The priority table is designed to segregate fault that is most likely responsible for other faults that show up simultaneously. The 3-bit code assigned to the fault with highest priority is sent to the

UCP. Following table shows priority assignment and corresponding 3-bit codes.

Priority, Code, Description

•

0, 000,No Fault

•

1, 001,Temperature Fault

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•

2, 010, VSWR Fault

•

3, 011, Overdrive Fault

•

4, 100, PS Failure

•

5, 101, MOSFET Fault

•

6, 110, RF IN Low Fault


The Monitor board contains the PA module control circuitry. It is a CPLD controlled circuit, which accepts commands from the TCU and returns status and monitoring signals to the TCU. Within the PA module, the communication path between Monitor board and the TCU is J1 on the Monitor board to J1 on the Signal Distribution board, J4 on the Signal distribution board to J2 on the Connector I/O board, and J2 to J1 on the

Connector I/O board. The Monitor board communicates with all of the other boards in the PA module via its connectors J1, J2, and J4. Connector J3 on the Monitor board is a test output used by engineering.

Table 4-16 PA Module Front panel LED Indications

Index

1

4

5

2

3

6

7

LED Color

Green

Red

Red

Red

Red

Red

Green

Indication

ON-OFF

Description

ON: Green, OFF: None

LDMOS Failure

When one or more LD-MOSEFET failed

P.S. Failure

When one or more PS failed

Temp Fault

When one or more Pallet temp fault

VSWR Fault

Reflected Power Overload

Power Overload

Input/Output Power Overdrive/ Overload

Input Power OK

OK: Green; Input Power Low: Red

4.6.3.5

J1 - PA or IPA Connector I/O Board

Refer to Figure 4-16. The pins of sections A through D of the connector are in horizontal rows of six pins, with pin 1 to the left and pin 6 shown to the right.

The pins of sections A through D are used for control, status, and monitoring.

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4-39


The pins of Sections E through L are arranged in dual vertical rows four pins each. All eight pins of each section (E through K) are connected together and used for three phase

AC input with the eight pins of section L connected to ground.

The three phase AC delta or wye configurations are shown in Table 4-14 on page 4-36.

If a 208 to 240 volt delta connection is used, connector sections F, H, and K are connected to L2, L3, and L1 respectively. If a 380 to 415 volt wye connection is used, connector sections F, H, and K are connected to the 3 phase neutral. The line or neutral choice is made by connecting jumpers between terminals 1 and 2 for neutral and between 2 and 3 for line inputs in the following listed IPA and PA backplane connectors. In the IPA backplane use TB1 through TB6, In the PA backplane use TB3 through TB8, TB10 through TB12, and TB14 through TB16.

56 Pin Section 24 Pin Section

E F G H J K L 1 2 3 4 5 6

A

B

C

D

RF Input

Connector

Figure 4-16 IPA (driver) or PA Module, Connector I/O Board, Connector J1 Detail

Table 4-17 Three Phase AC Inputs to Connector J1

Phases

L1 to L2/N

L2 to L3/N

L3 to L1/N

J1 Sections

E to F

G to H

J to K

Output to

Connector I/O

Board

TB1

TB2

TB3

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4.6.3.6

Signal Distribution Board


Signal Distribution Board serves to route analog and digital control and monitoring data between 4 other board subassemblies, such as:

•

Monitor Board

•

Four PA Pallets

•

I/O Connector Board

•

4-way splitter board

4.6.3.7

PA Module Phase Alignment

PA modules do not require phase alignment to optimize combining of modules. The modules are phase optimized at the factory to produce 90 degrees of phase shift (input to output at 800 MHz) with a tolerance of 5%. The factory phase alignment of each module insures that modules can be used in any position in the transmitter with minimal effects on transmitter operation.

4.6.3.8

PA Module Splitter

The power splitter 9010222071G is used in the Maxiva PA Module (p/n 9710040004) to equally divide RF signal that is applied on the input of the splitter between 4 power amplifier pallets. The splitter has a broad band response that covers the entire TV Band

IV/V frequency range, and requires no tuning. Insertion phase of the signals at each of the outputs is configured to provide minimum loss re-combining by the power combiner. The splitter contains two splitting stages. Each stage equally distributes the input signal between two outputs. Each RF output is isolated from the others to improve amplitude balance between amplifier pallets. The splitter contains envelope detector circuitry that delivers a sample of the down converted signal to the Monitor Board (p/n

901 0222 051G). It contains a directional coupler and a logarithmic amplitude detector.

4.6.3.9

PA Module Pallet Combiner

The power combiner (p/n 901 0222 091G) is used as part of the Maxiva PA Module (p/ n 971 0040 004) to combine the RF signals from the outputs of the 4 power amplifier pallets, and deliver the resulting signal to the output port. The combiner has a broadband response that covers the entire TV Band IV/V, and requires no tuning. The

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4-41

Section 4 Theory of Operation Maxiva ULX COFDM Series combining of the signals is done in series fashion with the first stage being a 2-way 3dB hybrid, the second stage being a 2-way 4.77dB hybrid, and the 3 rd

stage being a 2-way

6dB hybrid. Each RF input is isolated from the others by using 50 Ohm 500W reject loads. This allows continuous operation of the PA Module in the event of a PA Pallet failure. The combiner contains Forward and Reflected signal directional couplers at the output trace. Two directional couplers have envelope detector circuitry included. The detector circuitry serves to deliver a sample of envelope detected signal to the Monitor

Board (p/n 9010222051G). The sampled base band signal amplitude indicates power level in dBm. The third directional coupler serves to deliver a scaled down sample of output RF signal to a specially designated coaxial port at the front panel of the PA

Module.

4.6.3.10 RF Pallets

The PA pallet serves as the single stage of amplification in the Triton module. There are

4 PA pallets operating in parallel in this PA module. A simplified diagram of the pallet is given in Figure 4-17. Each pallet has a hybrid splitter on the input side of the FET’s.

The hybrid divides the RF input signal into two equal parts to feed the two pallet FET’s.

There is another hybrid at the output of the FET’s that is used to combine the amplified outputs. The RF pallets are field replaceable. Replacement instructions can be found in section 5.6 on page 5-11.

4-42

Figure 4-17 PA Pallet Simplified Block Diagram

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4.6.3.10.1 FET Bias

The LDMOS FET’s used in the Maxiva ULX pallets have been designed by the manufacturer to maintain the factory bias characteristics without the need for re-biasing in the field. The idle current for each FET is set at the factory to approximately 1 amp.

Variations between FET idle currents should be less than 10%.

4.6.4

Module Combiner

The module combiner is a compact, water cooled, hybrid combiner optimized to work across the entire UHF frequency band from 470MHz to 860MHz. There are several combiner configurations depending on the number of PA modules used in the cabinet.

Figure 1-2 on page 1-3 shows two 8-way PA module combiners (upper and lower with one combiner for each half of the cabinet). The combiner is fed by the PA module outputs.

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4.7

Cooling System


Information about the Maxiva ULX cooling system can be found in 1.2.8 on page 1-13 and in 2.5 on page 2-6.

4.7.1

Heat Exchanger/Pump Module Diagrams

Figure 4-18 is a block diagram that shows the major components in the heat exchanger pump module system. The diagram shows the transmitter as the heat source but does not give details of the plumbing external to the heat exchanger/pump module.

Figure 4-19 on page 4-46 shows the schematic diagram of the heat exchanger/pump module control panel. Information on interconnect wiring between the control panel and the transmitter see Table 2-5 on page 2-18.

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Figure 4-18 Heat Exchanger/Pump Module Block Diagram

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4-45


4-46

Figure 4-19 Heat Exchanger/Pump Module Schematic

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10/6/10

Figure 4-20 Heat Exchanger & Pump Module Schematic_Part 1

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4-47


4.7.2

Leak Detector and Cabinet Drains

A leak detector is installed at the bottom of the cabinet. The leak detector is shown in

Figure 4-21 on page 4-48. It is mounted in the bottom cabinet near the center. The leak detector consists of a small reservoir with a float. The TCU monitors this leak detector to alert the system should a leak occur. A leak detection will cause the transmitter and the pump to be shut off by activating the pump interlock signal. In order to reset the leak detector the float must be removed and a drain plug removed. Removing the drain plug allows the reservoir to drain into the drip pan at the bottom of the cabinet.

The cabinet can be emptied of coolant by opening the fittings at the end of the supply and return side drain hoses. Use a 7/16" open end wrench to open the drain valves.

Leak

Detector

Supply Side

Drain Hose

Return Side

Drain Hose

Figure 4-21 Leak Detector and Cabinet Drains

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4.8

Maxiva 16 Module Transmitter Diagrams

The Maxiva transmitter has many configurations for different power levels. A PA cabinet can hold up to 16 PA modules, and can have up to three cabinets. This paper refers to the 16 module transmitter which is housed in the main PA cabinet. When this configuration is understood, the other transmitter configurations should be understood since they are close to this one.

4.8.1

RF Block Diagram

A schematic orientated block diagram of the Maxiva 16 Module transmitter is shown in

Figure 4-22 on page 4-51. The exciter switcher (located in the TCU assembly) selects one exciter for on the air, the other one is connected to a load. Following the exciter switcher is a three way splitter, which provides RF drive for up to three PA cabinets.

From the three way splitter, the RF goes to the predriver assembly.

Note: The IPA and PA modules are the same.

The predriver assembly features an RF splitter and two predriver modules. It therefore has one input and three outputs. The predriver assembly is discussed in greater detail

4.6.2 on page 4-29, and its block diagram is shown in Figure 4-11 on page 4-31.

The two RF output signals from the predriver are applied to the IPA backplane, where they drive two IPA modules. The two IPA output are applied to the RF drive switch, where the output from one IPA drives the PA modules and the other is sent to a test load.

The on the air IPA output drives a two way splitter, with each of its outputs driving an eight way splitter. Each of these 16 RF outputs are used to drive the 16 PA modules.

The PA modules are inserted into mating connectors on back plane modules. Each backplane module will hold four PA modules, therefore, four PA backplanes are required to house the 16 PA modules.

The PA (and IPA) backplanes are interfaces which supply each PA (or IPA) module with the following:

•

Three phase AC power to feed the eight AC to DC converters within each PA module. These converters supply the DC power to the four PA pallets within each PA module.

•

RF drive.

•

Control and monitoring signals.

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4-49


•

Sync, required for analog TV transmitters only.


The outputs from the PA modules are combined as follows:

•

PA Slots 1 through 8 are combined in 8-Way combiner A13.

•

PA Slots 11 through 18 are combined in 8-Way combiner A12.

•

The outputs of the two 8-Way combiners are joined in 2-Way combiner A14.

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Exciter:

APEX-M2X

ATSC Mode separate manual

888-2624-003

Exciter:

APEX-M2X

DVB-T Mode separate manual

888-2624-003

J5 Exciter

J8

Switcher

J4

(In TCU)

801-0221-141

3-Way Splitter,

SP3, Page 3 of

Main Cabinet

Drawing

843-5601-001

RF drive for 2nd 2K unit

RF drive for 3rd 2K unit

Predriver

Assembly (A12)

843-5601-062

Driver

Switch

S2

2-Way

Splitter

SP7

8-Way

Splitter

SP6

8-Way

Splitter

SP5

These blocks are shown on the Main

Cabinet Wiring Diagram, 843-5601-001.

Driver Switch is on sheet 4, and Splitters are on sheets 4 or 5, depending on configuration.

4

4

4

4

PA Module 18

843-5601-012

PA Module 17

843-5601-012

PA Module 16

843-5601-012

PA Module 15

843-5601-012

PA Module 14

843-5601-012

PA Module 13

843-5601-012

PA Module 12

843-5601-012

PA Module 11

843-5601-012

PA Module 8

843-5601-012

PA Module 7

843-5601-012

PA Module 6

843-5601-012

PA Module 5

843-5601-012

PA Module 4

843-5601-012

PA Module 3

843-5601-012

PA Module 2

843-5601-012

PA Module 1

843-5601-012

J3

IPA Module A

843-5601-012

J4

IPA Module B

843-5601-012

Output to

PA Cabinet

Combiner or

High Power

Filter.

Figure 4-22 Maxiva 16 Module Transmitter Schematic Orientated Block Diagram

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4-51


4-52 888-2629-200


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10/6/10


Section 5

Maintenance and

Alignments

5

5.1

Introduction

This section contains all of the maintenance and alignment procedures for the Maxiva

ULX Series UHF transmitter. This includes routine maintenance, PA module replacement, PA Module repair, transmitter calibration and PC Board replacement procedures.

5.2

PA Module Removal and Replacement

!

CAUTION:

TOXIC BERYLLIUM

SOME COMPONENTS IN THE MODULE CONTAIN TOXIC BERYLLIUM. THIS LIMITS

MODULE REPAIR TO A MODULAR LEVEL CONSISTING OF PALLETS AND PC

BOARDS ONLY.

HOT SURFACE

THE MAXIVA PA MODULES ARE DESIGNED TO HANDLE VERY HIGH

TEMPERATURES AND MAY BE EXTREMELY HOT, UP TO 90

O

F (32

O

C) ABOVE

ROOM TEMPERATURE. DO NOT TOUCH THE MODULES WITH BARE HANDS

AFTER THE TRANSMITTER HAS BEEN RUNNING, ESPECIALLY IN HIGH AMBIENT

TEMPERATURE ENVIRONMENTS. SPECIAL GLOVES CAN BE OBTAINED FROM

HARRIS, PART #0990006483 OR GRAINGER ITEM #4JF36. BEFORE MODULE

REMOVAL ALLOW THE MODULES TO COOL IN THE RACK FOR 30 SECONDS

AFTER TURNING THEM OFF WITH THE CIRCUIT BREAKER.

HEAVY WEIGHT

THE PA MODULE WEIGHS APPROXIMATELY 22KG AND CAN BE AWKWARD TO

HANDLE. USE PROPER LIFTING TECHNIQUES WHEN REMOVING AND

REPLACING PA MODULES.

5-1 888-2629-200


Section 5 Maintenance and Alignments Maxiva ULX COFDM Series

!

CAUTION:

RADIO FREQUENCY HAZARD. DO NOT ATTEMPT TO OPERATE THE PA MODULE

WITH THE COVER REMOVED.

5.2.1

PA Slot Locations

The number and location of PA modules will vary depending on transmitter model. The following table outlines the slots that contain PA modules in various configurations.

Table 5-1 PA Slot Allocations for Single Cabinet Models

Slot No.

PA

PA

PA

PA

PA

PA

IPA-A

IPA-B

16PA

Models

PA

PA

PA

PA

PA

PA

PA

PA

PA

PA

4

3

6

5

2

1

8

7

10

9

14

13

12

11

18

17

16

15

PA

PA

PA

PA x x

IPA-A

IPA-B x x x x

10 PA

Models

PA

PA

PA

PA

PA

PA

PA

PA x x

PA

PA

PA

PA x x

IPA-A

IPA-B

12 PA

Models

PA

PA

PA

PA

PA

PA

PA

PA x x

PA

PA

PA

PA x x

IPA-A

IPA-B

6 PA

Models x x x x x x

PA

PA

PA

PA

PA

PA

PA

PA x x

IPA-A

IPA-B

8 PA

Models x x x x x x x x

IPA-A

IPA-B

PA1

PA2

PA3 x x x x x

3 PA

Models x x x x x x

PA

PA

PA

PA x x

IPA-A

IPA-B x x x x

4 PA

Models x x x x x x

PA

PA x x x x

IPA-A

IPA-B x x x x

2 PA

Models x x x x x x

Note: PA indicates that a module is present in the slot for the noted configuration. The

Slot No. identifies the PA as it is displayed on the GUI screen.

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5.2.2

PA Module Removal

Section 5 Maintenance and Alignments

TCU System Controller

Redundant Pre-Driver A

Apex M2X Exciter A

Apex M2X Exciter B

18

Redundant Pre-Driver B

PA Slots 11-18

A

B

11

8

Redundant Drivers

IPA A (slot 10)

IPA B (slot 9)

PA Slots 1-8

1

Figure 5-1 PA Module Location

See Figure 5-1 on page 5-3 to identify module numbers and their locations in the cabinet. PA and IPA (driver) modules can be removed (or installed) while the transmitter is operating, but the following steps should be followed:

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5-3


STEP 1 Prepare a clear path to a location to put the module once it has been removed .

STEP 2 Open the rear door.

STEP 3 Turn off corresponding PA module circuit breaker on the left rear side of the cabinet .

!

WARNING:

THE PA MODULES MAY BE HOT. ALLOW THE MODULE TO COOL BEFORE

REMOVAL.

STEP 4 Wait 30 seconds for module to cool.

STEP 5 Use a screwdriver (Phillips) to loosen and remove the screws that hold the module in the rack. There is one screw on each side of the module.

STEP 6 Pull the module halfway out of the rack, then reposition hands to the sides of the module to better support the weight (26.5kG).

Remove the module from the rack.

!

CAUTION:

DO NOT LET THE MODULE SWING DOWN WHEN PULLING THE MODULE OUT OF

THE RACK. THIS COULD CAUSE SEVERE DAMAGE TO THE CONNECTORS ON

THE BACK OF THE MODULE.

5.2.3

PA Module Installation

To install a PA Module:

STEP 1 Inspect the connectors on the rear of the module to be sure there is no damage to the liquid connectors or to the electrical connectors .

STEP 2 Inspect the connectors inside the rack to confirm there is no blockage and no damage to the liquid or electrical connectors.

STEP 3 Check to be sure that the PA module circuit breaker has been turned off.

STEP 4 Slide the PA module gently into the rack until contact is made with the mating connectors.

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Maxiva ULX COFDM Series Section 5 Maintenance and Alignments

STEP 5 Push evenly on the front of front of the module with a slight side to side motion to help align the mating connectors.

STEP 6 Use firm, moderate pressure to fully seat the module . If the module fails to seat with moderate pressure do not force the module into the rack. Remove the module and inspect for interference.

NOTE:

In some cases it has been noted that it can be difficult to reinsert a hot PA module.

If the connection is difficult (module doesn’t seat fully with moderate pressure) simply allow the module to cool sufficiently before reinserting.

Check the coolant connectors on the back of the PA module and on the coolant manifold. The manifold connector has an O-ring seal (Figure 5-2) which must be in good condition to prevent leaks. If there is evidence of a mechanical interference or misalignment of the coolant connectors on all the modules then a rack re-alignment may be required. This may be required if a manifold is replaced. The rack realignment helps align the coolant connectors in the manifold with the coolant connectors on the

PA modules. If rack alignment is needed refer to 5.2.5 on page 5-6.

O-ring

Figure 5-2 Manifold Coolant Connector O-ring

STEP 7 Install the hold down screws and hand tighten.

STEP 8 Turn on the module circuit breaker.

STEP 9 Press the transmitter ON button to reactivate all modules that are off.

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5-5


5.2.4

Operation With Inoperative PA Modules

The PA module reject loads, located inside the module combiner, are sized with enough margin to allow operation under any imbalance condition that may be encountered. As long as one module is installed and operational the transmitter will continue to produce

RF power but at reduced levels (depending on how many modules are removed).

5.2.5

PA Module/Rack Alignment

If difficulty installing modules is encountered and misalignment of the rack is encountered an alignment of the rack may be needed. The following steps outline the alignment procedure:

STEP 1 Disconnect power from transmitter. Turn off breakers AC1 and AC2 on the cabinet being aligned.

STEP 2 Drain system of coolant.

STEP 3 Remove all PA and IPA modules from the rack half being aligned.

STEP 4 Loosen manifold clamps (bolts) for the section of the rack being aligned . The clamps are shown in Figure 5-3.

NOTE:

If both halves of the rack need alignment start with alignment of the bottom half first. Align the top half second.

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Upper

Manifold Clamps

Manifold

Interconnect Hoses

Lower

Manifold Clamps

Cabinet

Drain Hoses

10/6/10

Figure 5-3 PA Module/Rack Alignment

STEP 5 Loosen hoses between upper and lower manifolds (If more than 8

PA's).

NOTE:

The system was drained to avoid leaking at this connection when the clamp is loosened. Loosening the clamp allows the upper and lower manifolds to move relative to each other.

888-2629-200


5-7


Alignment Shims


5-8

STEP 6 Using the top and bottom modules in each half as alignment fixtures, place a 0.02"-0.03" thick shim on the cabinet PA shelf guides for a top and bottom module.

Carefully insert the top and bottom modules

(in the section being aligned) and insure shim is captured between the module cold plate (bottom) edge notch and the cabinet shelf

NOTE:

The shims position the module slightly higher than normal. This insures that after alignment the module can slide up slightly and onto the manifold connector. This is done to insure that the manifold connectors are a little higher than the module connectors.

STEP 7 Insert the module slowly and carefully until fully inserted onto the manifold connectors.

NOTE:

The manifold may have to be moved slightly to allow proper alignment between module connectors and manifold connectors. Do not aggressively insert or damage to the connectors may result.

STEP 8 Once the two modules are fully inserted (and shims are in place) and seated on the RF connector, two fluid connectors, AC/control connector and alignment pin then tighten the manifold bolts .

STEP 9 Repeat procedure on other manifold as applicable .

STEP 10 Tighten all hose clamps and hardware loosened in previous steps .

STEP 11 Remove alignment modules and shims .

STEP 12 Install all PA and IPA modules.

STEP 13 Recharge system with coolant.

STEP 14 Turn on AC power and restore transmitter to normal operation.

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5.3

PA Module Bias


Re-bias of the PA modules is not required on the Maxiva ULX series transmitters.

5.4

PA Module Phasing

Phasing of the PA modules is tightly controlled at the factory. No phasing of the modules is required in the field. PA modules and IPA (driver modules) can be used in any location without re-phasing.

NOTE:

Phasing between cabinets is required to minimize cabinet combiner reject power and it is accomplished via the GUI screen. Cabinet phase and gain is controlled by adusting the relative phase and level values of each cabinet using the preamplifiers.

5.5

PA Module Component ID

Before attempting PA module repairs in the field it is important to properly identify the faulty components.

10/6/10

Figure 5-4 PA Module Pallet and Power Supply Numbering

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5-9


Figure 5-4 gives the power supply and pallet identification numbers.The test connector on the front of the PA module can be used to determine which pallet or power supply has failed. An optional hand held meter can be attached to the connector to display the status and fault information outlined in Table 5-2. If the optional meter is not available a multimeter can be used to measure voltages on the connector pins. The normal measured voltages are given in the following table in parenthesis. These voltage values assume that the module is enabled but no RF input is applied.

Table 5-2 PA Module Test ConnectorPin Out and Typical Voltages

Pin

1

3

5

7

9

11

13

15

17

19

21

23

25

Signal Pin Signal Pin Signal Pin

/ON-OFF STATUS (0V -

4.9V)

PS VOLT SEL-TB

(44=5.15V, 46=4.12V,

48=2.49V, 50= .87V)

2

4

PS8 VOLTAGE

(3.8V)

GND

27

29

P3 FET 1 CURRENT

(.3V)

P3 FET 2 CURRENT

(.3V)

28

30

AVG INPUT POWER

(.012V)

GND

OUTPUT POWER (.023V)

REFLECTED POWER

(.022V)

FAULT STATUS 3 (4.95V)

FAULT STATUS 2 (4.95 V) 16 PALLET 4 TEMP

(2.0V)

FAULT STATUS 1 (0V) 18 AMBIENT TEMP

(2.0V)

P1 FET 1 CURRENT (.3V)

10 PALLET 1 TEMP

(2.0V)

12 PALLET 2 TEMP

(2.0V)

14 PALLET 3 TEMP

(2.0V)




6

8

+12V (11.9V)

+12V (11.9V)

31 P4 FET 1 CURRENT

(.3V)

33 P4 FET 2 CURRENT

(.3V)

35

37

39

41

43

PA SUM CURRENT

(.3V)

PS1 VOLTAGE

(3.8V)

PS2 VOLTAGE

(3.8V)

PS3 VOLTAGE

(3.8V)

PS4 VOLTAGE

(3.8V)

32

34

36

38

40

42

44

20 ON/OFF FROM TB

(0 V)

45 PS5 VOLTAGE

(3.8V)

22 PSV TB SEL (0 V) 47 PS6 VOLTAGE

(3.8V)

46

48

49 PS7 VOLTAGE (3.8V) 50 24 GND

26 GND

Signal

GND

CANH (3.2V)

CANL (0V)

GND

/SPI-CS(TMS)

(3.2V)

SP1-SCK(TCK)

(3.2V)

SPI-MOSI(TDI)

(3.2V)

SPI-MISO (TDI)

(3.2V)

SPI-JTAG-SEL

(3.2V)

GND

BP SYNC

PRESENT (4.9V)

GND

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5.6

PA and IPA (driver) Pallet Replacement

Jumper

Allen Screws

(torque)

Support

Blue &

Gray Wires

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Jumper

Figure 5-5 PA Module Pallet (one of four per module)

STEP 1 Turn off PA module breaker.

!

WARNING:

MODULE MAY BE HOT. ALLOW THE MODULE TO COOL BEFORE REMOVAL.

STEP 2 Wait 30 seconds for the module to cool.

STEP 3 Unscrew retaining screws and remove PA module.

STEP 4 Remove PA module cover.

STEP 5 Remove four (4) center pallet hold down screws (Allen head).

STEP 6 Remove five (5) additional pallet hold down screws (Phillips head).

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STEP 7 De-solder two jumpers and the blue & gray DC supply wires.

STEP 8 Remove board and cleanup heat transfer compound.

NOTE:

Removal of the pallet may be difficult due to the presence of the heat transfer compound under the board. To remove the board first remove the cover supports either side of the board. Removal of the supports allows room to insert a flat blade screwdriver beneath the edge of the board. Use the screwdriver to gently pry upward without placing stress on adjacent boards. Repeat this process along the edges of the board in several places until it loosens up.

STEP 9 Reapply heat transfer compound. Use a small roller or brush to apply even, thin coat.

STEP 10 Install pallet and all hold down screws.

STEP 11 Torque four (4) allen screws to 30 in lbs.

STEP 12 Solder two jumpers and the blue & gray DC supply wires. Material to replace the jumpers is included in the pallet replacement kit. Cut the replacement jumpers to match those removed.

STEP 13 Replace PA module cover.

STEP 14 Replace PA module in rack. Tighten module hold down screws.

STEP 15 Turn on PA module breaker. Press the transmitter ON button to reactivate all modules that are OFF.

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5.7

PA Module AC/DC Converter (PS) Board

5.7.1

PS Board Removal and Replacement

Trim

Pot

WAGO

PS Board

Connector

Fuse

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Figure 5-6 PA Module AC/DC Converter (PS power supply) Board

NOTE:

PS board fuse is 5A 250V fast blow.

STEP 1 Turn off PA module breaker.

!

WARNING:

MODULE MAY BE HOT. ALLOW THE MODULE TO COOL BEFORE REMOVAL.

STEP 2 Allow the module to cool for 30 seconds .

STEP 3 Unscrew retaining screws and remove PA module .

STEP 4 Remove PA module cover.

STEP 5 Remove four (4) PS hold down screws (Phillips screws).

STEP 6 Remove supply wire from WAGO block.

STEP 7 Remove board from connector and cleanup heat transfer compound.

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STEP 8 Install a new heat transfer pad (411-0126-000).

STEP 9 Install PS hold down screws.

STEP 10 Reconnect supply wire to WAGO.

STEP 11 Replace PA module cover.

STEP 12 Replace PA module in rack. Tighten module hold down screws.

STEP 13 Turn on PA module breaker.

5.7.2

AC/DC Converter (PS) Board Output Voltage

The output of the PS board (also referred to as the AC/ DC converter board) changes depending on transmitter modulation type. To operate properly the output of the PS board must be initially adjusted to 48V. This adjustment is made in the factory on each board prior to installation into a module or shipment as a replacement part. The output voltage can also be set in the field if a module test system is available. The optional PA module test system part number is 971-0040-080.

5.7.2.1

Setting Voltage:

STEP 1 Follow the PS board replacement steps outlined in Section 5.7.1 on page

5-13 stopping at step 10.

STEP 2 Place the module in the module test fixture.

STEP 3 Remove JP1

STEP 4 Activate the module and set Vout to 48V using the trim pot shown in

Figure 5-6 on page 5-13.

STEP 5 Replace JP1.

STEP 6 Complete steps 10 -13 in Section 5.7.1 on page 5-13.

The TCU sends a Vtrim voltage to the PS boards. The Vtrim voltage varies depending on the transmitter modulation selection. The PS output varies depending on the Vtrim signal received from the TCU. The Vtrim levels are given below.

Vtrim Levels:

•

5.755V ---- 44V

•

4.122 V --- 46V

•

2.490V ---- 48V

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•

0.875V ---- 50V


5.8

Power Calibrations

Other than system forward & reflected calibirations during installation, power calibration should be required only if the down converter board (used in analog systems), the RF detector board (in TCU), or if a directional coupler or signal cable is replaced. However, calibration is simple and can be done whenever it is deemed necessary. The only required power calibrations are: a.

Total System Forward Power (after filters) b.

PA Cabinet Forward Power (before filters) c.

Total System Reflected Power (after filters) d.

PA Cabinet Reflected Power (before filters) e.

Exciter Forward Power f.

PDU Forward Power

NOTE:

Forward and Reflected power calibrations should only be done while operating the transmitter into a known good load or a low VSWR antenna system.

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5.8.1

Forward Power Calibration

Equipment Used:

•

Maxiva Series precision directional couplers (precision meaning that the coupling ratio has been measured at the exact operating frequency)

•

Averaging power meter with power probe

NOTE:

Power calibrations must be performed using the local GUI screen. In order to change calibration settings the user must supply a login and a password at the admin level. When the transmitter ships from the factory the local GUI default login is "admin" and the default password is "harris" (do not include quotation marks in login or password). If you change passwords be sure to retain them in a secure location. You will not be able to regain access without the password.

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Forward

Couplers

Reflected

Coupler

5-16

Figure 5-7

Typical Output Power Coupler

5.8.1.1

Calibrate Forward Total Power a.

Calibrate the averaging power meter following manufacturers instructions.

b.

Set the meter offset to that printed on the coupler, or as supplied with a data sheet included with the Factory Test Data.

c.

Remove the sample cable from the external Total Forward directional coupler to be calibrated (see Figure 5-7, below).

d.

Connect the power meter probe to the Total Forward directional coupler port.

e.

Hold in power LOWER button for 20 seconds or navigate to Output screen and set Cab. Ref. Pwr. to zero. Either of these steps will insure that the transmitter does not produce large amounts of RF power at turn on.

f.

Turn on and adjust the Maxiva COFDM transmitter to licensed nominal power as programmed in the System Setup screen. Verify the power output with the power meter attached to the forward port of the system output directional coupler.

g.

Allow the transmitter to run for several minutes to give the amplifiers time to warm up and stabliize.

h.

Press the manual button on the TCU and hold it in for 5 seconds.

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Maxiva ULX COFDM Series Section 5 Maintenance and Alignments i.

Re-adjust the transmitter power output as required to reach licensed nominal power. Be sure it is stable.

j.

Disconnect the power meter probe form the Forward coupler port then reconnect forward sample cable.

NOTE:

The detector voltage values are provided on the Sys Pwr Calibrate screen shown in Figure 5-8. They are in the column to the right labeleled Detector. The Sys

Fwd (kW) detector voltage level should be between 3.0 and 3.4V at full rated power. Operating in this range insures measurement accuracy (in detector’s linear region). If the detected levels are too high, attenuation will need to be added at the coupler port to reduce the detected voltage level.

k.

To access the Calibration screen press SYSTEM>SERVICE>SYSTEM

SETUP>CALIBRATE shown in Figure 5-8 on page 5-17.

10/6/10

Figure 5-8

System Power Meter Calibration Screen l.

Click on the corresponding window for System Fwd power, opening a numeric entry box.

m.

Enter the value (in kW) measured in step d. above.

n.

Click on DONE to store the changes, or CANCEL to ignore all changes made o.

Press the Auto Power Power Control button to enable ALC.

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5.8.1.2

Calibrate Forward Cabinet Power:

Maxiva ULX COFDM Series a.

Repeat the entire above procedure using the internal transmitter Incident (forward) sample (shown in Figure 5-9), entering the data in the corresponding PA cabinet window shown in Figure 5-10 on page 5-22.

NOTE:

Be sure to enter the incident (forward) coupler’s offset into the power meter. Different couplers will have different coupling values.

Reflected

Coupler

Forward

Coupler

Figure 5-9 Cabinet Coupler

5.8.2

Reflected Power Calibrate

This procedure establishes the values used to calculate the VSWR protection thresholds for Foldback and Fault events. These values are based on the "Nominal Power Output" value entered into the System Setup screen in Figure 3-22 on page 3-26.

•

The foldback power level (based on system power) is calculated using a

VSWR = 1.4:1. The VSWR foldback level can be related to reflected power using the following formula to calculate the reflected power factor:

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To determine the Nominal Output factor:

VSWR

VSWR

−

1

+

1

2

Foldback Power = Nominal Power Output x 0.0278

System Foldback Power = Nominal Power Output x Reflected Power Factor factor

•

The system fault threshold level (based on System reflected power level) can be set by the user. Setting the fault threshold level is done by entering a trip voltage level in the Sys Reflected window on the Threshold Setting screen.

The voltage entered here should correspond to the detected voltage level that is indicated when calibrating the system reflected power as described in

5.8.2.1 Calibrate Reflected Total Power

•

The cabinet fault threshold is set to a VSWR = 1.9:1 at the factory and is not adjustable by the user. A 1.9:1 VSWR corresponds to 9.63% reflected power.

NOTE:

The cabinet fault threshold is set to 1.9:1 at the factory. Contact Harris service if these values need to be changed.

5.8.2.1

Calibrate Reflected Total Power

10/6/10

NOTE:

Before attempting reflected calibration Forward calibration must be verified.

a.

Turn on and adjust Maxiva Series transmitter to 100% rated average peak power according to the bar graph.

b.

Press SYSTEM>SERVICE>SYSTEM SETUP>CALIBRATE to view the GUI screen shown in Figure 5-8 on page 5-17.

c.

Press Disable VSWR.

d.

Remove the sample cable from the external Forward directional coupler (see

Figure 5-7, above). e.

Remove the sample cable from the external Reflected directional coupler. If there is an attenuator on the reflected coupler port, keep it with the reflected sample cable. Attach the reflected cable and a 10 dB pad to the external forward directional coupler. If there is a pad already in place on the forward directional coupler port, keep it with the forward sample cable.

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NOTE:

The detector level should be approximately 2V when the reflected cable is attached to the forward port with a 10 dB pad. If the reflected detector voltage is too high when attached to the forward port with a 10 dB pad then additional pads must be added to get the voltage in the 2V range. These newly added pads will stay with the reflected cable when it is moved back to the reflected port later in the procedure. The 10 dB pad will be removed when the reflected cable is placed back on the reflected port f.

Click on the corresponding window for Sys Refld power, opening a numeric entry box.

g.

Enter the value that is 10% of licensed nominal output power.

h.

Click on DONE to store the changes, or CANCEL to ignore all changes made.

Record the reflected detector voltage for later use in setting thresholds.

NOTE:

At this time the VSWR protection could be verified by pressing the Enable

VSWR button CALIBRATE screen. The transmitter should fault off.

i.

Remove the 10 dB pad and return the reflected cable to the reflected port on the coupler. Reconnect the forward cable to the forward coupler port.

j.

Turn on the transmitter and adjust Maxiva ULX Series transmitter to licensed nominal output power

5.8.2.2

Calibrate Reflected Cabinet Power a.

Repeat the entire above procedure using the internal (cabinet) Incident and

Reflected coupler samples (see Figure 5-9 on page 5-18) to calibrate the reflected power at the cabinet output.

NOTE:

The detector level should be approximately 2V when the reflected cable is attached to the forward port with a 10 dB pad. If there are pads on the forward port to start with they should not be included with the added 10dB pad.

NOTE:

Enter the 10% of forward cabinet power value in the window for Cab Refld

(W). The reflected power trip point (1.9:1 VSWR) is set at the factory and not adjustable in the field.

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5.8.3

Exciter Output Calibration

STEP 1 Turn on the transmitter and adjust to nominal power.

STEP 2 With the exciters operating use the web browser to access each exciter and record the output levels for exciters A and B (if present).

These exciter levels were calibrated at the factory.

STEP 3 The transmitter GUI Exciter output is calibrated on the Sys Pwer

Calibrate screen. To access the Sys Pwr Calibrate screen press

SYSTEM>SERVICE>SYSTEM SETUP>CALIBRATE.

The screen is shown in Figure 5-8 on page 5-17.

STEP 4 To calibrate, press the window of the active exciter output to be calibrated and enter the values noted on the exciter web browser screens.

5.8.4

PDU Calibration

The predriver unit (PDU) has a forward power directional coupler for each preamp module to measure input power. This power reading shows up on the

SYSTEM>SERVICE>SYSTEM SETUP>CALIBRATE>CABINET CALIBRATE screen shown in Figure 5-10.

Calibration Procedure:

NOTE:

This value is preset at the factory. Should it need to be reset in the field use this procedure.

STEP 1 Turn on the transmitter and adjust to nominal power.

STEP 2 Remove the cable at the output of the PDU splitter and use and average power meter to measure the splitter power outuput.

STEP 3 Reconnect the cable.

STEP 4 Go to the Cab Pwr Calibrate screen (Figure 5-10) and check the

PDU detector value for the active PDU which should be between 1 and 4 V (set at factory and varies with transmitter model). This voltage comes from detectors at the input of each PDU. Enter the one half the value determined during STEP 1 with the numeric entry box.

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NOTE:

This voltage is used as a reference to indicate exciter power output. If too low the transmitter ALC will not adust in Auto. If less than a factory set threshold it assumes there is an exciter issue and disables ALC.

STEP 5 Press the window of the active PDU input to be calibrated and enter the values determined in STEP 5 . The value entered should be in uW

(micro Watts).

STEP 6 Press DONE to store the changes or CANCEL to discard the changes.

STEP 7 Select the other predriver and repeat the procedure to calibrate the other predriver power output.

5-22

Figure 5-10 Cab Pwr Calibrate Screen

STEP 8 End of procedure.

5.8.5

Threshold Settings

Go to SYSTEM>SERVICE>SYSTEM SETUP>CALIBRATE and press the Thresholds button.

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Figure 5-11 Threshold Setting Screen

5.8.5.1

Exciter A & B Threshold Settings

Exciter A and B detector levels should be approximately 2.7V. This assumes a 100mW

(average) out.

Exciter A and B threshold levels can be set using the following steps:

STEP 1 Set the exciter to nominal output 100 mW (average).

STEP 2 Lower exciter output power to 50 mW (using the web browser) .

STEP 3 Press the threshold Cal window and adjust the Cal value higher in

.1 V increments until the red fault LED on the TCU exciter switcher card lights.

NOTE:

To view the LED on the exciter switcher card the front panel of the TCU must be pivoted downward.

STEP 4 Lower the threshold Cal window value in .05 V increments until the red LED on the exciter switcher card goes out.

STEP 5 Press done to accept this level .

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STEP 6 Restore transmitter to normal operating condition and reset the exciter output power to 100 mW.


5.8.5.2

Cabinet Reject Load Thresholds

Cabinet reject loads should be set to approximately 3V thresholds at 100% reject power levels.

5.8.5.3

System Reflected Thresholds

System reflected threshold voltage should be set to approximately 100 mV less than the detector voltage level noted in "5.8.2.1 Calibrate Reflected Total Power" on page 5-19.

Approximately 2.4V is typical. For a 6kW digital transmitter this corresponds to a reflected power level of 168W.

5.8.5.4

System Foldback Power

System foldback power (Watts) can be set as needed to a maximum value of 2.8% of nominal output power.

5.8.5.5

FWD Pwr Warn

Sets kW level where power bar turns yellow.

5.8.5.6

Fwd Pwr Flt

Sets kW level where power bar turns red and fault is entered into log.

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5.9

PA Cabinet Fan Replacement

There are two 230V AC 50/60Hz fans in the Maxiva cabinet. They get their AC power from the control breakers on power distribution panel.

NOTE:

Deactivating the control breakers will turn off the cabinet fans but they also will disable the TCU and exciters.

The cabinet fans operate continuously whenever the transmitter is on. The fans are redundant, either of the fans can be removed while the transmitter continues operating with one remaining operational fan. The cabinet cooling fans supply air to the PA modules, IPA (driver) modules and the predrivers. Exhaust air from the fans exits the cabinet at the top.

5.9.1

Cabinet Fan Removal

STEP 1 Open the rear cabinet door.

STEP 2 Disconnect connectors J1 & J3 (see Figure 5-12) from the fan control board which lies just above the fan that is to be removed.

REMOVE

10/6/10

Figure 5-12 Fan Control Board Connectors J1 & J3

STEP 3 Use a 10 mm socket driver to remove the two nuts (see Figure 5-13) that hold the fan assembly in place.

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REMOVE

Figure 5-13 Fan Bracket Hardware

STEP 4 Fan enclosure can now be removed from the cabinet angling the rear of the unit toward the center of the cabinet and pulling it out through the door opening .

NOTE:

The fan capacitor is located inside the fan enclosure.

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Fan Capacitor

Figure 5-14 Fan Capacitor (inside fan enclosure)

STEP 5 Reverse the process to replace the fan.

5.10 PA Cabinet RF System Removal

Removal of the cabinet RF system is required if access to the PA backplanes, IPA backplanes, combiners or dividers is needed.

5.10.1 RF System Removal

STEP 1 Turn off the transmitter. Remove all power and turn of main breakers AC1 and AC2. Disable remote operation to prevent transmitter from being reactivated .

STEP 2 Remove the cabinet fan assemblies. The fan removal sequence is described in section 5.9 on page 5-25.

STEP 3 Loosen the clamp that holds the output coax in the flange (see Figure

5-15 on page 5-28).

STEP 4 Lift the output coax and inner conductor upward and away from the flange (see Figure 5-15 on page 5-28). Secure the coaxial line so it is out of the way.

STEP 5 Remove the four Phillips screws from the plate assembly at the top of the cabinet.

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Clamp


RF Output

Coax

Plate Screws

4 places

Figure 5-15 RF Output Plate

STEP 6 Loosen the clamp on the outer conductor flange coupling that is located the cabinet output directional coupler (see Figure 5-16 on page 5-29).

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Clamp

Figure 5-16 RF Output Coaxial Line Connection

STEP 7 Lift the output coax line (the line above the coupler) upward taking care to disconnect and support the inner conductor. Lift the inner and outer upward through the top of the cabinet. Store the coaxial line section in a safe location.

STEP 8 Loosen the clamp that holds the hybrid combiner reject port elbow in place while supporting the back to back elbow assembly and the reject load. Lower the elbow (see Figure 5-19 on page 5-31) to disconnect the inner conductor bullet. Lift the back to back elbows and reject load (with attached coolant hoses) up and out of the way.

It can be temporarily tied up out of the way with a small rope or with heavy duty tie wraps.

STEP 9 Remove the bolt from the RF support bracket at the bottom of the cabinet (13 mm wrench). The bolt is shown in Figure 5-17 on page 5-

30.

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Remove

Figure 5-17 RF Support Bracket - Lower

STEP 10 Use a 13 mm wrench to remove the two bolts from the center of the

RF support bracket (see Figure 5-18 on page 5-30).

Remove

Figure 5-18 RF Support Bracket Lower

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L

Reject

Load


Clamp

Elbow

Figure 5-19 Reject Load Elbow.

STEP 11 Remove the sample cables from the directional coupler at the output of the hybrid combiner.

STEP 12 While supporting the weight of the hybrid combiner/coax RF system loosen the clamps on outer conductor sleeves at the output of the lower and then the upper module combiners. Slide the coaxial sleeves to the right to expos the inner conductor.

The loosened upper clamp is show in Figure 5-20 on page 5-32.

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Clamp


Figure 5-20 Upper Combiner Output Clamp

STEP 13 Once the clamps on the combiner outputs are loose the hybrid coupler and coaxial assembly can be supported and then pulled away from the module combiners. The hybrid combiner/coaxial RF system can then be removed from the cabinet and stored in a safe location. The hybrid combiner/coaxial output assembly is shown in

Figure 5-21 on page 5-32. The cabinet with the RF system removed is shown in Figure 5-22 on page 5-33.

Figure 5-21 Hybrid Combiner/Coaxial RF System

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Figure 5-22 Cabinet with RF System Removed

STEP 14 Reverse the procedure to reinstall the cabinet RF system.

STEP 15 End of procedure

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5.11 Miscellaneous Maintenance


5.11.1 Cooling System Checks

Inspect the cooling system weekly for coolant leaks and check the coolant level.

5.11.1.1 Heat Exchanger Cleaning

The heat exchanger fins and pump motor housing fins should be examined for dust and dirt buildup once a month. Clean as necessary with water hose, soft bristled brush or compressed air.

!

CAUTION:

TAKE CARE NOT TO DAMAGE THE FINS. DO NOT CLEAN WITH HIGH PRESSURE

WATER, A WIRE BRUSH OR USE OTHER METHODS THAT MIGHT DAMAGE THE

FINS.

5-34

5.11.1.2 Alternate Pumps

Every three months select the opposite Pump in order to keep both pumps in a proper working state. Switching the pumps can be accomplished via the GUI screen (with pump module in REMOTE mode) by pressing SYSTEM then press the button for the inactive pump. This can also be done with the pump module in LOCAL mode by pressing the Pump Select button. This may also be a good time to manually operate

(open and close them several times) all valves to assure proper movement and closure.

NOTE:

See the cooling system drawings, manufacturers component manuals and the cooling system Technical Manual for details.

5.11.1.3 Pump Module Strainer Cleaning

The strainer is shown on the Plumbing Layout drawing; sheet two shows the details which include a ball valve either side of the strainer. The strainer is located on the pump module in the return line. The strainer should be inspected several times during the start up process and cleaned following the final flush. The frequency of inspection after

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Maxiva ULX COFDM Series Section 5 Maintenance and Alignments initial installation may vary depending on site conditions but in most cases annual inspection and cleaning of the cooling system strainer is recommended. The strainer must be disassembled and cleaned when the transmitter is off the air since the coolant flow must be disrupted prior to opening the strainer assembly. Follow the steps that follow to clean the strainer: a.

Turn off the transmitter and pump module.

b.

Close the ball valves on either side of the strainer .

!

CAUTION:

WEAR SUITABLE PROTECTIVE GLOVES AND EYE PROTECTION WHEN

REMOVING THE STRAINER CAP. LOOSEN THE CAP SLOWLY SINCE THE

COOLANT MAY BE UNDER PRESSURE. THE COOLANT MAY ALSO BE HOT.

c.

Remove strainer housing cap.

StrainerAssy.

Screen

Plug/Drain.

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NOTE:

A small amount of liquid will still be present in the pipe and strainer housing, and a receptacle (bucket) will be necessary to contain the spillage.

d.

Pull strainer screen e.

Inspect and clean strainer as needed f.

Replace the strainer, and perform the above steps in reverse order to restore the cooling system to normal operation.

5.11.1.4 Coolant Level Management:

The Maxiva cooling system is a closed (pressurized) system. The system contains a pressurized expansion tank with a bladder that separates the system coolant from pressurized air. The expansion tank is pressurized at the factory and should not need pressurization on site. The coolant level is checked by viewing the coolant passing through the sight glass located on the air purger and located at the highest point in the cooling system. The presence of air bubbles or lack of fluid in the sight glass is an indication that the system needs to be charged with additional coolant.

Air

Purger

Sight

Glass

5-36

Figure 5-23 Air Purger and Sight Glass

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5.11.1.5 Cooling System Maintenance Notes

5.11.1.5.1 Coolant Checks:

The pH level of the 50/50 glycol/water mixture should be above 8.0. A PH level that is below 8.0 indicates that the inhibitors in the glycol are ineffective. Should the PH level of the mixture drop below 8.0 either additives must be added or the coolant should be changed. The PH level should be checked regularly with either pH paper or with a pH meter. If these test items are not available a sample of the coolant can be sent to an independent service provider for analysis. The pH level should be checked at 3 month intervals.

The 50/50 glycol/water mixture should be checked at 3 month intervals as well.

5.11.1.5.2 Changing Pumps: a.

Turn off the transmitter and pump module.

b.

Close the ball (isolation) valves on either side of the pump that is to be changed.

c.

Disconnect the fittings on either side of the pump.

NOTE:

A small amount of liquid will still be present in the pipe and pump housing, and a receptacle (bucket) will be necessary to contain the spillage.

!

WARNING:

WEAR SUITABLE PROTECTIVE GLOVES AND EYE PROTECTION WHEN REMOV-

ING. LOOSEN THE CAP SLOWLY SINCE THE COOLANT MAY BE UNDER PRES-

SURE. THE COOLANT MAY ALSO BE HOT.

d.

Remove and replace the pump.

Take care to install the pump so the direction of flow is maintained in the proper direction.

!

CAUTION:

USE PIPE JOINT COMPOUND OR TEFLON TAPE ON MALE THREADED FITTINGS

AS REQUIRED PRIOR TO REINSTALLATION OF PUMP. USE JOINT COMPOUND

SPARINGLY TO AVOID CONTAMINATION OF COOLANT. IF FITTINGS WITH O-RING

SEALS ARE USED THE O-RINGS SHOULD NOT BE REUSED. USE A NEW O-RING

AND LUBRICATE IT LIGHTLY WITH SILICON GREASE.

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Section 5 Maintenance and Alignments Maxiva ULX COFDM Series e.

Perform the above steps in reverse order to restore the cooling system to normal operation .

f.

Once system operation is restored check the sight glass to be sure that air bubbles are not present and that the level of coolant is adequate.

Charge system as required to maintain coolant level.

5.11.1.6 Pump Module Operation Without Transmitter

The pump module can be operated independently, without being attached to the transmitter, by selecting the LOCAL mode on the pump module/heat exchanger cooling control panel.

!

CAUTION:

SELECTION OF LOCAL WILL ALSO ALLOW THE PUMP MODULE/HEAT

EXCHANGER TO BE OPERATED FROM THE CONTROL PANEL AS LONG AS THE

PUMP INTERLOCK IS NOT ACTIVE.

5.11.2 Air Filter Replacement

Monthly inspection and cleaning of the air filter is recommended. The filter can be easily removed from the rear door without tools.

5-38

Figure 5-24 Filter in Rear Door

STEP 1 Grasp filter material between fingers and lift upward until filter frame clears the lower edge of the door opening.

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STEP 2 Pull lower part of filter through the door opening.

STEP 3 Slide the filter assembly downward and away from the door.

Figure 5-25 Filter Being Removed from Rear Door g.

Clean with compressed air, wash with detergent/water, or replace as necessary.

h.

Reinstall dry filter by reversing the order of the above steps.

5.11.3 LCD Screen Adjustments

5.11.3.1 LCD Screen Contrast

The LCD display contrast can be adjusted by accessing the GUI

SYSTEM>SERVICE>ADMIN screen. Press the white text box for the LCD Contrast and a pop up window will appear to allow the setting to be adjusted.

5.11.3.2 Touch Screen Calibration

The GUI touchscreen has been calibrated at the factory. No further calibration is required.

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5.11.3.3 Date and Time Settings


Date and time settings can be performed using the local GUI screen. Refer to "3.9.3

System Service" on page 3-22. If the transmitter is connected to a network the date and time settings are done automatically.

5.11.4 Changing the Battery on the PCM Card

Transmitter control units (TCU’s) are shipped as components in several different Harris transmitter models. The TCU will contain different printed circuit cards depending on the transmitter application. TCU’s that have GUI (graphical user interface touch screen) displays will contain a PCM card. The PCM card is the second card from the right when looking at the front of the TCU.

M2X

Exciter

PCM

Card

TCU with front lowered

TCU front panel with

GUI

5-40

Figure 5-26 TCU with front panel lowered (Maxiva transmitter shown)

The PCM card contains a battery that is used for the real time clock in the TCU. The battery powers real time clock circuitry to maintain the clock time/date when the unit does not have AC power applied. The unit is typically shipped with the battery removed

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Maxiva ULX COFDM Series Section 5 Maintenance and Alignments from the PCM card. The battery should be installed before the transmitter goes into operation.

The clock battery (part number 660-0093-000) is packed inside a plastic bag that contains battery replacement instructions. Once the transmitter is installed and AC power has been connected the clock battery should be installed in the PCM card.

5.11.4.1 PCM Battery Installation Instructions:

STEP 1 Turn off the transmitter and disconnect power from the transmitter cabinet or disconnect the AC plug(s) from the rear of the TCU.

TCU AC connection

Figure 5-27 Rear of TCU (cards removed)

STEP 2 Use the cut outs built into the front of the TCU as handles, pull outward and down on the front cover of the TCU.

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5-41


Remove 1 screw from each side to pivot TCU down

Figure 5-28 TCU Slide Brackets

STEP 3 On Maxiva ULX transmitters the entire TCU unit can be pivoted downward for easier access to the cards. This is done by removing the front screw (shown in figure 5-28) on either side of the TCU slide brackets .

!

CAUTION:

THE TCU MUST BE SUPPORTED WHILE REMOVING THESE SCREWS TO KEEP IT

FROM FALLING DOWNWARD RAPIDLY.

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10/6/10


Figure 5-29 TCU Pivoted Downward

NOTE:

In other types of transmitters like LAX and HPX the TCU can’t be pivoted downward. In these cases a stool or ladder may be used to gain easier access to the top of the TCU unit.

STEP 4 Remove the top cover from the TCU to gain easier access to the

PCM card.

STEP 5 Locate the battery holder on the PCM card. Location is shown in figure 5-30.

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5-43


PCM battery holder

Figure 5-30 PCM Battery Holder (LAX version of TCU shown)

STEP 6 Use a small flat blade screw driver to gently pry open the battery hold down clip while sliding the battery under the clip. The + side of the battery must installed closest to the battery clip (i.e. the + side must point away from the board) in the holder. The installed battery is shown in figure 5-31.

!

CAUTION:

SEE FIGURE 5-31. NOTE THAT THE + SIDE OF THE BATTERY SHOWS NEAR THE

CLIP.

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10/6/10


PCM battery installed

10/6/10

Figure 5-31 PCM Card (removed from TCU) with Battery Installed

STEP 7 Close front panel .

STEP 8 Pivot TCU upward and reinstall the screw on each side of the slide bracket.

STEP 9 Replace the top cover.

STEP 10 Slide the TCU back into the rack.

STEP 11 Reapply AC power.

NOTE:

If connected to a network the system time and date will reset automatically after the TCU is restarted. If not connected to a network set the TCU system time/date using the Home/System/System Service screen on the GUI.


5.11.5 TCU Card Replacement

Should it become necessary to change cards in the TCU use the following procedure:

STEP 1 Go to the System>Service>Version screen and note the revision levels of the PCM and MCM cards if they are going to be changed .

STEP 2 Turn off the transmitter and disconnect power from the transmitter cabinet or disconnect the AC plug(s) from the rear of the TCU .

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5-45


STEP 3 Use the cut outs built into the front of the TCU as handles, pull outward and down on the front cover of the TCU.

STEP 4 On Maxiva ULX transmitters the entire TCU unit can be pivoted downward for easier access to the cards. This is done by removing the front screw (shown in figure 5-28) on either side of the TCU slide brackets .

!

CAUTION:

THE TCU MUST BE SUPPORTED WHILE REMOVING THESE SCREWS TO KEEP IT

FROM FALLING DOWNWARD RAPIDLY.

5-46

NOTE:

In other types of transmitters like LAX and HPX the TCU can’t be pivoted downward. In these cases a stool or ladder may be used to gain easier access to the top of the TCU unit.

STEP 5 Remove the top cover from the TCU to gain easier access to the

TCU cards.

STEP 6 Remove connectors from the rear of the card that is being changed.

STEP 7 Lift the board out of the slot and replace with new board.

NOTE:

If the MCM card is changed the flash drive card should be removed from the old board and installed in the new board. This will allow the system to retain previously stored calibration values.

STEP 8 Reverse the steps to reconnect and reinstall the TCU.

STEP 9 Verify that the software on the new MCM or PCM cardboard is the same as was on the board that was removed.

STEP 10 End of procedure

5.11.5.1 MCM Card Replacement

Follow the instructions given in 5.11.5 on page 5-45 for TCU card removal.

The MCM card in the TCU contains several jumpers, a cabinet selector switch (S1 rotary), and a toggle switch used to select VT-100 or DNLD inputs. Should the MCM

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Maxiva ULX COFDM Series Section 5 Maintenance and Alignments card need to be replaced the following components should be set to the same values aas the original board. The settings that should be checked are:

Blue jumpers:

JP1

JP2

JP4

JP5

JP-6

JP-7

JP-8

1-2

1-2

2-3

1-2

1-2

2-3

2-3

Rotary Switch (Cabinet ID S1):

Switch should be set to 1 for cabinet 1, 2 for second cabinet, etc.

DNLD/VT100 (toggle switch S2):

Set to VT100 if VT100 is connected to RS-232 port.

NOTE:

If the MCM card is changed the flash drive card should be removed from the old board and installed in the new board. This will allow the system to retain previously stored calibration values.

5.12 Typical Test Equipment

Table 5-3 Recommended Test Equipment

Equipment Type

TV Spectrum Analyzer R&S

Demodulator

Spectrum Analyzer

Power measurement

Manufacturer

R&S

Agilent

Agilent

Model Number

ETL

Options

ETL-B203 RF pre-select.

Harris Part

No.

(if applicable)

FSL-B4 OCXO Ref. Freq.

FSL-B7 Nar. Res. Filters

ETL-K220 ATSC Demod.

DIV7 ETL-K208 Meas. Log

EFA

4402 instead of ETL instead of ETL

E44182B power meter with E9300B sensor, 100 uW to 3 W

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5-47


Table 5-3 Recommended Test Equipment

Equipment Type

Frequency measurement

Miscellaneous Test

Equipment

Agilent

Bird

Narda

Eagle

Eagle

53131A or 53181A

Harris Part

No.

Options (if applicable)

010 high stability time base

015 range extension to 1.5 GHz, OR

030 range extension to 3.0 GHz

APM-16 wattmeter, with 1W to 1kW elements

Directional coupler

RLB-150 RF bridge

TNF-200 UHF RF notch filter

620-0457-000

700-1289-000

484-0300-000

Optional

Adapters and connectors

Fluke

Myat

Dielectric

Myat

87 digital multimeter with 801-400 current probe

3-1/8 inch to 4-1/16 inch adaptor



620-2395-000

620-1928-000

620-2297-000

620-2859-000

Adapters and connectors

3-1/8 inch to type N adaptor

Type N to BNC, male to female

Type N to BNC, female to male

BNC barrel, female to female

620-0128-000

620-0547-000

620-0604-000

620-0564-000 BNC barrel, male to male

SMA to BNC, male to female

SMA to N, male to female

SMB (push on) to BNC

620-2611-000

620-2562-000

620-0628-000

620-2563-000

Attenuator

Equipment Type Manufacturer

TV Spectrum Analyzer R&S

SMC to BNC, screw on jack to plug

BNC to TNC, jack to plug

BNC to TNC, jack to jack

TNC to N, plug to jack

TNC to N, jack to plug

10 dB attenuator, type N, male to female

Model Number

ETL

620-2821-000

620-2823-000

620-2824-000

620-2822-000

556-0074-000

Options

ETL-B203 RF pre-select.

Harris Part

No.

(if applicable)

Demodulator

Spectrum Analyzer

Power measurement

Frequency measurement

Miscellaneous Test

Equipment

R&S

Agilent

Agilent

Agilent

Bird

FSL-B4 OCXO Ref. Freq.

FSL-B7 Nar. Res. Filters

ETL-K220 ATSC Demod.

DIV7 ETL-K208 Meas. Log

EFA

4402 instead of ETL instead of ETL

E44182B power meter with E9300B sensor, 100 uW to 3 W

53131A or 53181A 010 high stability time base

015 range extension to 1.5 GHz, OR

030 range extension to 3.0 GHz

APM-16 wattmeter, with 1W to 1kW elements

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Section 6

Diagnostics

6

6.1

Introduction

This section contains diagnostic and troubleshooting information for the ULX series

UHF transmitter. Included is a complete description of all faults which can be displayed via the transmitter front panel TCU display or GUI (Graphical User Interface). Due to the complexity of the transmitter control system and the extensive use of surface mount components, the scope of this diagnostics section is to isolate the problems down to a

PC board or module level which can then be easily exchanged.

The GUI buttons and icons use a symbol and color code system. Some examples using the triangle shape are given below. The other shapes operate similarly.

a.

Green with a 1 - - ON and operating normally.

b.

Green symbol - - ON and operating normally.

c.

Light Gray - - "Grayed Out" - Not communicating or not available.

d.

Yellow - Warning - A non-critical subsystem or parameter is out of tolerance and should be addressed by engineering personnel.

e.

Red - - Critical Fault - This could be a sub-system fault in which the subsystem is muted or shut off (such as a PA Module) or could be a system level fault which could mute or shut the transmitter off.

10/6/10

When a fault occurs one or more of the 5 LED’s on the TCU will illuminate RED. To track down the cause of the fault, begin by looking at the TCU Home screen and the

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6-1

Section 6 Diagnostics Maxiva ULX COFDM Series

.

software buttons along the right side as shown in Figure 6-1, aother option is to start by going to the System Log and seeing what faults have occurred and in what order. If you are not familiar with GUI navigation, refer to Section 3.

LED’s

Figure 6-1 TCU Fault LED’s

6.2

GUI System Log

6-2

The GUI contains a System Log which is a listing of all faults which have occurred. To see the System Log press SYSTEM then SYSTEM LOG. This will bring up the screen in Figure 6-2. The System Log gives the following information: a.

# - This gives the number of the fault. There can be up to 99 faults in the log, then it is FIFO (First IN, First Out) b.

Fault Type - This is simply the name of the fault.

c.

Time and Date - This gives the exact time and date that the fault occurred.

d.

Active or Inactive - If the fault is highlighted in red, it is still active and cannot be cleared. If the fault is not highlighted, then the fault is gone and can be cleared if so desired.

Function Buttons: a.

RESET - Will erase all inactive faults in the log.

b.

NEXT and PREV - These buttons allow you to scroll through the entire fault list if necessary.

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Maxiva ULX COFDM Series c.

BACK - Will take you back to the System main menu.

Section 6 Diagnostics

NOTE:

Tables 6-1 and 6-2 give a complete listing of all possible faults in the Maxiva transmitter. They also give a brief description of each fault, the trip point and the transmitter action taken in response to the fault.

Figure 6-2 Fault Log Screen

6.3

Maxiva Three-Strike Fault Actions

6.3.1

Reflected Power Faults

The TCU monitors reflected power at the Cabinet output and at the System output.

When the reflected power level (typically 10% of the rated power or a 1.9:1 VSWR) is exceeded the TCU generates an RF MUTE. If after three attempts to restart (three strikes) subsequent faults occur, the transmitter will turn OFF and operator intervention will be needed to turn it back ON. The three strike counter resets after 30 seconds with no faults.

Reflected power faults that initiate a three strike procedure are:

•

Cabinet Reflected Power

•

System Reflected Power

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6-3


6.3.2

Module Faults


Should a module failure occur (say a power glitch) the TCU will initiate a three-strike action. This action will cause a reset of only the PA Module experiencing the fault and not the entire transmitter.

The module three strike policy is:

•

The TCU will try to restart the module three times within a 10 second window. After that, if a fault is still present, the module will be turned OFF until it receives the restart command from the Main Controller (ON

Command).

•

There is a 3 second delay between restart attempts.

•

The fault-strike restart process is the same as the system restart command, all of the module faults will be reset.

•

During the 10 second three-strike window, any of the nuisance faults will be reported to the Main Controller.

These are the module faults which will be allowed three strikes:

•

Over Voltage Pallet

•

Under Voltage Pallet

•

Over Temperature Module Controller

•

Over Current Module Driver

•

Over Temperature Pre-driver Heatsink

•

Over Drive Module RF Input

•

Over Drive Module RF Output

•

Under Current Phase and Gain Board

•

Over Current Phase and Gain Board

•

Over Current Pallet

•

Under Current Pre-Driver

•

Over Current Pre-Driver

•

Over Temperature Power Supply Board

•

Low Voltage Output DC Converter

•

Short Circuit

•

High Module Reflected Power

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6.4

Fault Tables


The following tables provide a listing of Maxiva Transmitter faults along with a brief description, the fault level or threshold and the action taken by the transmitter.

Table 6-1 Maxiva Drive Chain Fault List

TYPE Description Fault Level or

Threshold

IPA A Fault: Power

Supply, LDMOS,

VSWR, Power

Overload, Temperature, Input Power

IPA B Fault: Power

Supply, LDMOS,

VSWR, Power

Overload, Temperature, Input Power

PDU (Predriver) A

Fault

The IPA can report up to 6 faults via their parallel control pins

Any one fault active

The IPA can report upto 6 faults via their parallel control pins

Any one fault active

Predriver current is below TBD mA

PDU Predriver B

Fault

Exciter A Power

Output

The Predriver current is monitored inside the PDU. A fault is sent if it is below the normal minimum current.

The Predriver current is monitored inside the PDU. A fault is sent if it is below the normal minimum current.

Exciter A power level low

Predriver current is below TBD mA

Trip point is 50% of nominal. Trip point adjustable by epot

Transmitter

Action

Three

Strike

Available in Life

Support

YES IPA Switch to alternate IPA if in Auto Mode

YES

IPA Switch to alternate IPA if in Auto Mode

YES


NO


NO

Exciter Switch to alternate

Exciter if in

Auto Mode

NO

YES

YES

YES

YES

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6-5


Table 6-1 Maxiva Drive Chain Fault List


TYPE

Exciter B Power

Output

Description

Exciter B power level low

Fault Level or

Threshold

Trip point is 50% of nominal. Trip point adjustable by epot

EXCA NO COMMU-

NICATIONS

Exciter A not communicating with transmitter main controller

EXCB NO COMMU-

NICATIONS

EXCA Summary

Fault

Exciter B not communicating with transmitter main controller

Exciter A reports a summary fault

EXCB Summary

Fault

No serial communications traffic detected

No serial communications traffic detected

Exciter B reports a summary fault

Exciter Switch to alternate Exciter if in Auto

Mode

Exciter Switch to alternate Exciter if in Auto

Mode

NO

Transmitter

Action

Three

Strike


Support

YES Exciter Switch to alternate

Exciter if in

Auto Mode

NO


Exciter if in

Auto Mode

NO


Exciter if in

Auto Mode

NO

NO

YES

NO

NO

YES

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Table 6-2 PA and IPA Module Fault List

TYPE

Temperature Fault

VSWR Fault

Power Overload

(including Input Power

Overdrive)

LD-MOSFET Failure

Input Power Low

Description


Fault Level or

Threshold

Transmitter

Action

Three

Strike


Support

YES

YES

YES

YES

YES

YES

YES

YES

YES

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6-7


TYPE

Table 6-3 Power Supply Faults List

Description Fault Level or

Threshold

Transmitter

Action

Three

Strike

+VA VDC

FLT

+15V Voltage Failure

Value is more than +/-

15% of normal reading

-VA VDC FLT -15V Voltage Failure Value is more than +/-


+5 VDC FLT +5V Voltage Failure Value is more than +/-


+3.3 VDC

FLT

+3.3V Voltage Failure

WARNING

AC Mains

High

AC Mains

Low

AC Mains voltage has exceeded 10% above nominal

AC Mains voltage has exceeded 15% below nominal

WARNING

Any phase is greater than +/- 5% of the average of all three phases

Wrong sequence AC Phase

Imbalance

AC Phase

Sequence

AC line imbalance phase to phase

Wrong Phase sequence detected

FUSE OPEN

WARNING

WARNING

WARNING

WARNING

NO

NO

WARNING

MOV Fuse 1 Fuse failed on MOV board

FUSE OPEN

NO

NO

NO

NO

YES

YES

NO

RF MUTE,

Pump and

Heat exchanger turned OFF.

Transmitter returns to ON state automatically when fault clears.

WARNING

NO

NO


Support

YES

YES

YES

YES

YES

YES

YES

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Table 6-3 Power Supply Faults List


Threshold


Transmitter

Action

Three

Strike


FUSE OPEN


FUSE OPEN


Value is more than +/-


WARNING

WARNING

WARNING

NO

NO

NO


Support

YES

YES

YES

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6-9


TYPE

Table 6-4 Output Faults List

Description Fault Level or

Threshold

Transmitter

Action

Three

Strike

Cabinet

VSWR

(Reflected

Power Fault)

System

VSWR

(Reflected

Power Fault)

Cabinet

Reflected Power has exceeded

10% of rated power

System Reflected

Power has exceeded 10% of rated power

Trip point is set at

VSWR = 1.9:1. Trip point adjustable by epot

RF MUTE, Fault

OFF after 3strike. The Time interval between strikes should be about 3 seconds


VSWR = 1.9:1

(Foldback starts at

1.4:1). Trip point adjustable by epot.

Foldback set point adjustable by software

YES

RF MUTE, Fault

OFF after 3strike. The Time interval between strikes should be about 3 senconds

YES

Cabinet Forward Power

Fault (Visual

Power in

Analog TV)

Cabinet

Aural Power

Fault (Analog TV only)

System Forward Power

Fault

System Aural

Power Fault

(Analog TV only)

Cabinet Forward


Aural Power is below 50% of rated power

System Forward


Aural Power is below 50% of rated power

WARNING

WARNING

WARNING

WARNING

NO

NO

NO

NO

YES

NO

YES

NO


Support

YES

YES for trip

NO for Foldback. Foldback routine requires

PCM action

YES

NO

YES

NO

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Table 6-4 Output Faults List


Threshold

Transmitter

Action

System

Power Foldback

Reject 1

Fault

Reject 2

Fault

Reject 3

Fault

The forward power is folded back (reduced) to maintain the reflected power below 2.8% of nominal power

(1.4:1 VSWR)


VSWR = 1.4:1.

This is a software trip point which depends on the transmitter nominal power

WARNING Reject power threshold exceeded

Reject power threshold exceeded

Reject power threshold exceeded

WARNING

WARNING

WARNING

NO

NO

NO


Three

Strike

NO

YES

YES

YES


Support

NO

YES

YES

YES

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6-11


TYPE

Table 6-5 System Faults List

Description Fault Level or Threshold

Transmitter

Action

Three

Strike

Air Temp Ambient control enclosure air temperature has exceeded 65°C.

The source of this temp can be from the temp sensor in the MCM module for instance.

Coolant Flow Coolant flow is less than the minimum

Liters per minute flow rate for the number of PAs present

Coolant Leak Coolant leak detected inside transmitter cabinet

65°C

Depends on transmitter model

N/A

Coolant Inlet

Temperature

Coolant temperature has exceeded

55°C

Warning at

55°C, Fault at

65°C

WARNING NO

RF MUTE followed by pump switchover. If still insufficient flow RF

MUTE stays active until proper flow is restored. Transmitter returns to ON state automatically when fault clears.

Transmitter Fault

OFF. A manual turn

ON is required for recovery

WARNING. RF

MUTE if coolant temperature reaches 65°C.


NO

NO

NO


Support

YES

YES

YES

YES

6-12 888-2629-200


10/6/10



TYPE Description Fault Level or Threshold

Transmitter

Action


Three

Strike

Coolant Outlet Temperature

Coolant Fault

Coolant

Warning

Fan 1 Fault

Fan 2 Fault

System

Safety Interlock

Coolant temperature has exceeded

55°C

The tank in the pump module is empty

The coolant in the tank is low

Fan AC current too low or too high

Warning at

55°C, Fault at

68°C

WARNING. RF

MUTE if coolant temperature reaches 68°C.


NO

Open circuit from level detector inside tank

Transmitter Fault

OFF. A manual turn


WARNING

NO

NO Open circuit from level detector inside tank

NO Fault levels

LOW: 100 mA,

HIGH: 800 mA

WARNING

WARNING NO

Open circuit Transmitter Fault

OFF. A manual turn


NO


Support

YES

YES

YES

YES

YES

YES

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6-13



TYPE Description Fault Level or Threshold

Transmitter

Action

Open circuit


Three

Strike


Support

YES System RF

Mute Interlock

Cabinet

Safety Interlock

Cabinet RF

Mute Interlock

Open circuit

Open circuit

Transmitter RF

MUTE. Transmitter returns to ON state automatically when the interlock is closed.

NO

Cabinet Fault OFF.

A manual turn ON is required for recovery

NO

Cabinet RF MUTE.

Cabinet returns to

ON state automatically when the interlock is closed.

NO

YES

YES

6-14 888-2629-200


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Section 7

Parts List

7

7.1

Replaceable Parts List

Table 7-1

Table 7-2

Table 7-3

Table 7-4

Table 7-5

Table 7-6

MAXIVA 16PA FORMAT TRANSMITTER - - - - - - 9950228001G (P)

SYS, CLOSED LP CLING; 3 FAN, 208/240VAC, 50HZ 708 0088 001 (A)



SYS, CLOSED LP CLING; 3 FAN, 380VAC, 60HZ - - 708 0088 004 (A)

CABLE, ANALOG EXCITER B I/O- - - - - - - - - - 952 9253 058 (A)

Table 7-7

Table 7-8

Table 7-9

*ASSEMBLY, TRITON PA MODULE - - - - - - - - 971 0040 003 (B)

ASSEMBLY, PA MODULE, BASIC, TRITON - - - 971 0040 100 (E)

ASSEMBLY, MAXIVA ULX PA MODULE- - - - - - 971 0040 004 (P)

Table 7-10 DUAL CIRCUIT BREAKER ASSEMBLY, 208-240V - 971 0040 033 (J)

Table 7-11 ANALOG PKG 16PA - - - - - - - - - - - - - - - - - 971 0040 059 (B)

Table 7-12 CABLE ,ANALOG EXCITER A I/O - - - - - - - - - 952 9253 057 (A)

Table 7-13 CABLE ANALOG RF - - - - - - - - - - - - - - - - 952 9253 063 (C)

Table 7-14 CUSTOMER I/O ASSEMBLY, ANALOG - - - - - - 971 0040 022 (D)

7-5

7-5

Table 7-15 MAXIVA 16PA BASIC TRANSMITTER - - - - - - - 981 0418 001 (AB) 7-6

Table 7-16 ASM, TOP, UCP-TRITON SYSTEM-16PA- - - - - - 981 0293 002 (F) 7-7

Table 7-17 MAXIVA COMMON COMPONENTS - - - - - - - - 981 0400 001 (AD) 7-8

Table 7-18 FAN ASSEMBLY, MAXIVA ULX - - - - - - - - - 971 0040 025 (F) 7-9

Table 7-19 PRE DRIVER UNIT, MAXIVA ULX - - - - - - - - 971 0040 030 (K)

Table 7-20 PRE DRIVER TRAY, MAXIVA ULX - - - - - - - 971 0040 031 (K)

Table 7-21 DP, MAXIVA ULX - DIGITAL, 1 CAB XMTR - - - - 988 2627 001 (B)

7-10

7-10

7-11

7-3

7-3

7-4

7-4

7-5

7-5

7-2

7-3

7-3

7-3

7-3

7-3

For table above and in tables that follow in this section the (X) or (XX) after the table title part number is the revision level of that bill of material and is for reference only.

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7-1

Section 7 Parts List


Harris PN

Table 7-1 MAXIVA 16PA FORMAT TRANSMITTER - 9950228001G (T P)

Description

472 1888 000 "XFMR, 480V/208V, 3 PH, 112.5 KVA, K13 RATED"0 EA

708 0090 010 "PUMP MODULE, 380/415 VAC 50HZ"

708 0090 011 "PUMP MODULE, 380/415 VAC 60HZ"

Qty UM

0 EA

0 EA

708 0090 012 "PUMP MODULE, 208/240 VAC 50 HZ"

708 0090 013 "PUMP MODULE, 208/240 VAC 60 HZ"

0 EA

0 EA

708 0090 014 "50KW HEAT EXCHANGER, 380/415V 50HZ"0 EA




774 0156 058 "KIT, COOLANT CHARGE PUMP"

774 0156 080 "KIT, PLUMBING ULX/VLX 1PA HOSE"

0 EA

0 EA

774 0156 081 "KIT, PLUMBING ULX/VLX 1PA PIPE"

943 5276 184 MAXIVA ULX SYSTEM WIRING KIT

952 9253 017 CABLE JUMPER PLUG 208-240V

952 9253 018 CABLE JUMPER PLUG 380-415V

0 EA

0 EA

0 EA

0 EA

952 9253 019 CABLE EXC A ASI

952 9253 020 CABLE EXC B ASI

952 9253 021 CABLE EXC A RF EXTERNAL

952 9253 022 CABLE ECX B RF EXTERNAL

0 EA

0 EA

0 EA

0 EA

952 9253 058 "CABLE, ANALOG EXCITER B I/O"

971 0040 003 "*ASSEMBLY, TRITON PA MODULE"

0 EA

0 EA

971 0040 004 "ASSEMBLY, MAXIVA ULX PA MODULE" 18 EA

971 0040 020 "CUSTOMER I/O ASSEMBLY, DIGITAL" 0 EA

971 0040 033 "DUAL CIRCUIT BREAKER ASSEMBLY, 208-240V"0 EA

971 0040 037 "DUAL CIRCUIT BREAKER ASSEMBLY, 380-415V"0 EA

971 0040 059 ANALOG PKG 16PA

971 0040 075 "KIT, CE DIGITAL MAXIVA ULX"

0 EA

0 EA

971 0040 080 "UNIT, PA DIAGNOSTICS"

971 0040 095 "KIT, SINGLE EXCITER"

0 EA

0 EA

981 0222 012 "MAXIVA ULX, PA MODULE TEST FIXTURE"0 EA

981 0418 001 MAXIVA 16PA BASIC TRANSMITTER 1 EA

988 2627 200 "DP, MAXIVA ULX-ATSC, 1 CABINET" 0 EA

988 2628 200 "DP, MAXIVA ULX-ANALOG, 1 CABINET" 0 EA

988 2629 200 "DP, MAXIVA ULX-COFDM, 1 CABINET" 0 EA

992 9139 090 "KIT, INSTALL MATERIAL, MAXIVA 1 PA CAB"0 EA

995 0063 001 "FORMAT, EXCITER, APEX M2X (DVB-T/H)"0 EA

995 0063 002 "FORMAT, EXCITER, APEX M2X (ISDB-T)" 0 EA

995 0063 005 "FORMAT, EXCITER, APEX M2X (ATV)" 0 EA

995 0063 200 "EXCITER, APEX M2X (ATSC)" 0 EA

484 0606 000 "FILTER, LOW PASS, UHF, BAND A"

484 0607 000 "FILTER, LOW PASS, UHF, BAND B"

0 EA

0 EA

484 0608 000 "FILTER, LOW PASS, UHF, BAND C" 0 EA

484 0781 000 "FILTER, LOW PASS, UHF, 4-1/16'' BAND A" 0 EA

484 0782 000 "FILTER, LOW PASS, UHF, 4-1/16'' BAND B" 0 EA

484 0783 000 "FILTER, LOW PASS, UHF, 4-1/16'' BAND C" 0 EA

484 0784 000 "FILTER, LOW PASS, UHF, 4-1/16'' BAND D" 0 EA

981 0202 001 "FILTER, LOW PASS DTV IN-SYSTEM" 0 EA

981 0202 002 "FILTER, LOW PASS DTV IN-SYSTEM"


0 EA

0 EA

Reference Designators

A1

"A2,A3"

"A2,A3"

"A2,A3"

"A2,A3"

7-2 888-2629-200


10/6/10

Maxiva ULX COFDM Series Section 7 Parts List


484 0505 000 "FILTER, UHF DTV, (REFLECTIVE)"

484 0511 000 "FILTER, UHF DTV; (REFLECTIVE)"

484 0603 000 "FILTER, UHF ANALOG, 30KW"

0 EA

0 EA

0 EA

0 EA

Harris PN

610054000

Table 7-2 "KIT, COOLANT CHARGE PUMP" - 774 0156 058 (B P)

Description

"FILTER BAG, 7DIA X 18L 10MIC"

359 0555 000 "ADAPTER, HOSE TO FTG"

359 1599 075 "VALVE, CHECK 0.75"" NPT"

359 1600 075 "NIPPLE, HEX BRS 3/4 X 3/4"

359 1601 000 "BUSHING, HEX BRS 1 X 3/4"

424 0677 000 "HOSE, WATER SS 60"""

432 0575 000 "PUMP, 1/4HP 230VAC 50/60HZ"

Qty UM

1 EA

3 EA

1 EA

1 EA

1 EA

2 EA

1 EA


Table 7-3 "KIT, PLUMBING ULX/VLX 1PA HOSE" - 774 0156 080 (A P)

Harris PN

631030021

Description Qty UM

"* PIPE SEALANT ""PST"" LOCTITE 565" 1 EA

631030022 "PASTE, PIPE THREAD TEFLON"

299 0018 000 "THREAD-TAPE, TEFLON 1.00''W"

1 EA

1 RL

302 0318 000 "SCREW, HHMS 3/8-16 X 1 SST"

302 0320 000 "SCREW, HHMS 3/8-16 X 1-1/2 SST"

25 EA

25 EA

306 0047 000 "NUT, HEX 3/8-16" 25 EA

310 0011 000 "WASHER, FLAT 3/8 SST (ANSI REGULAR)" 25 EA

314 0011 000 "LOCKWASHER, SPLIT 3/8 SST (ANSI)"

358 1131 000 NUT W/SPRING 3/8-16

25 EA

15 EA

359 1933 000 "ADAPTER, M-M GARDEN HOSE" 1 EA

843 5601 562 "LAYOUT, PLUMBING MAXIVA 1PA, DRYCOOLER"0 DWG

217510003 "HOSE, RUBBER 1.500"" ID"

359 1573 000 "HOSE BARB, 1-1/2"""

100 FT

6 EA

943 5585 257 "ASSY, MANIFOLD SUPPLY/RETURN MAXIVA"1 EA

358 3493 000 "HOSE BARB, 1-1/4""H X" 2 EA


359 1598 000 "VENT, AUTOMATIC AIR"

358 1722 000 "HOSE CLAMP, SST, SAE-20"

359 1735 000 "CLAMP, HOSE, 1-1/2"" HEAVY DUTY"

358 2179 000 "ROD, THREADED 3/8-16 X 10FT LG"

1 EA

4 EA

12 EA

12 EA

358 3945 000 "CBL TRAY, 6""W X2"" H X 10' LENGTH" 1 EA

358 3946 000 "CBL TRAY, SUPPORT HANGER CLIP" 24 EA

624 0004 200 "PIPE CLAMP, NON-INSUL 2.00IN"

358 3564 000 "CLAMP, PIPING, WITH CUSHION"

4 EA

6 EA

358 3481 100 "*CHANNEL, 1-5/8"" SQ OUTDOOR (10FT)" 1 EA

359 1932 000 "ELBOW, STREET,90 DEG, 1-1/2 IN" 2 EA

Harris PN

631030021

631030022

860004047

Table 7-4 "KIT, PLUMBING ULX/VLX 1PA PIPE" - 774 0156 081 (A P)

Description Qty UM

"* PIPE SEALANT ""PST"" LOCTITE 565" 1 EA

"PASTE, PIPE THREAD TEFLON"

"SOLDER, SILVER SIZE .125"""

1 EA

1 LB

860026000 "*SOLDER FLUX, PASTE, 'STAY-CLEAN'" 1 EA

299 0018 000 "THREAD-TAPE, TEFLON 1.00''W" 1 RL

302 0318 000 "SCREW, HHMS 3/8-16 X 1 SST" 25 EA


10/6/10 888-2629-200


7-3



302 0320 000 "SCREW, HHMS 3/8-16 X 1-1/2 SST"

306 0047 000 "NUT, HEX 3/8-16"

25 EA

25 EA

310 0011 000 "WASHER, FLAT 3/8 SST (ANSI REGULAR)" 25 EA

314 0011 000 "LOCKWASHER, SPLIT 3/8 SST (ANSI)" 25 EA

358 1131 000 NUT W/SPRING 3/8-16

358 2179 000 "ROD, THREADED 3/8-16 X 10FT LG"

359 0253 000 "COUPLING 1-1/2"" CXC"

359 1933 000 "ADAPTER, M-M GARDEN HOSE"

15 EA

12 EA

4 EA

1 EA

843 5601 562 "LAYOUT, PLUMBING MAXIVA 1PA, DRYCOOLER"0 DWG

939 8106 939 CU TUBING 1.625 OD (1.5 NOM) 10 FT LENGTH10 EA

359 0226 000 ADAPTER 1-1/2 CXM

358 3493 000 "HOSE BARB, 1-1/4""H X"

6 EA

2 EA

943 5585 257 "ASSY, MANIFOLD SUPPLY/RETURN MAXIVA"1 EA

359 1598 000 "VENT, AUTOMATIC AIR" 1 EA


359 0246 000 ELBOW CU 90DEG 1.500C X 1.500C

4 EA

14 EA

359 0255 000 ELBOW 45 DEG 1-1/2

358 3564 000 "CLAMP, PIPING, WITH CUSHION"

4 EA

6 EA

358 3481 100 "*CHANNEL, 1-5/8"" SQ OUTDOOR (10FT)" 1 EA

359 1897 000 PIPE HANGER 1.5IN LAY-IN 6 EA

Harris PN

34010082

Table 7-5 MAXIVA ULX SYSTEM WIRING KIT - 943 5276 184 (B P)

Description

"CU, STRAP 0.020 X 2"" X 50"

250 0443 000 "CABLE, 12C 20AWG STRD"

253 0059 000 "CABLE, 2C 22AWG AUDIO"

Qty UM

1 EA

50 FT

50 FT

618 0511 100 "*COAX CABLE, RG-223/U, 100 FT REEL" 1 RL

620 0818 000 "PLUG, BNC STRAIGHT CABLE" 4 EA

620 2174 000 'N' PLUG CRIMP ST 4 EA


Harris PN

Table 7-6 "ASSEMBLY, MAXIVA ULX PA MODULE" - 971 0040 004 (P P)

Description

843 5601 012 "WIRING DIAGRAM, PA MODULE"

Qty UM

0 DWG

943 5601 129 "PANEL, FRONT, PA MODULE" 1 EA

971 0040 100 "ASSEMBLY, PA MODULE, BASIC, TRITON"1 EA


Harris PN

74030001

Table 7-7 "ASSEMBLY, PA MODULE, BASIC, TRITON" - 971 0040 100 (G P)

630001060

880001089

Description

"BRZ, FGR STK 97-520-02"

*COMPOUND #4

"TAPE, ELEC 1.75 IN W"

302 0803 025 "SCREW, MACH M3-0.5 X 25 SEMS"

Qty UM

0.143 EA

0 EA

0 RL

24 EA


302 0952 000

310 0059 000

SCREW SKT HD CAP M4 X 12

"<*>WASHER, FLAT M3 SST (DIN9021)"

16 EA

4 EA

311 0011 030 "WASHER, FLAT M3 SST (DIN125)" 5 EA

315 0021 030 "LOCKWASHER, SPLIT M3 SST (DIN127)" 21 EA

315 0021 040 "LOCKWASHER, SPLIT M4 SST (DIN127)" 16 EA

325 0020 000 "NUT, KEP M3" 4 EA

"4#A3,4#A4,4#A5,4#A

6,4#A7,4#A8,4#A9,4#

A10"

"#A13,A14,A15,A16"

A1

"#A13,A14,A15,A16"

A1

7-4 888-2629-200


10/6/10


336 1330 000 STDOFF-M/F-4.5MM HEX-M3X0.5X5L

9 EA

336 1390 000 "RETAINING RING, 1.062"" SHAFT (27MM)" 1 EA

350 0046 000 RIVET POP .156X.254

359 1591 000 "*COUPLING, BODY, VALVED 3/8SAE"

8 EA

2 EA

408 0338 000 "GASKET, EMI, 0.13 TALL X 0.19"

410 0627 000 "STDOFF, M3 X 0.5 8MM"

1.3 EA

12 EA

411 0126 000 "THERMAL INTERFACE, AC-DC CONV" 8 EA

414 0348 000 "CORE, EMI SUPPRESSION, 0.5"" ID" 1 EA

414 0394 000 "CORE, SNAP ON HIGH FREQ 0.2"" ID"

612 2580 001 "*SCREW LOCKS, FEMALE 2-56"

1 EA

1 EA

843 5601 012 "WIRING DIAGRAM, PA MODULE" 0 DWG

9010222011G "PWA, AC/DC CONVERTER INTERFACE" 8 EA

9010222021G "PWA, AC DISTRIBUTION"

9010222041G "PWA, I/O CONNECTOR BOARD"

1 EA

1 EA

9010222051G "PWA, PA MONITOR BOARD" 1 EA

9010222061G "PWA, SIGNAL DISTRIBUTION BOARD" 1 EA

9010222071G "PWA, 4-WAY SPLITTER & SPREADER"

9010222081G "PWA, PA PALLET"

1 EA

4 EA

9010222091G "PWA, 4-WAY COMBINER & SPREADER" 1 EA

922 1300 019 "CABLE, RF INPUT" 1 EA

943 5601 009 "RING, TEFLON, 7/8"" RF RECPTACLE" 1 EA

943 5601 011 "INSULATION, AC DISTRIBUTION PWA" 1 EA

943 5601 046 "FENCE, PALLET SHIELD"

943 5601 047 "FENCE, RF DIVIDER"

3 EA

1 EA

943 5601 048 "COVER, PA MODULE"

943 5601 061 "WASHER, SHOULDER"

1 EA

4 EA

943 5601 101 "FENCE, PALLET SHIELD" 1 EA

943 5601 122 PA COLDPLATE ASSEMBLY TRITON PA MODULE1 EA

943 5601 125 "PANEL, SIDE WALL, RIGHT"

943 5601 126 "PANEL, SIDE WALL, LEFT"

943 5601 128 "PANEL, FRONT WALL"

943 5601 130 "COVER, SOLDER"

1 EA

1 EA

1 EA

1 EA

943 5601 137 "SHIELD, COMBINER TRITON PA MODULE"1 EA

943 5601 230 "BODY, 7/8"" RF PLUG" 1 EA

943 5601 388 "MODULE 7/8 CONDUCTOR, CENTER"

943 5601 392 "INSULATION, I/O PWA"

1 EA

1 EA

943 5601 430 "PANEL, BACK WALL"

952 9253 001 CABLE KIT MODULE

1 EA

1 EA

"A3,A4,A5,A6,A7,A8,

A9,A10"

A2

A1

A18

A12

A11

"A13,A14,A15,A16"

A17

A1

Harris PN

10

Table 7-8 "PWA, PA PALLET" - 9010222081G (K P)

Description

B/M NOTE:

550100005 "*THERMAL COMPOUND, 8OZ JAR"

302 0803 001 "SCREW, SEMS M2.5 X 8 SKT HD,SS"

544 1706 002 TERMINATION 50R 250W 5%

646 2110 000 "BARCODE, SN_ITEM_REV"

700 1411 000 TERMINATION 50 OHM 10W 5%

801 0222 081 "SCH, PA PALLET"

8010222183G UHF 3DB HYBRID

9010222082G "PWA SMT, PA PALLET"

Qty UM

0 DWG

0 EA

30 EA

1 EA

1 EA

1 EA

0 DWG

2 EA

1 EA


R2

R32

"HY1,HY2"

10/6/10 888-2629-200


7-5



943 5601 015 "HEAT SPREADER, PALLET"

943 5601 022 DC JUMPER

943 5601 041 "ASSEMBLY, MOSFET"

943 5601 117 INDUCTOR

1 EA

2 EA

2 EA

2 EA

"JP1,JP2"

"Q1,Q2"

"L1,L2"

Harris PN

Table 7-9 CABLE KIT MODULE - 952 9253 001 (D P)

Description

952 9253 002 CABLE MODULE A2J10



952 9253 005 CABLE RIBBON W1

952 9253 006 CABLE RIBBON W2/W4

952 9253 007 CABLE RIBBON W3

952 9253 008 "CABLE, MODULE JUMPERS"

Qty UM

1 EA

1 EA

1 EA

1 EA

2 EA

1 EA

1 EA


Table 7-10 ANALOG PKG 16PA - 971 0040 059 (B P)

Harris PN Description

952 9253 057 "CABLE ,ANALOG EXCITER A I/O"

952 9253 063 CABLE ANALOG RF

952 9253 064 "CABLE COAX, 86,87,88,89"

Qty UM

1 EA

1 EA

4 EA

952 9253 065 CABLE RIBBON W4 1 EA

971 0040 022 "CUSTOMER I/O ASSEMBLY, ANALOG" 1 EA


Harris PN

Table 7-11 "KIT, CE DIGITAL MAXIVA ULX" - 971 0040 075 (A P)

Description

302 0972 000 SCREW SKT HD CAP M5 X 18

344 0248 000 "SCREW, #8 X 3/4L SHEET METAL"

358 0498 000 "*HOSE CLAMP, SST, SAE-48"

448 1082 000 "GASKET, EMI/RFI SHIELDING,"

448 1383 000 "LATCH, FLUSH MOUNT, BLACK"

448 1399 000 "HINGE, METAL LIFT-OFF"

943 5601 553 "WINDOW, CE DOOR"

943 5601 555 "SHIELD, CE DOOR"

943 5601 556 "BRKT, CE DOOR"

943 5601 557 "FOAM SHIELD, CE DOOR"


1 EA

2 EA

2 EA

1 EA



2 EA

1 EA

943 5601 632 TRITON EXHAUST HONYCOMB BRACKET 1 EA

943 5601 633 TRION EXHAUST HONYCOMB 1 EA

943 5601 957 "DOOR, FRONT" 1 EA

Qty UM

4 EA

12 EA

22 EA

27.15 FT

2 EA

2 EA

1 EA


Harris PN

Table 7-12 "UNIT, PA DIAGNOSTICS" - 971 0040 080 (D P)

Description

256 0166 015 "CABLE ASSY, USB-A/B, 1.5M"

256 0346 000 "CABLE, 50C 0.050"" PLUG, 3M"

303 4125 016 "SCREW, MACH M2.5 X 16"

Qty UM

1 EA

1 EA

4 EA

307 0001 025 "NUT, STD HEX M2.5"

311 0011 025 "WASHER, FLAT M2.5 SST (DIN125)"

4 EA

8 EA

315 0021 025 "LOCKWASHER, SPLIT M2.5 SST (DIN127)" 4 EA

344 0440 250 "SCREW, 4-40 X 1/4L SELF-TAP PPH" 4 EA


7-6 888-2629-200


10/6/10


344 0440 625 "SCREW, 4-40 X 5/8L SELF-TAP PPH"

406 0527 000 "DISPLAY, LCD 4 X 20"

4 EA

1 EA

409 0111 000 "SPACER, NYLON .312LG .188OD .115ID" 4 EA

612 2580 001 "*SCREW LOCKS, FEMALE 2-56" 1 EA

727 1519 002 "GROMMET, LIGHT PIPE" 6 EA

727 1519 003 "LIGHT PIPE, 0.2"" L X 0.190"" DIA CLEAR" 6 EA

9010222411G "PWA, PA INTERFACE, SWITCH"

9010222421G "PWA, PA INTERFACE, CONTROL"

943 5601 504 "MODIFICATION, ENCLOSURE"

1 EA

1 EA

1 EA

Table 7-13 "MAXIVA ULX, PA MODULE TEST FIXTURE" - 981 0222 012 (C P)

Harris PN Description

250 0506 000 "CABLE, 4C 12AWG TYPE S0"

250 0684 020 "CABLE, 7-16M TO 7-16M 2.0M"

432 0573 000 "COOLING SYSTEM, LYTRON MCS"

Qty UM

20 FT

1 EA

1 EA

544 1768 000 "RES, 2.5KW LOAD DIGITAL, 8892D-300" 1 EA

609 0031 000 "AC INLET, 15AMP MALE IEC-C14" 1 EA

610 1296 000 "PLUG, IEC C-14 FOR 14AWG"

620 2604 000 "ADAPTOR, 7/8 FL TO UNFL"

3 EA

1 EA

620 2605 000 "CONN, ANCHOR INS 7/8"

620 3254 000 "DIR COUPLER, 1-5/8"" UHF"

620 3429 000 "REDUCER, 1-5/8 TO 7/16 JACK"

628 0017 000 "ADAPTER, 7/8 TO 7-16"

1 EA

1 EA

1 EA

1 EA

843 5601 612 "BLOCK DIAGRAM, AC DISTRIBUTION" 1 DWG

943 5601 600 "CHASSIS, MODULE TEST FIXTURE" 1 EA

943 5601 602 "COVER, MODULE TEST FIXTURE"

943 5601 603 "COVER, MTG TEST FIXTURE"

1 EA

1 EA


943 5601 604 "HINGE, STOP, TEST FIXTURE" 1 EA

943 5601 605 "ANGLE, STOP, MODULE TEST FIXTURE" 1 EA

943 5601 606 "GUIDE, MODULE TEST FIXTURE" 1 EA

943 5601 608 "AC PANEL INTERFACE, MODULE TEST FIXTURE"1 EA

971 0040 080 "UNIT, PA DIAGNOSTICS" 1 EA

981 0223 001 "CONTROL UNIT, MAXIVA PA MODULE TEST FIXTURE."1 EA

981 0223 002 "PA MODULE INTERFACE UNIT, MAXIVA PA MODULE TEST FIXTURE"1 EA

981 0223 003 "ASSY, PA MODULE FIXTURE, MAXVIA ULX"1 EA

Harris PN

217510002

217510004

880020015

Table 7-14 MAXIVA 16PA BASIC TRANSMITTER - 981 0418 001 (AF)

Description

"HOSE, 1/2'' ID, BLUE"

357 0126 002 "GUIDE RAIL, PLASTIC"

358 1318 000 "HOSE CLAMP, (MINI) SST, SAE-4"


358 3637 000 "PLATE, END STOP, DIN RAIL MTG"

358 4038 000 "HOSE CLAMP, LINED, SST, SAE-28"

359 1269 000 "HOSE, 3/8'' ID, BLUE"

Qty UM

15.5 FT

"HOSE, GEN PURPOSE, EPDM, 1.25"" ID, RED"9.9 FT

"TAPE, SCOTCH FOAM" 1 RL

300 2910 000 "SCREW, M5 X 16MM, BLK W/WASHER" 54 EA

335 0465 000 "O-RING, EPDM, #016, 5/8'' ID" 14 EA

336 1254 000 "*HOSE CLAMP, (MINI) SST, SAE-6"

336 1391 000 "NUT, CAGE M5"

6 EA

54 EA

36 EA

6 EA

1 EA

3 EA

8 EA

3.76 ME


TB1 & TB2

10/6/10 888-2629-200


7-7


359 1875 000 "COUPLING, VALVED TIP, FACE SEAL"

430 0292 000 "FAN GUARD, 6.14"" DIA."

430 0684 000 "FAN, 20-28 VDC, 24V NOMINAL"

556 0179 100 "ATTEN, SMA, 10DB, 2W, 50 OHM"

36 EA

2 EA

1 EA

1 EA

560 0121 021 POSISTOR 3.75 AMP 60VDC 29MM DISC 1 EA

570 0405 000 CONTACTOR 60A 3P 600V 4 EA

606 1139 200 CKT BRKR 20 AMPS 4P 480VAC 18 EA


A19B1

AT8

A19CB1

"K1,K2,K3,K4"

"CB1,CB2,CB3,CB4,C

B5,CB6,CB7,CB8,CB9

,CB10,CB11,CB12,CB

13,CB14,CB15,CB16,C

B17,CB18"

610 1253 000 "HDR, MALE 4C 1ROW STRAIGHT"

620 0498 000 ADAPTOR 3-1/8 FL TO UNFL

620 0499 000 "COUPLING, STRAIGHT 3-1/8"

620 0544 000 "CONN, ANCHOR INS 3-1/8; 50 OHM"

620 0918 000 "CONNECTOR, INNER COND 3-1/8"

620 2275 000 "ELBOW, EQUAL, 3-1/8, 90 DEG"

620 3004 000 "ADAPTOR, SMA-PLUG TO N-JACK"

620 3008 000 "ADAPTER, SMA FEM TO SMA MALE"

1 EA

2 EA

9 EA

1 EA

10 EA

5 EA

1 EA

1 EA

620 3277 000 "DIR COUPLER, 3-1/8"" UHF"

620 3750 000 "SPLITTER/COMBINER, 3-WAY"

646 1483 000 "NAMEPLATE, HARRIS LOGO"

646 1701 000 "NAMEPLATE, MAXIVA"

1 EA

2 EA

1 EA

1 EA

700 1422 042 "RF LOAD, 10KW, 3-1/8, WATER COOL" 1 EA

792 0207 000 "3.01DB HYBRID, 20KW AVE OUTPUT POWER"1 EA

9010222101G "PWA, 4PA BACKPLANE BOARD"

917 2558 099 "STANDOFF, M/F, M4 X 25"

4 EA

16 EA

917 2567 017 "DIN RAIL, CUT LENGTH 612MM"

943 5560 052 "PANEL, FRONT BLANK 2U"

943 5601 049 CABLE BACKPLANE AC

943 5601 088 "OUTER CONDUCTOR, 3 1/8"

943 5601 089 "PLATE, HYBRID SUPPORT"

943 5601 091 "PLATE, MANIFOLD MTG"

943 5601 097 "MANIFOLD ASSY, 10 PORT"

943 5601 145 "BRACKET, SPLITTER MTG"

943 5601 146 "BRACKET, SPLITTER SUPPORT"

943 5601 169 "HOSE BARB, 38 PUSHLOCK"

943 5601 170 "HOSE BARB, 12 PUSHLOCK"

943 5601 192 "PLUG, 916"

943 5601 218 "PIN, GUIDE"

943 5601 232 "INNER CONDUCTOR, 1.315"

943 5601 238 "MANIFOLD ASSY, 8 PORT"

943 5601 239 "COVER, BACKPLANE BOARD"

943 5601 334 "OUTER CONDUCTOR, 3 1/8"

943 5601 335 "INNER CONDUCTOR, 1.315"

943 5601 391 "PLATE, HYBRID"

943 5601 397 "INSULATOR, BACKPLANE"

943 5601 445 "PLATE, RF OUTPUT"

943 5601 460 "SUPPORT, COMBINER LOAD"

943 5601 466 "BRACE, COMBINER"

943 5601 620 "LABEL, UNIT 1 FRONT"

943 5601 629 "LABEL, 16 PA REAR"

1 EA

1 EA

1 EA

4 EA

1 EA

1 EA

2 EA

1 DWG

1 DWG

1 EA

1 EA

8 EA

2 EA

1 EA

6 EA

2 EA

2 EA

1 EA

6 EA

6 EA

4 EA

18 EA

2 EA

2 EA

4 EA

DC1

"SP1,SP2"

A14

"A5,A6,A8,A9"

7-8 888-2629-200


10/6/10


943 5601 939 COAX BLOCK

952 9253 012 CABLE BRKR SLOT 1 - SLOT 4

952 9253 014 CABLE MODULE SPLITTER

952 9253 036 CABLE AC INPUT 9 + PA'S

952 9253 039 CABLE PKG SPLITTER HIGH POWER

952 9253 059 CABLE IPA1

952 9253 074 "CABLE, FAN REAR DOOR"

971 0040 040 "SPLITTER, 2-WAY, MAXIVA ULX"

16 EA

1 EA

16 EA

1 EA

1 EA

1 EA

1 EA

1 EA

971 0040 045 "8-WAY SPLITTER, MAXIVA ULX"

971 0040 055 "8-WAY COMBINER, MAXIVA ULX"

971 0053 416 "ASSY, BUSBAR 4P 4-BRKR (16TAP)"

971 0053 420 "ASSY, BUSBAR 4P 5-BRKR (20TAP)"

2 EA

2 EA

3 EA

1 EA

981 0293 002 "ASM, TOP, UCP-TRITON SYSTEM-16PA" 1 EA

981 0400 001 MAXIVA COMMON COMPONENTS 1 EA

SP7

"SP5,SP6"

"A12,A13"

A4

Harris PN

266010002

Table 7-15 MAXIVA COMMON COMPONENTS - 981 0400 001 (AJ)

Description

"GROMMET STRIP, 0.090"

303 7125 022 "BOLT, SST, M8-1.25 X 18"

336 1391 000 "NUT, CAGE M5"

336 1430 000 "PIN, PULL 3/16 OD X 3.0 LG"

358 2589 000 "MOUNT, RIBBON CABLE, 2''"

448 1026 000 "HINGE, METAL LIFT-OFF"

448 1383 000 "LATCH, FLUSH MOUNT, BLACK"

583 0118 001 "RELAY, COAXIAL TRANSFER"

610 1253 000 "HDR, MALE 4C 1ROW STRAIGHT"

612 2156 003 "PLUG, 3C 1ROW VERTICAL"

620 3014 000 "ADAPTER, BULKHEAD SMA"

628 0020 000 "RF ADAPTER, 7/8"" 50 OHMS"

629 0093 000 "SENSOR, LIQUID LEVEL, FLOAT"

629 0181 000 "METER, FLOW 1 IN, 8-60 GPM"

646 1353 000 "NAMEPLATE, XMTR EQUIPMENT"

646 1773 000 "LABEL, POWERSMART 2.0 X 0.35"

700 1413 000 "ATTENUATOR 40DB, 1KW"

843 5601 001 WIRING DIAGRAM PA MAIN

9010222131G "PWA, IPA BACKPLANE"

9010222141G "PWA, CUSTOMER I/O BOARD"

9010222601G "PWA, CONTACTOR CONTROL CE"

917 2558 099 "STANDOFF, M/F, M4 X 25"

917 2567 021 "DIN RAIL, CUT LENGTH 756MM"

943 5575 324 "PLATE, GROUND"

943 5600 046 "ARM, MOUNTING"

Qty UM

12 FT

880020015 "TAPE, SCOTCH FOAM" 0.12 RL

300 2910 000 "SCREW, M5 X 16MM, BLK W/WASHER" 18 EA

4 EA

18 EA

1 EA

10 EA

358 2628 000 CABLE PUSH MOUNT

358 3197 000 "SLIDES 10"" PAIR"

359 1268 000 "VALVE, 3/8"" MINI BALL"

359 1273 000 "HOSE END, 3/8"" BARBED"

2 EA

1 PR

2 EA

2 EA

359 1874 000 "FTG, 1.25 HOSE BARB X 1 MIPT, BRASS" 2 EA

359 1922 000 "HOSE BARB, 3/8 HOSE X 3/8 FIPT" 2 EA

424 0502 000 BUMPER 5/8 DIA X 1/4 THK

448 0868 000 AIR FILTER 14 X 20 X .88

1 EA

1 EA

3 EA

2 EA

1 EA

1 EA

1 EA

1 EA

2 EA

1 EA

1 EA

1 EA

1 EA

1 EA

0 DWG

1 EA

1 EA

1 EA

4 EA

1 EA

2 EA

2 EA


S2

J2

J3

S1

U1

R1

A7

A1A1

A17

10/6/10 888-2629-200


7-9


943 5601 009 "RING, TEFLON, 7/8"" RF RECPTACLE"

943 5601 102 "BRACKET, LEVEL SENSOR"

943 5601 115 "PANEL, MODULE BREAKERS"

943 5601 118 "SIDE, MODULE BREAKER PANEL"

943 5601 119 "TOP, MODULE BREAKER PANEL"

943 5601 120 "COVER, MODULE BREAKERS"

943 5601 135 "CHASSIS, I/O"

943 5601 138 "COVER, BREAKER/MOV ACCESS"

943 5601 139 "SIDE, MODULE BREAKER PANEL"

943 5601 148 "COVER, DOWNCONVERTER"

943 5601 155 "DUCT, PREDRIVER"

943 5601 214 "PANEL, MOUNTING, IPA INTERFACE"

1 EA

1 EA

2 EA

1 EA

943 5601 216 "SPACER, HEX IPA INTERFACE" 3 EA

943 5601 217 "ADAPTER, RF, MALE, LARGE FLANGE" 2 EA

943 5601 228 "CONDUCTOR, CENTER, IPA ADAPTER" 2 EA

943 5601 235 "SENSOR, TEMP" 2 EA

2 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

943 5601 240 "COVER, IPA BACKPLANE BOARD"

943 5601 241 "SUPPORT, PREDRIVER"

943 5601 244 "STRAP, GROUND"

943 5601 310 "DRIP PAN, MAXIVA"

943 5601 325 "BRACKET, CABLE RETRACTOR"

943 5601 328 "PLATE, ANGLED COVER"

943 5601 330 "COVER, ACCESS"

943 5601 332 "SHIELD, I/O BOARD"

943 5601 398 "INSULATOR, IPA BACKPLANE"

943 5601 432 "PANEL, UCP-M2X MOUNTING"

943 5601 433 "RAIL, M2X MOUNTING"

943 5601 434 "RAIL, UCP CABLE MOUNTING"

943 5601 435 "RETRACTOR, CABLE"

943 5601 436 "CLAMP, LOAD/MANIFOLD"

943 5601 437 "ANGLE, FRONT TRIM"

943 5601 532 "PLATE, CONTACTOR MTG"

1 EA

2 EA

2 EA

1 EA

1 EA

2 EA

2 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

943 5601 533 "PLATE, COVER"

943 5601 544 "BRACKET, COAXIAL SWITCH"

943 5601 703 CABLE SHIELD

943 5601 900 "WELDMENT ASSY, CABINET"

943 5601 913 "PANEL ,DOOR"

943 5601 920 "PANEL, SIDE"

943 5601 921 "PLATE, PLENUM CLOSEOUT"

943 5601 927 "BRACKET, FILTER"

943 5601 928 "PLENUM, DOOR"

943 5601 934 "SLIDE ANGLE, UEP"

943 5601 939 COAX BLOCK

952 9237 027 "CABLE, CAN BUS DISTRIBUTION"

952 9253 010 CABLE IPA BREAKERS

952 9253 011 CABLE BRKR SLOT 5 - SLOT 8

952 9253 016 CABLE CONTROL

952 9253 023 "CABLES, CABINET RIBBONS"

952 9253 072 "CABLE, DRIVE COAX (84)"

952 9253 073 "CABLE, DRIVE COAX(85)"

971 0040 025 "FAN ASSEMBLY, MAXIVA ULX"

971 0040 030 "PRE DRIVER UNIT, MAXIVA ULX"

1 EA

4 EA

2 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

1 EA

2 EA

1 EA

1 EA

1 EA

1 EA

2 EA

1 EA


"U2,U3"

"A10,A11"

A12

7-10 888-2629-200


10/6/10


971 0040 031 "PRE DRIVER TRAY, MAXIVA ULX" 2 EA "A12A2,A12A3"

Harris PN

Table 7-16 "FORMAT, EXCITER, APEX M2X (DVB-T/H)" - 995 0063 001 (H 5)

Description

917 2501 156 "LABEL, LABEL CE"

971 0035 003 "KIT, BATTERY BACKUP"

9710035011G ASM-SUB-TX/IO INTERFACE MODULE

981 0274 001 "EXCITER, APEX M2X BASIC"

971 0035 014 ASM-SUB-BLANK PANEL B

971 0035 015 ASM-SUB-BLANK PANEL C

971 0035 013 ASM-SUB-BLANK PANEL A

Qty UM

1 EA

0 EA

0 EA

1 EA

1 EA

0 EA

1 EA


Harris PN

266010007

550100005

860001002

Table 7-17 "EXCITER, APEX M2X BASIC" - 981 0274 001 (Y 5)

Description

"GROMMET STRIP, 0.063"

"*THERMAL COMPOUND, 8OZ JAR"

"*ADHESIVE, THREADLOCK 242"

860001004 "SEALANT, HIGH STRENGTH"

252-808-000 "SCREW, FHMS M3-0.5 X 6 SST"

256 0227 000 "CABLE, FFC 40C, 2ROW 61MM LONG"



303 4104 016 "SCREW, MACH M4-0.7 X 16"

303 4203 006 SCREW MACH M3-0.5 X 6

303 4204 035 "SCREW, MACH M4-0.7 X 35"

304 0174 000 "NUT, JAM, BRASS 1/2-28"

306 0028 000 "NUT, HEX KEPS M4 ZINC"

307 0001 040 "NUT, STD HEX M4-0.7 X .8H"

314 0014 000 "WASHER, INT LOCK 1/2"

315 0023 040 "WASHER, EXT LOCK M4"

33-351 "EMI CLIP, SMALL SINGLE"

336 1330 000 STDOFF-M/F-4.5MM HEX-M3X0.5X5L

337 0005 000 "SCREW, SEMS M3 X 6 SKT HD, SST"

35-733 "STUD,BALL,TREELOCK"

356 0216 000 "CABLE TIE, 5.6'' NYLON NATURAL"

358 1214 000 "SCREWLOCK, M/F 4-40X3/16"""

410 0471 000 "STANDOFF, HEX M3 X 16, M/F"

426 0149 000 VIBRATION MOUNT M/F .375D X .625H

430 0325 000 "FAN GUARD, 80MM WIRE-FORM"

430 0478 000 "FAN, RADIAL, 12V 46.62CFM 80MM"

610 1425 003 "RECP, 3C 1ROW VERTICAL"

646 0665 000 "LABEL, INSPECTION"

646 2110 000 "BARCODE, SN_ITEM_REV"

660 0093 000 "BATTERY, LITHIUM 3V 10MM COIN"

843 5588 001 WIRING DIAGRAM UEP

843 5588 038 "FAMILY TREE, UEP"

9010213011G "*PWA, MCF5484 UC MODULE"

9010215101G "*PWA, UP/DOWN CONVERTER"

9010215181G "*PWA, SIGNAL PROCESSOR"

943 5588 002 CHASSIS_M2X

943 5588 020 "HEATSINK, AMPLIFIER MODULE"

Qty UM

0.15 FT

0 EA

0 EA

0 EA

28 EA

3 EA

13 EA

8 EA

1 EA

4 EA

4 EA

7 EA

10 EA

2 EA

7 EA

3 EA

19 EA

13 EA

3 EA

4 EA

3 EA

2 EA

6 EA

4 EA

2 EA

2 EA

2 EA

1 EA

1 EA

1 EA

0 DWG

0 DWG

1 EA

1 EA

1 EA

1 EA

1 EA


"W3,W4,W5"

#BT1

10/6/10 888-2629-200


7-11



943 5588 030 BLOCK-MOUNTING-PCA_UEP

943 5588 045 "PANEL, DIVIDER"

943 5588 062 "BRACKET, AC CORD"

943 5588 068 "PLATE, TRAVEL LIMIT"

6 EA

1 EA

1 EA

1 EA

952 9248 001 "CABLE, KIT UEP" 1 EA

971 0035 004 ASM-SUB-FRONT-CONTROL-PANEL-CTR UEP1 EA

971 0035 007 ASM-POWER MODULE

971 0035 016 "ASSY, M2X FRONT PANEL"

1 EA

1 EA

971 0035 018 "ASSY, M2X PFRU"

971 0035 019 ASM-SUB-COVER-NONVENTED

1 EA

1 EA

Harris PN

Table 7-18 "FORMAT, EXCITER, APEX M2X (ISDB-T)" - 995 0063 002 (H 5)

Description







Qty UM

0 EA

0 EA

1 EA

1 EA

0 EA

1 EA


Harris PN

Table 7-19 "FORMAT, EXCITER, APEX M2X (ATV)" - 995 0063 005 (G 5)

Description



9710035020G "ASSY, ATV INPUT OPTION"




Qty UM

0 EA

0 EA

1 EA

1 EA

0 EA

1 EA


Harris PN

Table 7-20 "EXCITER, APEX M2X (ATSC)" - 995 0063 200 (E P)

Description Qty UM

861 1135 132 APEX M2X SW/FW ATSC COMPLETE APP 0 DWG

9010215091G "PWA, BATTERY BACKUP"



988 2624 002 "DP, UEP, ATSC"



1 EA

1 EA

1 EA

1 EA

1 EA

1 EA


7-12 888-2629-200


10/6/10


7.2

Heat Exchanger/Pump Module Replacement Parts

Table 7-21 Spart Parts for Pump Module & Heat Exchager

DCI Part

Number

14780

14782

11965

1478

15194

2301

2311

9303

6419

14862

14861

12810

9638

2062

14716

12429

14845

Part Description

Replacment Motor Assembly, 19.7" diameter - Harris PN 7080061001 This fan is used for air cooler Harris PN: 7080060008, 7080060006, 7080060010

Replacement Motor Assembly, 19.7” DIA This fan is used for 50kW Harrris PN:7080090015,

7080090017

1-1/2" NPT Check Valve

Gauge Cock 1/4" NPTFXNPTM MiniI Brass Ball Valve w/ T-Handle, 300 PSI rating , max

Temp 212F, teflon seat and Viton seals

0.25” Blow-Down Valve with 3/4” garden hose male cap and retainer

1/2" Brass Ball Valve, NPT, full port, two piece, UL, FM, & CSA approved, 150 WSP, chrome plated brass ball, PTFE seats, seals and thrust washer, BUNA o-rings

1 1/2" Brass Ball Valve, NPT, full port, two piece, UL, FM, & CSA approved, 150WSP, chrome plated brass ball, PTFE seats, seals

Type "J" MGO Thermocouple with jack, 0.250 OD X 4" long, 304SS sheath, ungrounded junction, 1/4" NPTM brass compression FTG, STD male

Ft of Type "J" Thermocouple Extension Wire 20Ga red / white with solid duplex-parallel extruded PVC jacket insulation, 221F insulation

1.25” Terminator Ball Valve union end No PT, C x M, copper X male NPT

1.5” Terminator Ball Calve union end NO PT, F x F, NPT

1.5 Ball Valve with strainner, pressure ports and union, FPT X FPT union with 3/4" bypass port,

1/4" strainer drain port, brass (#15)

0.75" B&G AIR VENT NO 87, brass, non-ferrous automatic air vent

0.5" Fast Fill Dual Pressure Relief / Presssure Reducing Valve, FNPT, brass, max pressure 10

PSI, adjustment range 10 TO 25 PSI

1.5" Bell & Gossetti In Line Air Scoop, 3/4" NPT top vent, 1/2" bottom tank connection overall length 8.125", max flow 35 GPM, max op.

0002 Gallon, Diaphragm Expansion Tank, 1 gallon acceptance volume, 12 PSI pre-charge, 0.5" system connection, max op. temp 240F, max

Motor Pump 126, 2HP, 1.25”X1.25”, TEFC, 60Hz, 380-400V/3/60 or 230-460/3/60, 3500

RPM, J56, Standard Fitted, BN-CM Seal, 5.25” Impeller Diameter, 35 gpm @ 35 psi

10/6/10 888-2629-200


7-13




DCI Part

Number


14850

14848

14849

14322

14315

14855

13841

6603

2197

14726

1595

15134

11965

15133

12957

Pressure Gauge, 0-100 PSI, 2.5", LF, 1/4" brass NPTM, bottom MNT,glycerin filled, bronze tube, brass socket, acrylic window S.S. case

Brass Garden Hose-to-Pipe Rigid Adapter 3/4" Male Garden Hose, 1/2" NPT male connections

1-1/2" NPT Check Valve

Replacement Filter for 1.5” Ball Valve with Strainer, 304SS with 20-mesh screen

CONTROL PANEL

8028 ABB Non-Fused Disconnect Switch, 30A 600V-3P, UL98

3785

11212

ABB Disc. Shaft, 180mm (w/3786 & 11212 SH 30-100A)

ABB Disconnect Selector Handle, 30-100A, Red/Yellow

14856

14857

ABB Door mounted, Non-Fused Disconnect Switch, 30A 600V-3P, UL508

ABB Selector Handle for UL508 Door Mounted Disconnect (OT16,25,32ET3), Black, UL/

NEMA type 1/3R/12, IP65

12957

11024

15009

15032

Transformer, 150VA

Fuse Holder & Cover Kit for Sola XFMR

Fuse, 2A-600V, Class CC Time Delay Rejection Type

Fuse, 3.2A-600V, Class CC Time Delay Rejection Type

Power Supply, 15W/12VDC/1.2A Output

Socket Base for ABB Alternating Relay, 11-Pin

Alternating Relay, 120VAC, DPDT, with rotary switch, 11-pin octal base.

Hold Down Clips for ABB Alternating Relay (DPDT, 11 pin)

Circuit Breaker, 2A-1P, 480Y/277V, UL1077, D curve.

Circuit Breaker, 0.5A-1P, 480Y/277V, UL489, D curve.

IDEC Relay Socket, Finger Safe, for GT5Y Timer, and 4PDT relay, screw connections

IDEC Relay, 4PDT, 12 VDC

Cutler-Hammer, MMP, 4.0-6.3A, frame-B, rotary operator, class 10 overload protection


7-14 888-2629-200


10/6/10




7902

7883

10535

10538

10536

14779

10543

10539

10561

10545

14852

10837

11027

15013

15012

9300

14825

DCI Part

Number

15008

15014

15011



Cutler-Hammer, MMP Plug Connection Kit, frame-B

Cutler-Hammer, MMP Auxiliary Contact, 1NO-1NC, front mount, 1NO-1NC, seq-A, use with

XT series MMPs

Cutler-Hammer Contactor,7A,3P, 120VAC Coil, 1NO aux contact

Cutler-Hammer Aux-Contact, 2 NO-2 NC,front mount, frame B-C

Cutler-Hammer, MMP Line Side Adapter, frame B

Cutler-Hammer, MMP 3-Ph Bussbar, 4-MMP commoning link-B, frame-B

IDEC Momentary Pushbutton, 1NC Contact, black flush type

IDEC Selector Switch, 2-Position, 1NC contact

IDEC Contact Block, 1NC

IDEC Pilot Light, Green LED, 120VAC round flush type

Cage Clamp Term. Block RED/2L

Cage Clamp Term. Block WHITE/2L

Cage Clamp Term. Block BLUE/2L

Cage Clamp Term. Block ORANGE/2L

Cage Clamp End Plate GREY/2L

Cage Clamp Term.Block(GRND) Green/Yellow/4L

Cage Clamp End Plate GREY/4L

Cage Clamp Term.Block End Stop

Tempco TEC-9300 Temperature Controller, 90-264 Vac, 1/16DIN, Universal Input, NEMA-4X/

IP65 Front Panel.

Output-1: Relay

Output-2: Relay

Alarm-1: Relay

Model TEC-9300-411110

10/6/10 888-2629-200


7-15



7-16 888-2629-200


10/6/10


Appendix A Cutting & Soldering Transmission Line

A.1 Suggested Cutting And Soldering Procedure

The purpose for this procedure is to provide guidelines for field cutting and soldering of

RF transmission line used to interconnect the transmitter to the RF system.

Try to cut and flange the longest pieces first. Complete one run at a time in order to avoid accumulated errors. (i.e.: Cut, solder, and hang line from antenna port of

Bandpass filter to patch panel. Then cut, solder, and hang line from the Amplifier output to the input port of the Bandpass filter.)

Listed in Table A-1 are some tools and materials that have proven effective for RF Feed

Line Construction.

Table A-1 Tools and Materials Needed For RF Feed Line Construction

Welding Torch Set

Oxygen and Acetylene Tanks

Welder’s Mask or Goggles

Power Band Saw (can be rented) and Extra Blades

Silver Solder 1/16 inch diameter, 30%-45%, Hard Stay-Silv #45, Aladdin #45,

HARRIS part number 086 0004 060

Hacksaw and Extra Blades

Plumb Bob

Chalk Line

Wrenches

Crowbar

Paste flux (Engelhard Ultra-Flux 1 lb jar) HARRIS part number 086 0004 046 Rope

Muriatic Acid (quart) Saw Horses or Cutting Table

Baking Soda (two 1-pound boxes)

Three plastic 5-gallon buckets or containers with open tops

Come-along or Chain-Fall Hoist

Ladders

Scotch Brite

Steel Wool

Emery Cloth (roll type like plumber uses)

Carpenters Square

Garden Hose

25-Ft Tape Measure

Files

Rubber Hammer

Level

Hole Saw, 1-7/8 inches, for installing directional couplers

Claw Hammer

Gloves

Safety Glasses Safety Glasses

NOTE: All-thread rod, hangers, angle iron or channel will be needed to support transmission line, dummy load, etc.

10/6/10 888-2629-200


A-1


A.2 Line Cutback and Flange Soldering Procedure

1.

Determine the flange-face to flange-face length of the transmission line run needed.

If the run includes an elbow, see Figure A-1 to determine the elbow length.

2.

Subtract twice the cutback dimension of the flange. This dimension varies with flange manufacturer. See Figure A-2.

3.

Using one of the suggested methods for cutting the line given in Section A.3, cut the outer conductor to the length just calculated.

4.

If holes in the outer conductor are needed for directional couplers, tuning paddles, etc. they should be added now with the holes properly deburred.

5.

Using the suggested techniques for installing the flanges given in Section A.4, solder a flange to each end of the outer conductor.

6.

Measure the flange-face to flange-face dimension after soldering to confirm the proper length and to determine the initial length of the inner conductor.

7.

Determine the length of the inner conductor by using the flange-face to flange-face dimension of the outer conductor and subtracting the dimension of the anchor connector (bullet) shown in Figure A-3. This dimension determines the proper cutback of the inner conductor for both ends of the line at the same time. do not double this dimension when subtracting from the outer conductor length.

8.

Cut the inner conductor and debur the cut edges.

9.

Ensure the inside of the outer conductor is clean; then insert the inner conductor. The line is ready to install.

Figure A-1 Measurements When Elbows Are Used

A-2 888-2629-200


10/6/10


See Section Below

Mating Surface

Groove For

O-ring

Teflon Portion of Bullet

Cut Length

Outer Conductor

Flange to Flange Length

Flange

Silver Solder Ring

(some suppliers may not provide this grove) Outer Conductor

Cut Back For Each Flange

Note: The cutback will vary for different transmission line manufacturers.

Figure A-2 Outer Conductor Measurements

10/6/10

Cutback for inner conductor.

The amount of cutback vary for different transmission line manufacturers.

Figure A-3 Measurement for Cutback of Inner Conductor

888-2629-200


A-3


A.3 Cutting The Transmission Line

A square smooth cut is required. Several methods, listed below, may be used with the choice depending on tools and labor available.

1.

Method 1. A hand hack saw and cast iron cutting guide are a good combination for making a cut with a minimum of tools for one or two pieces, but can be very labor intensive for putting up an entire system. See Figure A-4.

2.

Method 2. Hand Band Saw. These popular saws can be rented or purchased. See Figure A-5.

3.

Method 3. Swing Arm Band Saw. This is a good way to go if one can be rented or borrowed. Many pipe fitters and electrical contractors own them. If the saw has an automatic feed, cut slowly. It is critical that the support saw horses be made level with the saw. Test cuts should first be made using scrap pipe or a wood 4x4 to verify that the blade is not creeping and the saw is in alignment. See Figure A-6.

Caution

DO NOT OVER TIGHTEN THE VISE USED WITH THESE SAWS. IT WILL BE

DIFFICULT TO PUT THE FLANGE ON AN OUT OF ROUND PIPE.

4.

Method 4. Tubing Cutter. This is generally not recommended. Many cuts end up with crimped ends due to dull cutters or trying to cut too fast. Use with caution. Avoid if possible unless someone is available that has had a lot of experience using a tubing cutter on this type of installation. See Figure A-7.

5.

Method 5. Cut Off Saw. These saws are similar to radial arm saws. It is rare to find one big enough to cut 6-1/8” line. The set up is similar to the swing arm band saw.

See Figure A-6.

A-4

Figure A-4 Guide For Use With Hand Hack Saw

888-2629-200


10/6/10


Start Cut Stop Cut

On the first pass score the cut. Do not let the blade go below the surface.

Turn Line

Approximately

45 Degrees

Correct Depth Cut Too Deep

Finish cut on second pass. Keeping the blade from falling too far below the surface keeps the cut smooth

Figure A-5 Cutting With a Hand Band Saw

10/6/10 888-2629-200


A-5


Figure A-6 Swing Arm Band Saw Cutting Tips

A-6 888-2629-200


10/6/10


Figure A-7 Use Of Tubing Cutter Results In Crimped Cut (Exaggerated)

A.4 Soldering Flanges

Transmission line flanges that are supplied with the optional transmission line kit are the silver solder type. Although the attachment of this type of flange may require more care and skill than the soft solder type, it has been found that the silver soldered flange provides much greater reliability. The services of a steam fitter or plumber may be helpful if personnel are not available that are experienced with silver soldering.

A.4.1 Soldering Procedure

1.

The line should be free of burrs. The outer corner may be beveled slightly to make assembly of flange easier. See Figure A-8.

2.

Emery cloth should be used to clean the outside of the line where it will meet the flange. Also clean the inner surface of the flange with emery cloth.

3.

Insert the solder ring into the groove on the flange. If solder rings are not included with the flange, they can be made from 0.062-inch diameter silver solder wire (30-

45% silver).

4.

Apply a thin coat of flux to the line and to the flange.

5.

Slide the flange onto the end of the outer conductor.

Warning

SKIN BURN HAZARD. TEMPERATURE OF THE HEATED LINE IN THE FOLLOWING

STEPS IS QUITE HIGH AND PRECAUTIONS MUST BE TAKEN TO AVOID CONTACT

WITH EXPOSED SKIN.

6.

Stand the line on end (vertical) for soldering (flange to be soldered pointing down).

Ensure that the flange remains square with the outer conductor.

7.

Using a #3 or #4 torch tip, heat the entire circumference of the line and flange. Keep the torch moving and heat 2 or 3 inches of the line/flange at a time. Aim the torch at the copper just above the crack between the flange and the line. This will minimize the need for fill solder. If the brass flange is heated more than the copper line, the flange will expand and create an unnecessary gap to fill with solder. Use caution.

There is a fine line between melting the solder and melting the brass flange or burning a hole in the copper. The solder will pull up into the joint from the solder ring by capillary action. Once it starts to flow, do not stop until the entire circumference of the joint has solder appearing in it. If the solder from the internal solder ring does not

“wick up” and become visible at the joint after a few minutes, a small amount of solder can be applied to the joint to enhance the heat transfer. See Figure A-9.

10/6/10 888-2629-200


A-7


Figure A-8 Bevel Cut End and Remove Burs

Figure A-9 Torch Aiming Location

A.5 Cleaning The Soldered Joint

Vigorous scrubbing with a wire brush and steel wool will remove torch black with good results. In addition, cleaning with an acid solution can make this job easier. The procedure is as follows:

Warning

MURIATIC ACID USED IN THE FOLLOWING PROCEDURE IS HAZARDOUS. USE

EYE AND SKIN PROTECTION WHEN HANDLING OR MIXING. KEEP AN EXTRA BOX

OF BAKING SODA HANDY FOR FIRST AID OR TO NEUTRALIZE SPILLS. PERFORM

THE PROCEDURES OUTDOORS IF POSSIBLE. IF THE WORK MUST BE DONE

INDOORS, WORK ONLY IN WELL VENTILATED AREA.

A-8 888-2629-200


10/6/10


Warning

IN THE FOLLOWING MIXING PROCEDURE, ALWAYS PUT WATER IN THE CON-

TAINER FIRST AND THEN ADD ACID TO THE WATER. ADDING WATER TO A CON-

TAINER OF ACID MAY RESULT IN A VIOLENT & DANGEROUS REACTION.

1.

Prepare three plastic 5 gallon buckets as follows:

A.

Bucket #1 - Water

B.

Bucket #2 - One quart muriatic acid in four gallons of water (See Warnings

Above)

C.

Bucket #3 - One pound baking soda in five gallons of water

2.

After soldering is finished, dip the end of the line in the water to cool.

3.

Set the cooled end of the line into the acid-water mixture for 5-10 minutes. This will loosen the film and brighten the silver.

4.

Immerse the end of the line into the soda solution. This will stop the action of the acid.

5.

Use a Scotch Bright pad or steel wool to scrub off the remaining torch black.

6.

If the flux scale is particularly stubborn repeat the process.

7.

When finished, rinse thoroughly when done with water and dry the line before assembling.

A.5.1 Alternate Cleaning Method

The following is an alternate procedure to clean the soldered transmission line. The following materials are needed.

• Water and Hose

• Small Paint Brush

• Rubber Gloves

• Scotch Brite Pad or BBQ Grill Cleaning Pad With Handle

• Naval Jelly (or equivalent rust remover).

10/6/10

Warning

NAVAL JELLY CONTAINS PHOSPHORIC ACID AND CAN BE DANGEROUS IF IT

COMES IN CONTACT WITH SKIN OR EYES OR IF IT IS SWALLOWED. READ AND

FOLLOW THE PRECAUTIONS AND EMERGENCY PROCEDURES ON THE NAVAL

JELLY CONTAINER BEFORE USING.

1.

After soldering the flange, dip the end of the line into water or spray it with a hose until it is cool.

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A-9


2.

Using a small paint brush, apply a coating of Naval Jelly to the torch black and flux scale on the outside and inside of the line. Let the Naval Jelly set from 10 to 20 minutes.

3.

Scrub the line with Scotch Brite or the BBQ Grill pad to loosen the torch black and flux scale.

4.

Flush with water until the Naval Jelly residue is gone.

5.

Repeat the process until all the torch black and flux scale is removed.

The first application of the Naval Jelly will remove the torch black and some of the flux scale. Normally, if vigorous scrubbing is done, repeating the process a second time will completely clean the line.

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Appendix B Cooling System Help

B.1 Coolant and Water Recommendations

The cooling loop uses a 50% mixture by volume of deionized water and industrial grade ethylene glycol. The recommended ethylene glycol product is called “Ucartherm”, made by Union Carbide.

Equivalent coolants from another manufacturer may be used as long as its inhibitors are similar. Also, information on the properties of the product must be obtained from the manufacturer in order to calculate the transmitter power output calorimetrically.

Caution

DO NOT USE AUTOMOTIVE GRADE ANTI-FREEZE AS A SUBSTITUTION FOR

INDUSTRIAL GRADE GLYCOL. IT DOES NOT CONTAIN THE PROPER INHIBITORS

FOR THIS APPLICATION AND WILL LEAD TO EVENTUAL DAMAGE OF THE

SYSTEM.

Description

Table B-1 Recommended Coolants

Part Numbers

051-1010-001 Ucartherm Cooling Fluid, ethylene glycol-based concentrated solution

Ethylene Gasket Kit 335-0304-000

051-1012-000

DOWFROST HD: Inhibited propylene glycol-based heat transfer fluid

Propylene Gasket Kit

DOWTHERM SR-1: ethylene glycol-based concentrated solution

Ethylene Gasket Kit

335-0301-000

051-1010-002

335-0304-000

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B-1


Caution

SINCE THE WATER USED TO MIX WITH THE GLYCOL WILL AFFECT THE

CORROSIVITY OF THE MIXTURE, ONLY HIGH QUALITY DEMINERALIZED WATER

THAT HAS BEEN DISTILLED, DEIONIZED OR REVERSE-OSMOSIS PROCESSED

SHOULD BE USED. THIS WATER MUST HAVE A CONDUCTIVITY OF NO MORE

THAN 5 MICROSIEMENS (OR HAVE A RESISTANCE OF LESS THAN 200K OHMS.

The quality of water mixed with glycol concentrate can impact system performance.

Poor quality water can cause scale, sediment deposits, or sludge throughout the cooling which will reduce heat transfer efficiency. Poor quality water can also cause damage to the system by depleting the corrosion inhibitor and can lead to the creation of a number of corrosions including general and acidic attack corrosions.

Good quality processed water contains:

•

Less than 50 ppm of calcium

•

Less than 50 ppm of magnesium

•

Less than 100 ppm (5 grains) of total hardness

•

Less than 25 ppm of chloride

•

Less than 25 ppm of sulfate

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B.2 Plumbing System Installation

B.2.1 Materials needed

•

Mapp gas torch set

•

Extra Mapp gas tanks

•

Welders mask or goggles

•

Tubing cutter for 2.5 inch tubing (a hacksaw may be used instead of the tubing cutter)

•

Flux (Stay Clean Flux) or equivalent (Harris part number 086 0004 040; one 16 oz bottle provided with plumbing kit)

•

Soft silver solder (96.5% tin; 3.5% silver) such as Aladdin #450 (Harris part number

086 0004 038) is needed. Three 1 lb rolls of 1/16 inch soft silver solder is supplied with plumbing kit. 1/8 inch silver solder (Harris part number 086-0004-047) is also available.

•

Wire brush and rags

•

Water hose

•

Thread rod, angle iron or channel and hangers needed to support the plumbing

•

Tubing cutter or a hack saw (always de-bur the line (remove any rough points or flared-in edges at the cut after cutting)

Warning

TEMPERATURE OF THE HEATED LINE IN THE FOLLOWING STEPS IS QUITE HIGH.

PRECAUTIONS MUST BE TAKEN TO AVOID CONTACT WITH EXPOSED SKIN.

B.2.2 Pipe Sizing and Routing

If a typical system layout is not used, the typical plumbing layout should still be consulted for pipe size information and connection details and techniques at the amplifier cabinets, RF loads, pump module and outside heat exchanger. A custom plumbing installation must not unduly restrict flow rates or change the design of the cooling system. Locate the plumbing so that access to transmitter system components is not restricted.

NOTE:

Pipes must be sized no smaller than shown on the typical plumbing layout drawing. Their routing should minimize turns and long runs.

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B-3

B-4


If additional amplifier cabinets are to be added to the system in the future, consider these plans when sizing and laying out the cooling system. Doing so now may slightly increase the installation cost, but will greatly lower the cost of conversion later.

The plumbing lines must be type “M” hard drawn copper with soft silver soldered joints

(96.5% Tin, 3.5% Silver; Aladdin #450 silver solder or equivalent). An adequate amount of soft silver solder (Harris part 086-0004-038) is supplied with the plumbing kit. Good silver brazed joints are acceptable but not required. A poorly done brazed joint is much harder to repair than a soft silver solder joint.

B.2.3 Standard Coolant Plumbing Practices

Good plumbing equipment installation practice is required to ensure system integrity.

Appropriately measured, cut, deburred, supported and soldered copper pipe sections, facilitate mechanical integrity of the coolant transportation system. The “glue” that holds the system together is quality soldering.

This process includes the need to condition all surfaces to be soldered by thorough cleaning with emery cloth or a non-sudsing scouring pad, with an even application of flux, liquid flux being preferred. This applies to all common surfaces of plumbing fittings and straight pipe sections. Any improperly cleaned and poorly fluxed surfaces, either one or both, will not allow the solder to flow properly for continuous adherence of the solder to the two surfaces being soldered. After cleaning and fluxing, a continuous and evenly distributed application of heat without overheating will result in an evenly distributed flow of solder between the surfaces being soldered for a plumbed system that does not leak. Remember that solder flows from a colder surface to a hotter surface no matter the orientation of the surfaces being soldered.

Since considerable heat is necessary to make the solder flow, some torch black and flaking may develop inside the pipe. Before hanging the line, it is recommended that a hose and wire brush or rag be used to clean and flush the inside of the line where possible. It is also recommended to wash the flux off the final soldered joint to prevent future tarnishing.

NOTE:

Keep in mind that an over application of solder can result in solder balls falling in to the associated piping with the possibility of water flow restriction and/or blockage. Also, an under application of solder can result in water leakage paths between the common surfaces of the fitting being soldered.

Propane or Mapp gas is the recommended fuel for soldering copper plumbing pieces.

These gasses are available in small metallic bottles that mate directly to appropriate torches. Also, a “Turbo Torch” or equivalent with appropriately sized regulator and hose combination can be used with larger gas tanks (large cooking stove tank). If these

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Maxiva ULX COFDM Series gas sources are not available, use of acetylene gas with an acetylene only torch is acceptable. In any event, only skilled plumbing and soldering practitioners, knowledgeable of the specific soldering equipment being used, should perform the required work.

NOTE:

A soldering combination of silver bearing solder, i.e. Harris (not Harris Broadcast) Stay-Brite R (086-0004-038), and “Stay Clean” liquid soldering and tinning flux (086-0004-040) or equivalent, is recommended. Also, pipe thread joints should be conditioned with Teflon tape (299-0018-000) and a thin film application of a smooth, non-hardening thread sealing, compound with integrated Teflon is recommended, i.e. Locktite #565, or “Gasoila” (690-0017-000), prior to mating any two threaded pieces together.

When connecting threaded plumbing fittings, use a layer of teflon tape and some pipe dope on the male fittings . Do not use pipe dope on the female fittings because it will bunch up on the inside surface of the plumbing and interfere with normal cooling system operation. It is difficult to remove excess pipe dope from inside the system.

A final comment about the installation process centers around the need for the discipline of personnel in and around the cooling system installation area. Under no circumstances should anyone, cooling system installer and/or workers in other disciplines and areas, walk on pipes and fittings that have or have not been positioned and soldered. Although probably convenient for passage between adjacent work areas, walking on already soldered pipe can and historically has led to premature loss of solder joint integrity, among other self evident undesirable integrity results.

Caution

IF FREEZING CONDITIONS EXIST DURING CHECKOUT AND FLUSHING

PROCEDURES, FLUSHING PROCEDURE AND SUBSEQUENT FILL WITH FINAL

GLYCOL/WATER MUST BE FINISHED BEFORE STILL WATER IS ALLOWED TO

REMAIN IN HEAT EXCHANGER. IF PROCEDURE CANNOT BE FINISHED, CARE

MUST BE TAKEN TO PREVENT WATER FROM FREEZING IN OUTSIDE COOLING

SYSTEM EQUIPMENT. IF WATER REMAINS IN OUTSIDE EQUIPMENT LONG

ENOUGH TO FREEZE, THE UNITS WILL BE DAMAGED. PUMP A MIXTURE OF

GLYCOL/WATER INTO OUTSIDE EQUIPMENT TO PREVENT DAMAGE.

B.3 Routine System Operation and Maintenance a.

As a general rule of thumb, the entire system including all cabinets should be inspected for leaks on a routine basis. And any indication of a potential leak noted and corrected. The transmitter cabinet is equipped to detect internal leaks. For the rest of the system plumbing; however small leaks could evade detection.

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B-5

B-6


If a system leak, is detected around a plumbed solder joint, the coolant should be drained, the leak point resoldered, and the system refilled and tested.

Repairs for a leak originating at a threaded joint may be initially attempted by tightening the affected joint without draining the system. If this tightening effort does not correct the problem, then the system must be drained, the problem area opened and replumbed as necessary, followed by a system refill and test.

b.

Probably the single most important maintenance step: Inspect the bottom of the heat exchanger bi-monthly. Inspect the coil itself for any debris that may have become trapped on the coil face. This would block air flow and decrease cooling efficiency of the heat exchanger. Debris can be removed using a hose and pressurized water system. In dusty environments or areas where an abundance of vegetation is present this inspection will be required weekly c.

To achieve even usage time per unit and ascertain that back-up integrity exists, it is recommended that the pumps in the pump module are operated alternately one month at a time.

a.

Check the pump module pressure gauge to ensure that a consistant stable pressure is indicated.

b.

Inspect and clean the filtration loop. c.

Check flow rate.

d.

Per the comment included in B.2.3 Standard Coolant Plumbing Practices section, mandate a continual discipline of NOT allowing plumbing pipe, fittings, etc., to be walked on.

e.

The system must be analyzed for glycol concentration, annually. Analysis can be provided by the glycol manufacturer or via use of an analytical test kit supplied through the manufacturer.

f.

See Transcool documentation for detailed maintenance instructions.

B.3.1 Reserve Coolant Supply

A sufficient reserve supply of coolant and corresponding deinonized water should be kept on hand to refill the entire system in the event of a major leak.

B.3.2 Clean-Up Plan

A plan for containment and spill clean-up acceptable to local environmental regulations should be considered.

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B.3.3 Operating Environment

Ambient air temperatures near the heat exchanger dry cooler should not rise above

45°C for typical installations.

B.3.4 Measuring Specific Gravity

Specific gravity can be measured with a conventional float hydrometer and jar or a

MISCO DFR 200 (or equivalent) digital refractometer to verify the 50/50 mixture. The hydrometer should be capable of measuring specific gravity in the 1.02 to 1.08 range.

Extract a sample of the coolant being used and cool it to 60 o

F (Note: this is the temperature to which your hydrometer has been calibrated.)

Read the specific gravity as accurately as possible. With this number the concentration or per cent of glycol in the solution can be determined. Let us assume the S.G. reads

1.060 on the hydrometer scale.

NOTE:

The specific heat and specific gravity of water is not always equal to 1.0, see

Tables B-2 and B-3 on page B-8.

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B-7


20

22

24

26

28

10

12

14

16

18

30

32

34

36

38

Table B-2 Specific Gravity and Density of Water at Atmospheric Pressure

6

8

2

4

Temp. deg C Specific gravity Density lb/cu ft Temp. deg C Specific gravity Density lb/cu ft

0 0.99987

62.4183

40 0.99224

61.9428

0.99997

1.00000

62.4246

62.4266

42

44

0.99147

0.99066

61.894

61.844

0.99997

0.99988

62.4246

62.4189

46

48

0.98982

0.98896

61.791

61.737

Temp

Cp

°

F

0.99973

0.99952

0.99927

0.99897

0.99862

0.99823

0.99780

0.99732

0.99681

0.99626

0.99567

0.99505

0.99440

0.99371

0.99299

62.4096

62.3969

62.3811

62.3623

62.3407

62.3164

62.2894

62.2598

62.2278

62.1934

62.1568

62.1179

62.0770

62.0341

61.9893

50

52

54

56

58

60

62

64

66

68

70

72

74

76

78

0.98807

0.98715

0.98621

0.98524

0.98425

0.98324

0.98220

0.98113

0.98005

0.97894

0.97781

0.97666

0.97548

0.97428

0.97307

Table B-3 Specific Heat of Water at 1 Atmosphere of Pressure (ICT)

32

1.001

50

1.002

100

1.004

150

1.009

61.682

61624

61.566

61.505

61.443

61.380

61.315

61.249

61.181

61.112

61.041

60.970

60.896

60.821

60.745

212

1.021

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B.3.5 Example

The easiest way to understand this process is to work an example. The data used in this example is shown below.

• S.G. at 60 o

F = 1.060

B.3.5.1 Determining Percent of Ucartherm

Refer to Figure B-5, on page B -14 and the 60 o

F curve (interpolation will be required).

Reading across the 1.06 S.G. line to the intersection of the 60 o

F curve (Point A) and then vertically down to the percent of UCARTHEM in the solution, shows that this particular sample is a 40% (by weight) glycol mixture.

B.4 Heat Transfer Solutions

B.4.1 Ethylene Glycol

Commercial Grade “Ucartherm” (Union Carbide Corporation) Ethylene Oxide/Glycol is the recommended heat transfer fluid to be used for the liquid portion of the cooling system. Ucartherm can be purchased from Harris in 55 Gallon lots using the following part numbers:

051-1010-021 - Ucartherm 50/50 solution

051-1010-001 - Ucartherm 100% concentrate

Automotive grade antifreeze is not recommended due to the silicon additives which can cause incompatibility problems with pump seals and other components within a system.

Due to a tendency of the glycol to break down over time when mixed with chlorinated water, it is recommended that distilled water be used for the solution.

The life expectancy of a “Ucartherm” system can be as long as 10-15 years for a clean system installed and monitored per the recommended procedures.

Glycols are excellent penetrants. Systems tested with water and checked to be tight sometimes will leak when glycol solutions are then added. Recheck the system for leaks after installing the glycol mixture.

Distribution information may be obtained by contacting Union Carbide Corporation

(800-568-4000).

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B-9


B-10

Figure B-1 Ucartherm Operating Practices

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Figure B-2 Ucartherm Maintenance and Freeze Protection

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B-11


B-12

Figure B-3 Ucartherm Freezing Point

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Figure B-4 Ucartherm Physical Properties

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B-13


B-14

Figure B-5 Specific Gravity of Ucartherm/Water Solution

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Boiling Point of Ucartherm/Water Solution

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Figure B-6 Boiling Point of Ucartherm/Water Solution

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B-15


B-16

Figure B-7 Thermal Conductivity of Ucartherm/Water Solution

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Figure B-8 Specific Heat of Ucartherm/Water Solution

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B-17


Figure B-9 Ucartherm Shipping Data

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Figure B-10 Eucartherm Handling, Storage and Emergency Assitance

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B-19


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Appendix C Grounding Considerations,

Surge & Lightning Protection

C.1 Surge and Lightning Protection

A lightning storm can cause transients in excess of 2kV to appear on power or field signal lines. The duration of these transients varies from a few hundred nanoseconds to a few microseconds. Power distribution system transient protectors can efficiently protect the transmitter from transients of this magnitude. Transients are shunted to ground through the protection devices and do not appear on the output. To protect the transmitter from high transients on field cables, electronic surge protectors are recommended.

All lightning protection is defensive in nature, that is, reacting to a lightning strike that has already occurred; therefore, its effectiveness is limited. Nothing can provide total immunity from damage in the case of a direct lightning strike. However, surge protectors installed immediately after the main power disconnect switch in the power distribution panel will afford some protection from electrical surges induced in the power lines.

Surge protection devices are designed to operate and recover automatically. When operated within specifications, a surge protector does not require testing, adjustment, or replacement. All parts are permanently enclosed to provide maximum safety and flexibility of installation.

To assure the safety of equipment and personnel, primary power line transformers must be protected by lightning arrestors at the service entrance to the building. This will reduce the possibility that excessive voltage and current due to lightning will seek some low impedance path to ground such as the building metallic structure or an equipment cabinet. The most effective type of power line lightning protection is the one in which a spark gap is connected to each primary, secondary, and the case of the power line transformer. Each spark gap is then independently connected to earth ground. In cases where driven ground rods are used for building ground, the primary and secondary neutrals must be separated by a spark gap. If two separate ground rods are used, the rods must be at least 20 feet apart. All connections between lightning arrestors, line connections, and ground must be made as short and straight as possible, with no sharp bends.

C.2 System Grounding

Signals employed in transmitter control systems are on the order of a few microseconds in duration, which translates to frequencies in the megahertz region. They are therefore radio-frequency signals, and may be at levels less than 500 microvolts, making them

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C-1

C-2

Maxiva ULX COFDM Series susceptible to noise appearing on ground wires or adjacent wiring. Thus, all ground wiring must be low in impedance as well as low in resistance, without splices, and as direct as possible. Four basic grounds are required:

1.

AC ground

2.

DC ground

3.

Earth ground

4.

RF ground

C.2.1 Ground Wires

Ground wires should be at least as large as specified by the local electrical code. These leads must be low impedance direct runs, as short as possible without splices. In addition, ground conductors should be insulated to prevent intermittent or unwanted grounding points.

Connection to the earth ground connection must be made with copper clamps which have been chemically treated to resist corrosion. Care must be taken to prevent inadvertent grounding of system cabinets by any means other than the ground wire.

Cabinets must be mounted on a support insulated from ground.

C.2.2 AC Ground

The suggested grounding method consists of two separately structured ground wires which are physically separated from each other but terminate at earth ground. The green ground wire from the AC power input must connect to the power panel and the ground straps of the equipment cabinets.

The primary electrostatic shield of the isolation transformer, if used, connects to the AC neutral wire (white) so that in the event of a transformer primary fault, fault current is returned directly to the AC source rather than through a common ground system. The

AC neutral is connected to earth ground at the service entry.

Use of separate grounds prevents cross-coupling of power and signal currents as a result of any impedance that may be common to the separate systems. It is especially important in low-level systems that noise-producing and noise-sensitive circuits be isolated from each other; separating the grounding paths is one step.

Noise Grounding Plate. Where excessive high-frequency noise on the AC ground is a problem, a metal plate having an area of at least 10 square feet embedded in concrete and connected to the AC ground will assist in noise suppression. The connection to AC ground should be shorter than 5 feet, as direct as possible, and without splices. Local wiring codes will dictate the minimum wire size to be used.

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Peripheral Equipment Grounds. All peripherals are supplied with a separate grounding wire or strap. All branch circuit receptacles must permit connection to this ground. This service ground must be connected through the branch circuit to a common grounding electrode by the shortest and most direct path possible. This is a safety ground connection, not a neutral.

Often, circuit common in test equipment is connected to power ground and chassis. In these cases, isolated AC power must be provided from a separate isolation transformer to avoid a ground loop.

C.2.3 DC Ground

DC grounds in the transmitter are connected to a ground bus, which in turn is routed to a common cabinet ground and then connected to an earth ground. The use of separate ground busses is a suggested method of isolation used to prevent cross-coupling of signals. These ground buses are then routed to the cabinet ground and to earth ground.

C.2.4 Earth Ground

The transmitter must be connected to earth ground. The connection must have an impedance of 5 ohms or less. For example, a one-inch metal rod driven 20 feet into moist earth will have a resistance of approximately 20 ohms, and a large ground counterpoise buried in moist earth will exhibit a resistance on the order of 1 to 5 ohms.

The resistance of an electrode to ground is a function of soil resistivity, soil chemistry and moisture content. Typical resistivity of unprepared soil can vary from approximately 500 ohms to 50kohms per square centimeter.

The resistance of the earth ground should be periodically measured to ensure that the resistance remains within installation requirements.

C.2.5 RF Ground

Electrical and electronic equipment must be effectively grounded, and shielded to achieve reliable equipment operation. The facility ground system forms a direct path of low impedance of approximately 10 ohms between earth and various power and communications equipment. This effectively minimizes voltage differentials on the ground plane to below levels which will produce noise or interference to communication circuits.

The basic earth electrode subsystem consist of driven ground rods uniformly spaced around the facility, interconnected with 2 or 4 inch copper strap. The strap and rods should be placed approximately 40 inches (1 meter) outside the roof drip line of the structure, and the strap buried at least 20 inches (0.5 meters). The ground rods should be

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C-3

Maxiva ULX COFDM Series copper-clad steel, a minimum of eight feet (2.5 meters) in length and spaced apart not more than twice the rod length. Brazing or welding should be used for permanent connections between these items.

Where a resistance of 10 ohms cannot be obtained with the above configuration, alternate methods must be considered.

Ideally, the best building ground plane is an equipotential ground system. Such a plane exists in a building with a concrete floor if a ground grid, connected to the facility ground system at multiple points, is embedded in the floor.

The plane may be either a solid sheet or wire mesh. A mesh will act electrically as a solid sheet as long as the mesh openings are less than 1/8 wavelength at the highest frequencies of concern. When it is not feasible to install a fine mesh, copper-clad steel meshes and wires are available. Each crossover point must be brazed to ensure good electrical continuity. Equipotential planes for existing facilities may be installed at or near the ceiling above the equipment.

Each individual piece of equipment must be bonded to its rack or cabinet, or have its case or chassis bonded to the nearest point of the equipotential plane. Racks and cabinets should also be grounded to the equipotential plane with a copper strap.

RF transmission line from the antenna must be grounded at the entry point to the building with 2 or 4 inch copper strap. Wire braid or fine-stranded wire must not be used.

All building main metallic structural members such as columns, wall frames, roof trusses, and other metal structures must be made electrically continuous and grounded to the facility ground system at multiple points. Rebar, cross over points, and vertical runs should also be made electrically continuous and grounded.

Conduit and power cable shields that enter the building must be bonded at each end to the facility ground system at each termination.

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Appendix D Lightning Protection Recommendation

D.1 Introduction

What can be done with a 2 million volt pulse pushing 220,000 amps of current into your transmitting plant? Like the 500 pound gorilla it does what ever it wants to. There is not much that can be done to protect against a major direct lightning strike. This is called a significant impulse lightning stroke. It usually lasts less than 100 microseconds and is most destructive to electronic equipment because it contains huge amounts of high frequency energy.

Here are some examples of this damage:

• Melted ball and horn gaps.

• Ground straps burned loose.

• H.V. rectifier stacks shorted.

• Massive arc marks in the output circuit of AM transmitters.

• Ball lightning traveling into building on outer conductor of transmission line.

Figure D-1 is a map of the United States that shows the number of lightning days expected in any year, with Colorado, New Mexico, and Florida leading the list.

Figure D-2 shows the incidents to tall structures. A triggered event is one that happens because the tower was present. Without the tower the strike would not have occurred.

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Figure D-1 Map Showing Lightning Days Per Year

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D-1


All Triggered Events

40

30

20

10

500 1000 1500

Structure Height In Feet

2000

Figure D-2 Lightning Incidents to Tall Structures

D.2 Environmental Hazards

There are devices and procedures that do offer protection from lessor environmental hazards than lightning. Some of these anomalies are listed and defined:

1.

Over voltage/under voltage (brownout). Where the lines voltage differs from the nominal RMS for longer than one cycle.

Remedy Automatic voltage regulators, preferably individual regulators on each phase. This can only be accomplished when the power feed line is delta or 4/wire wye connected, See Figure D-3.

2.

Single phasing. This is where one leg of the three phase service is open.

Remedy Protection afforded by a loss of phase detector. Without protection power transformers and 3 phase motors over heat.

3.

Radio frequency interference (RFI). This is something we must design into all transmitters, however, equipment may be purchased that is susceptible, is not protected, and may develop problems.

Remedy RFI filters on the ac lines and control lines are sometimes effective. Sometimes the entire device must be enclosed in an RF free space.

4.

Electromagnetic pulse (EMP). This is a interfering signal pulse that enters the system by magnetic coupling (transformer). Generally caused by lightning.

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Lightning from cloud to cloud produces horizontally polarized waves while lightning from cloud to earth produce vertically polarized waves. The waves couple into the power lines and transmission lines causing large induced voltage that destroy high voltage rectifier stacks and output circuit faults. High frequency energy is coupled back into the transmitter causing VSWR overloads, See Figures D-4 and D-5.

Remedy Ball or horn gaps at the base of the antenna prevent the voltage from exceeding some high potential. Transient suppressor devices on the input power lines remove excessive voltage spikes. Buried power and transmission lines will reduce the amount of coupled energy to a great extent. This does not totally eliminate the problem because there are currents traveling in the earth, which prefer to travel on the metal conductors, when lightning strikes close to the station.

5.

Surge. A rapid increase in voltage on the power lines usually caused by lightning. The duration is less than 1/2 cycle and can be very destructive.

Remedy Transient protectors are very effective in preventing damage to the equipment when properly designed and installed, See Figure D-6.

Table D-1 Significant Lightning Stroke Characteristic

Charge Range

Peak Currents

Rise Time to 90%

2 to 200 coulombs

2,000 to 400,000 Amperes

300 Nanoseconds to 10

Microseconds

Duration to 50%

Potential Energy at

99%

100 Microseconds to 10 Milliseconds

1010 Joules*

* Only a small portion is manifested in a surge, usually less than

10,000 Joules.

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D-3


Figure D-3 Regulators for Delta and 4-Wire WYE systems

D-4

Figure D-4 EM Flux Field

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2400

A

2000

B

1600

C

1200

800

0 1 2

A = 1/2 mile from station

B = 1 mile from station

C = 2 miles from station.

3

Time in usec

4 5

Figure D-5 Sample Surge Voltage as a Function of Distance From Stroke to Line

6

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D-5


Figure D-6 Surge Protectors and Ferrite Chokes

D.3 What Can Be Done?

Installation of the transmitter building, antenna tuning unit if applicable, and antenna should be done so that the risk of destruction due to lightning is minimal and the efficiency of the over all system is maximized. To do this, separate ground systems should be installed for the building and antenna. This forces all of the RF return currents to flow in the transmission line shield. The coax can be buried below the antenna ground plane to still further reduce the RF current coupled to it.

In medium and short wave installations the antenna ground plane is very important as it is of the radiating element. RF current leaving the antenna must return via the ground path (ground wave). For this reason the “antenna coupling unit” must be close to the base of the tower and securely connected to the ground plane.

Figure D-7 shows the basic elements of a properly designed antenna system.

• Good ground plane.

• Ball gap on tower.

• Series inductor in tower feeder.

• Antenna coupling unit connected to antenna ground.

• The

π

circuit is equivalent to the normal Tee used by Harris.

• Underground coax.

• Guy wire length broken by insulators and grounded at the bottom end.

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The transmitter building must be given extra protection to insure reliable equipment operation. A low impedance safety ground system must be installed using 3 inch wide copper strap hard soldered at all joints and connected to multiple ground rods located at the perimeter of the building. The ground rods should be wet to make good connection to the earth water table. All equipment cabinets within the building must be connected to the ground straps for safety reasons.

Figure D-7 Basic Elements of a Properly Designed Antenna System

D.4 AC Service Protection

All incoming ac lines should have a choke connected in series to limit the high frequency surges on the lines followed by a surge protector. The surge protector must be connected to the building ground system by short direct connections, see Figure D-6.

A surge protector is a solid state device that has a high impedance until the voltage across it reaches its rated clamping voltage, at which time its impedance suddenly decreases. The protector will then conduct hundreds to thousands of amperes to ground.

All protectors are rated for maximum voltage and maximum surge energy. If the surge energy exceeds rating of the device it will normally short and for this reason must be fused so it will disconnect itself from the line being protected. When this happens all protection is lost so some warning system must be used to tell the operators that a new protector should be installed.

Speed is essential to protect equipment from current surges with rates of rise exceeding

10,000 amps per microsecond and pulses that last no longer than 100 microseconds.

Very short, low inductance ground straps are required to pass surges of this type.

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D-7


The surge protectors must be selected for the line to ground voltage and the maximum energy to be diverted. Bigger is always better in this case. There are several manufacturers of surge protectors:

• Lightning Elimination Associates., Inc.

• Current Technology

• Control Concept

• MCG Electronics, Inc.

• EFI Corp.

• General Electric

All of these vendors provide parts and systems to protect broadcast transmitters.

All audio and control lines should be protected the same as described for ac lines with components sized accordingly.

All coaxial lines should have the shield connected to the system ground at the point of entrance and in addition have a ferrite choke around it located between the entrance point and the equipment rack. This will provide a high impedance for current flowing in the shield but does not affect the signal currents.

D.5 Conclusion

The 1% chance of a major lightning strike probably can not be protected against but the other 99% can be controlled and damage prevented. Install surge protection on all incoming and outgoing lines at the wall of the building connected to a well designed ground system. Properly install the antenna ground system with spark gap adjusted correctly and maintained. With this done you can sleep peacefully at night if your bed isn’t under the feed line.

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